Quantifying the effects of mass transport in the curing and leaching of agglomerated ores using X-ray Microtomography

Abstract

Agglomeration and subsequent curing are widely used as pre-treatments for ore prior to heap leaching as they both improve the permeability of the heap and bring leaching solution into close contact with the ore, initializing the leaching reactions. In this thesis, a low-grade copper sulphide ore was used for the experiments and two different agglomeration/leaching solutions were tested, namely a more standard sulphuric acid solution including ferric/ferrous ions, and a solution which also contained chloride ions. A novel image processing methodology was developed to track grains over both the curing and leaching process, taking into account the anisometric changes experienced by the agglomerates and the formation and depletion of species. A combination of XMT and SEM/EDX was used to characterise the chemical and mineralogical changes occurring over both processes. The formation and depletion of mineral components were quantified and tracked beyond the typical time scales used industrially, highlighting that the presence of chloride ions makes a substantial difference to the chemical and structural evolution of the agglomerates. Over the curing process, at least 20 days are required to perceive a significant degree of dissolution. Reprecipitation of metal containing species was observed, especially near the agglomerate surfaces. These precipitates are water-soluble species, and 50% of the initial sulphides were extracted from the agglomerates containing chloride ions, but only 20% from the other agglomerates after curing and water washing. A model of the agglomerate behaviour over the curing process is proposed based on the results observed from the XMT measurements. This model considers both the metal dissolution extent, as well as the reprecipitation of species due to water evaporation. The mathematical model is explained together with the computational approach used to solve it, and the simulation results are compared with the experimental results. This model is able to successfully predict the trends seen in the experiments, with the relative reaction and evaporation rates being a controlling factor. The leach performance was assessed for agglomerates leached using the same recipes used for the agglomeration stage. The compaction and changes in microporosity in the sample were quantified, showing that these changes do not significantly influence the leaching performance. By taking advantage of the more selective leaching that takes place when chloride ions are added to the leach solution, the leaching variability in the system was assessed. SEM/EDX measurements were then used to calibrate the XMT quantifications, isolating the dissolution of copper-containing grains from the pyrite dissolution. It was, thus, possible to quantify the surface kinetics of the hundreds of thousands of grains in the sample, with these kinetics being represented by a family of bi-modal curves. It was shown that the mass transport and mineralogical changes occurring throughout the curing and leaching processes could be quantified both at the grain-scale and the macro-scale by using the developed methodology for combining SEM/EDX measurements with XMT. By incorporating this data into particle scale and, ultimately, heap scale leach models, improved predictions and optimisation of leach performance can be made.Open Acces