Extraction of Mn from Black Copper Using Iron Oxides from Tailings and Fe2+ as Reducing Agents in Acid Medium

Comparative Study of MnO2 Dissolution from Black Copper Minerals and Manganese Nodules in an Acid Medium

The low grade of copper deposits and the use of the froth flotation process have caused excessive tailing production. In recent years, experts have looked for new alternative methods to improve this situation. Black copper minerals are abundant resources not exploited by large-scale copper mining and possess high Mn concentrations. On the other hand, manganese nodules are submarine resources and show high concentrations of Cu, Ni, Fe, and, mainly, Mn. However, both mineral resources are refractory to conventional leaching processes, and so a reducing agent is necessary for their treatment. We studied the use of tailings obtained from the flotation of foundry slags with a high content of Fe3O4 as reducing agents at different MnO2/tailings ratios and H2SO4 concentrations. Mn dissolution was compared in marine nodule and black copper minerals samples. It was found that higher Mn dissolutions are obtained from marine nodules, likely due to the acid consumption created by Cu dissolution from black copper minerals. The remnant elements in manganese nodules were leached under an oxidant condition.

Optimization of Cu and Mn Dissolution from Black Coppers by Means of an Agglomerate and Curing Pretreatment

Black coppers are mineraloids with a high content of Cu and Mn. These have an amorphous crystalline structure that makes them refractory to conventional leaching processes. For this reason, these mineral resources are not incorporated in industrial leaching heap processes and are taken to dumps. In the present study, an agglomerate pretreatment process incorporating NaCl is evaluated, and a curing stage, followed by acid-reducing leaching for Cu and Mn dissolution from a high-grade black copper mineral. For this, an experimental design was developed both to evaluate the impact of the dependent variables on the response, to generate analytical models that represent the copper and manganese recoveries under the set of sampled conditions. The models indicate that the curing time and the NaCl concentration have a primary effect on the recovery of both elements. In contrast, the optimization model suggests that the optimal operating levels are reached at relatively high levels of time (>130 h) and of NaCl concentration (>22 kg/t).

Leaching of Pure Chalcocite in a Chloride Media Using Waste Water at High Temperature

Studying the dissolution of chalcocite allows to understand the behavior of the most abundant secondary sulfide ore in copper deposits, while digenite (Cu1.8S) and other intermediate sulfides (Cu2−xS) are often associated with chalcocite. The most common mechanism of dissolution is by two stages, and chloride ions benefit the kinetics of dissolution. In this study, a pure chalcocite mineral (99.9% according to XRD (X-Ray Diffraction) analysis) is leached in chloride media using NaCl and wastewater as the sources of chloride. Magnetic leaching tests are performed at 65, 75, and 95 °C, using a particle size between −150 and + 106 μm. Chloride concentration and leaching time are the main variables. A substantial dissolution of chalcocite was obtained with 0.5 M H2SO4, 100 g/L of chloride and a leaching time of 3 h. The apparent activation energy (Ea) derived from the slopes of the Arrhenius plots was 36 kJ/mol. The XRD analysis proves the presence of elemental sulfur (S0) as the main component in the leaching residue. No significant differences in copper extraction were detected when using 100 g/L of chloride ion or wastewater (39 g/L).

Reducing-Effect of Chloride for the Dissolution of Black Copper

Oxidized black copper ores are known for their difficulty in dissolving their components of interest through conventional methods. This is due to its non-crystalline and amorphous structure. Among these minerals, copper pitch and copper wad are of great interest because of their considerable concentrations of copper and manganese. Currently, these minerals are not incorporated into the extraction circuits or left untreated, whether in stock, leach pads, or waste. For the recovery of its main elements of interest (Cu and Mn), it is necessary to use reducing agents that dissolve the present MnO2, while allowing the recovery of Cu. In this research, the results for the dissolution of Mn and Cu from a black copper mineral are exposed, evaluating the reducing effect of NaCl for MnO2 through pre-treatment of agglomerate and curing, and subsequently leaching in standard condition with the use of a reducing agent (Fe2+). High concentrations of chloride in the agglomerate process and prolonged curing times would favor the reduction of MnO2, increasing the dissolution of Mn, while the addition of NaCl did not benefit Cu extractions. Under standard conditions, low Mn extractions were obtained, while in an acid-reducing medium, a significant dissolution of MnO2 was achieved, which supports the removal of Cu.

Copper Extraction from Black Copper Ores through Modification of the Solution Potential in the Irrigation Solution

This article presented the behavior of ores containing black copper under acid leaching. The solution potential was modified by adding agents, and five leaching conditions were evaluated, one as a control based on sulfuric acid leaching (conventional), and the others by changing the solution potential with: ferrous sulfate (FeSO4), white metal (Cu2S), sulfur dioxide (SO2), and ozone (O3). Leaching behavior was evaluated with laboratory bottle (ISO-pH) and column leaching tests. Two ores samples from the Lomas Bayas mine were used. The samples, identified as low (LG) and high grade (HG), were characterized as 0.13–0.25% Cu and 0.15–0.38% Mn, respectively. The mineralogical analysis indicated that black copper represented around 20% of total Cu (0.05% Cu). The results of the bottle tests indicated that the solution potential decreased with the addition of reducing agents, while the copper extraction rate with the HG sample increased to 83.7%, which exceeded the extraction rate obtained by conventional acid leaching by 25%. Ozone did not favor the extraction of Mn and Cu extraction when the solution potential increased. Cu and Mn extraction were directly related. The results of the column leaching tests showed that it was possible to maintain the solution potential at values below 600 mV (SHE) with the addition of white metal and sulfur dioxide while obtaining the highest copper extraction rate of approximately 60%, which was 18% higher than the rate obtained with conventional leaching. Sulfuric acid consumption was 11 kg/t over 45 days of leaching.

Leaching Manganese Nodules in an Acid Medium and Room Temperature Comparing the Use of Different Fe Reducing Agents

The deposits of Fe-Mn, in the seabed of the planet, are a good alternative source for the extraction of elements of interest. Among these are marine nodules, which have approximately 24% manganese and may be a solution to the shortage of high-grade ores on the surface. In this investigation, an ANOVA analysis was performed to evaluate the time independent variables and MnO2/reducing agent in the leaching of manganese nodules with the use of different Fe reducing agents (FeS2, Fe2+, Fe0 and Fe2O3). Tests were also carried out for the different reducing agents evaluating the MnO2/Fe ratio, in which the Fe0 (FeC) proved to be the best reducing agent for the dissolution of Mn from marine nodules, achieving solutions of 97% in 20 min. In addition, it was discovered that at low MnO2/Fe ratios the acid concentration in the system is not very relevant and the potential and pH were in ranges of −0.4–1.4 V and −2–0.1 favoring the dissolution of Mn from MnO2.

A Stochastic Model Approach for Copper Heap Leaching through Bayesian Networks

Multivariate analytical models are quite successful in explaining one or more response variables, based on one or more independent variables. However, they do not reflect the connections of conditional dependence between the variables that explain the model. Otherwise, due to their qualitative and quantitative nature, Bayesian networks allow us to easily visualize the probabilistic relationships between variables of interest, as well as make inferences as a prediction of specific evidence (partial or impartial), diagnosis and decision-making. The current work develops stochastic modeling of the leaching phase in piles by generating a Bayesian network that describes the ore recovery with independent variables, after analyzing the uncertainty of the response to the sensitization of the input variables. These models allow us to recognize the relations of dependence and causality between the sampled variables and can estimate the output against the lack of evidence. The network setting shows that the variables that have the most significant impact on recovery are the time, the heap height and the superficial velocity of the leaching flow, while the validation is given by the low measurements of the error statistics and the normality test of residuals. Finally, probabilistic networks are unique tools to determine and internalize the risk or uncertainty present in the input variables, due to their ability to generate estimates of recovery based upon partial knowledge of the operational variables.