A high iron containing copper and nickel based secondary resource analysing 22.43% Cu, 7.94% Ni and 36.28% iron has been treated to recover valuable metals by leaching with sulphuric acid. It was found that recovery of copper and nickel increased with increase in temperature and sulphuric acid concentration and in a two-stage leaching with 20% (v/v) sulphuric acid at 368 K above 99.9% copper and 82.35% nickel were recovered. The leaching data best fitted into chemical controlled kinetic model showing chemical reaction at the surface of the solid matrix. Activation energy of 20 kJ/mol and 44 kJ/mol were acquired for dissolution of copper and nickel, respectively. Attempts were also made to separate iron from the leach liquor by using Versatic 10 and recovery of copper and nickel in the form of their sulphate by solvent extraction; the copper and nickel could then be recovered as salts, metal cathodes or metal powder

Kumar, Vinay

Pandey, B D

Sahu, S K

English

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548	Mineral Processing Technology (MPT 2007)Recovery of Cu and Ni from a Secondary Resource by Hydrometallurgical Route	549Recovery of Cu and Ni from a Secondary Resource by Hydrometallurgical RouteS.K. Sahu, B.D. Pandey and Vinay KumarMetal Extraction & Forming Division, National Metallurgical Laboratory, Jamshedpur-831007E-mail: sushanta_sk@yahoo.comABSTRACT: A high iron containing copper and nickel based secondary resource analysing 22.43% Cu, 7.94% Ni and 36.28% iron has been treated to recover valuable metals by leaching with sulphuric acid. It was found that recovery of copper and nickel increased with increase in temperature and sulphuric acid concentration and in a two-stage leaching with 20% (v/v) sulphuric acid at 368 K above 99.9% copper and 82.35% nickel were recovered. The leaching data best fitted into chemical controlled kinetic model showing chemical reaction at the surface of the solid matrix. Activation energy of 20 kJ/mol and 44 kJ/mol were acquired for dissolution of copper and nickel, respectively. Attempts were also made to separate iron from the leach liquor by using Versatic 10 and recovery of copper and nickel in the form of their sulphate by solvent extraction; the copper and nickel could then be recovered as salts, metal cathodes or metal powder. 1. INTRODUCTIONThe increasing demand of metals in the world calls for exploitation of metal containing low grade ores and/or secondary resources. Compared to pyrometallurgical option, hydrometallurgical extraction of metals from these resources is highly attractive. This attractiveness is attributed to economical, environmental and technical reasons.There are several papers reporting the extraction of non-ferrous metals from secondary sources using different reagents. Recovery of nickel from spent catalyst has been studied using sulphuric acid (Al-Mansi and Menom, 2002), nitric acid (Loboiko et al. 1983), hydrochloric acid (Chandhary et al., 1993) and ammonia (Vicol and Haves, 1986) as leachants. Although these lixiviants have been previously reported for leaching nickel from spent catalyst, sulphuric acid has been found to be cheapest and quite effective. At National  Metallurgical Laboratory, Jamshedpur (Pandey et al., 2002; Sahu et al., 2004), copper concentrate a by-product of uranium ore of Jaduguda has been processed by pressure sulphuric caid leaching for recovery of copper, nickel and cobalt followed by separation of these metals by solvent extraction. In this process ferrous sulphate produced during leaching is oxidised to ferric sulphate under oxygen pressure and subsequently hydrolysed to produce Fe(OH)3. Therefore iron dissolution into the leach liquor is restriced. But operation and maintenance of autoclave restricts its application by small and medium scale industries.From chalcopyrite and pentlandite, copper and nickel may be oxidised by following dead roasting in fludized bed (Opie et al., 1980). Consequently, a by-product conatining copper oxide and nickel oxide along with nickel ferrite are produced and there is a need for leaching of these phases in hot concentrate acid. Such a by-product obtained from South African mines is available for the recovery of copper and nickel by a simple process such as that following hydrometallurgical route. This paper describes the extraction and recovery of copper and nickel from the by-product by acid leaching-iron removal by solvent extraction.2. EXPERIMENTALPrior to leaching of valuable metals from the oxide, chemical composition and mineral phases of the material supplied by Refmet Technology (P) Ltd. were determined. Leaching experiments were carried out in a glass vessel placed on a Multi-talented hot plate having temperature controller cum indicator facility. In all the leaching experiments desired amount of analytical grade sulphuric acid was used for leaching of the metals. All other chemicals used for the analysis were analytical grade reagents.  Initial pulp density of the slury was kept at 10% (wt/vol). After 3h of leaching the slury was filtered with whatman 41 filter paper and the filtrate was analysed for copper, nickel and iron by titrimetric method (Mendham et al., 2004). Based on the chemical analysis of the leach liquor percentage recovery of copper and nickel was calculated. From this liquor iron was removed by solvent extraction with Versatic 10 in kerosene.3. RESULTS AND DISCUSSIONThe by-product contains 22.43% Cu, 7.94% Ni, 36.28% Fe, 3.05% SiO2 and 2.72% Al2O3. The major phases identified by XRD are CuO, NiO, Fe3O4, CuFe2O4 and NiFe2O4. In sieve analysis 75.5% of the material was found to be of size < 50 µm and only 6.3% of the material was of size >100 µm. All the size fractions had almost similar chemical compositions. Recovery of copper and nickel from the by-product was studied by varying parameters such as sulphuric acid concentration, temperature and pulp density. 3.1 	Effect of Temperature on Leaching of the Metals with Sulphuric AcidThe effect of temperature on the leaching of metals from the by-product was studied at constant initial sulphuric acid concentration (20% vol/vol) and pulp dnsity (10% wt/vol). The results given in Figure 1 showed that leaching of copper and nickel increased with increase in temperature and attained maximum at 368 K. 3.2 	Effect of Sulphuric acid Concentration on LeachingAt 368 K and 10% (wt/vol) pulp density, the effect of sulphuric acid concentration on the leaching of the valuable metals was examined and results are presented in Figure 2. It was observed that extraction of copper and nickel increased with increase in sulphuric acid concentration. After leaching for 3 h with 20% sulphuric acid at 368 K and 10% (wt/vol) pulp density 96.3% Cu and 52.5% Ni were recovered and the leach liquor contained 21.6 g/L copper 4.16 g/L nickel and 27.6 g/L iron. In this condition nickel dissolution was low as compared to recovery of copper.Fig. 1: Effect of temperature on the recovery of copper and nickel. Pulp Density: 10% (wt/vol), H2SO4: 20% (vol/vol).Fig. 2: Effect of sulphuric acid concentration on the recovery of copper and nickel. Temperature: 368 K, Pulp Density: 10% (wt/vol).3.3 Effect of Pulp Density on LeachingWhen pulp density was increased from 10% to 20% (wt/vol) at 368 K and 20% (vol/vol) sulphuric acid concentration only a minor change in recovery was observed. The leach liquor contained 41.9 g/L Cu, 9.14 g/L Ni and 53.96 g/L Fe at 20% (wt/vol) pulp density with recovery of 93.4% Cu, 57.5% Ni and 74.4% Fe. Further increase in pulp density to 30% (wt/vol) resulted in crystallization of mixed sulphate salts in the leaching vessel which may be attributed to saturation of leach liquor.3.4 Kinetics of LeachingThe rate of copper and nickel dissolution from the by-product was tested against chemical controlled model (Wordsworth and Miller, 1979). The kinetic data (Figure 3) for leaching of copper and nickel fitted well into the chemical controlled model (Eq. 1)1 – (1-x)1/3 = kc.t	(1)The Arrhenius plot (Figure 4) for leaching of copper and nickel was obtained in the temperature range 323-368 K. The activation energy acquired for dissolution of copper and nickel was found to be 20 kJ/mol and 44 kJ/mol, respectively.Fig. 3: Chemical-controlled kinetic model of copper and nickel dissolution with sulphuric acid. Sulphuric acid: 20% (vol/vol), PD: 10% (wt/vol).Fig. 4: Arrhenius plot for chemical-controlled kinetic model for leaching of copper and nickel.3.5 	Two-stage Leaching of Metals and Separation of Iron by Solvent ExtractionAs mentioned above, leaching with 20% (vol/vol) sulphuric acid at 20% (wt/vol) pulp density, nickel recovery was found to be only 57.5%. To improve the recovery of nickel the leach residue containing 4.74% Cu, 10.72% Ni and 29.6% Fe was further leached with 30% sulphuric acid solution at 20% (wt/vol) pulp density and 368 K temperature for 3 h. In the second stage, a leach liquor containing 9.35 g/l Cu, 12.54 g/L Ni and 46.2 g/L iron was obtained. The overall recovery in two-stage leaching was found to be 99.9% Cu, 82.35% Ni and 94.4% Fe. Leach liquors obtained in two stage leaching were mixed together. Mixed leach liquor contained very high amount of iron along with unused acid. Therefore, it is required to purify the leach liquor prior to recovery of copper and nickel in usable form.Mixed leach liquor with 34.1 g/L Cu, 9.95 g/L Ni and  52.1 g/L Fe was evapourated to its 50% volume and kept overnight to get mixed crystals of copper, nickel and iron sulphate. The mixed crystals were separated by filtration. The filtrate can be reused for leaching of the by-product after adjustment of acid in the filtrate.  The mixed crystals were then re-dissolved in water. The pH of the leach liquor from the dissolution of crystals was found to be 0.5.The leach liquor containing 40.7 g/L Cu, 11.9 g/L Ni and 62.2 g/L Fe was used to study the solvent extraction and separation of iron using Versatic 10 as an extractant in kerosene. Figure 5 showed percentage extraction of iron which increased with increase in equilibrium pH of the leach liquor. Also extraction of iron increased with the increase in O : A ratio. With 50% Versatic 10 solution at pH 3.0 and O : A = 2 : 1, 77% iron was extracted, whereas with 30% Versatic 10 solution at pH 2.2 and at O : A = 5 : 1, 79% iron was extracted in a single stage and the raffinate contained 40.5 g/L Cu, 11.6 g/L Ni and 13 g/L Fe. The remaining iron may be removed by hydrolysis. Copper-nickel from this solution could be recovered as pure sulphate solution by solvent extraction with LIX 84/Cyanex 272. These metals can be recovered in desired form such as their sulphate salts, metal cathodes or metal powder by appropriate treatment.Fig. 5: Effect of pH and O : A ratio on the solvent extraction of iron from leach iquor with Versatic acid4. CONCLUSIONExtraction of copper and nickel has been carried out by sulphuric acid leaching of a by-product. Recovery of copper and nickel increased with increase in temperature and sulphuric acid concentration. In a two-stage sulphuric acid leaching 99.9% Cu and 82.35% Ni were recovered. From the leach liquor iron (79%) was removed by 30% Versatic 10 in kerosene at 2.2 pH and O : A = 5 : 1, in a single stage. Rest of the iron was removed by hydrolysis. From the purified leach liquor separation of copper and nickel by solvent extraction with LIX 84 and Cyanex 272 as pure copper and nickel sulphate solutions could be achieved. The metals can be recovered in desired form by appropriate treatment of the pure salt solutions.REFERENCES	[1]	Al-Mansi N.M. and Monem N.M.A., Recovery of nickel oxide from spent catalyst, Waste Management, 22,  85 (2002).	[2]	Chandhary A.J., Donaldson J.D., Boddington S.C. and Grimes S.M. In Heavy metal in the environment. Part II: A hydrochloric acid leaching process for the recovery of nickel value from a spent catalyst. 34, 137 (1993).	[3]	Loboiko A.Ya., Atroshchenko V.I., Grin G.I., Kutovoi V.V., Fedorova N.P., Volovikov A.N., Alekseenko D.A., Golodenko N.I. and Pantaz'ev G.I., Recovering nickel from spent catalyst. Otkrytiya, Izobret., Prom. Obraztsy, Tovarnye Zanki. 14, p. 33 (1983) .	[4]	Mendham J., Denney R.C., Barnes J.D. and Thomas M.J.K., In: Vogels Text Book of Quantitative Chemical Analysis, 6th Editions, (2004).	[5]	Opie W.A., Coffin L.D. and Cusanelli D.C., A minimum pollution. Low energy pyrometallurgical process for treating chalcopyrite concentrate. In: J.C. Yannopoulos, J.C. Agrawal (Eds.), Extractive Metallurgy of  Copper. New York, 1, 416, (1980).	[6]	Pandey B.D., Bagchi D., Kumar V. and Agrawal A., Premchand, Pressure sulpuric acid leaching of a sulphide concentrate to recover copper, nickel and cobalt, Trans. Inst. Min. Metall. C 111, 106 (2002).	[7]	Ritcey G.M., Iron—An overview of its control in solvent extraction of metals. In J.E. Dutrizac A.J. Monhemius (Eds.) Iron Control in Hydrometallurgy, Ellis Horwood: Chichester, UK, 247 (1986).	[8]	Sahu S.K., Agrawal A., Pandey B.D. and Kumar V., Recovery of copper, nickel and cobalt from the leach liquor of a sulphide concentrate by solvent extraction, Minerals Engg. 17, 949 (2004). 	[9]	Vicol M. and Haves A.M. Recovery of nickel from spent catalysts Potoroaca, Combinatul de Ingrasaminte Chimice, Piatra-Neamt 112, 832 (1986). 

Recovery of Cu and Ni from a Secondary Resource by Hydrometallurgical Route

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Recovery of Cu and Ni from a Secondary Resource by Hydrometallurgical Route

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