Extractive Metallurgy

Module on Mineral Processing

delivered at

African University of Science and Technology, Abuja

by

Prof Richard Amankwah

August 2012

Extractive metallurgy

Hydrometallurgy

Pyrometallurgy

Electrometallurgy

For economic reasons, it is always good to

present the material in a concentrated form
especially for pyro and electrometallurgical
processes
Extractive metallurgy by Prof R K Amankwah

Hydrometallurgy

Leaching - selective dissolution of a metal or

mineral
The metal dissolved should acquire stability in the
aqueous phase
Lixiviant

Pregnant Solution (mainly the valuable

mineral)

Material
Leaching

Residue (gangue)

Tails

Extractive metallurgy by Prof R K Amankwah

Mechanism

Diffusion of the ions in the leach solution to

the interfacial boundary layer

Adsorption onto the mineral surface

Reaction

Desorption of reaction products into the

interfacial boundary layer
Diffusion of reaction products across the
boundary layer
Extractive metallurgy by Prof R K Amankwah

Factors affecting leaching

Particle size

Temperature

Pulp density

Agitation

Pressure and

Concentration of leaching reagent

Extractive metallurgy by Prof R K Amankwah

Types of leaching systems

Agitation and non-agitation systems

Non-agitation systems

Insitu

Heap

Dump

Vat

Agitation systems

Agitation by air or impellers or both

Extractive metallurgy by Prof R K Amankwah

Heap leaching (schematic)

Extractive metallurgy by Prof R K Amankwah

Layout of heap leach plant

ADR

Auxiliary
Ponds

Drum agglomeration

Pregnant
solution

Heaps

Crushing,
Agglomeration

Humidification layer with drainage

pipes

Agitation leaching

Solution purification and concentration

Dilute solutions need to be concentrated and
multi-metal solutions generated by co-leaching
need to be purified. Methods include;







Ion-exchange
Crystallization
Solvent extraction
Precipitation/cementation
Adsorption
Extractive metallurgy by Prof R K Amankwah

Carbon adsorption technology

Production
Technical application (carbon-in-pulp, carbonin-leach, carbon-in-solution, carbon-in-column)

Cross-section through activated carbon

Extractive metallurgy by Prof R K Amankwah

CIP/CIL Flow sheet

Extractive metallurgy by Prof R K Amankwah

Pretreatment

Metal values locked up in sulphides

The need to pretreat in order to liberate

occluded metal

Pretreatment processes

Hydrometallurgical pretreatment

Pyrometallurgical pretreatment

Extractive metallurgy by Prof R K Amankwah

Pyrometallurgy
Extraction of metals or minerals of interest
from their ores by the application of thermal
energy or heat

The processes considered here include,

Drying

Calcination

Roasting and

Smelting
Extractive metallurgy by Prof R K Amankwah

Drying
Drying in mineral processing simply means
evaporation of water from an ore, concentrate or
mineral

Can be accomplished by;

Exposure of the material to sun and air,

Heating the ore or substance above the boiling point
of water at atmospheric pressure, and
Reducing the atmospheric pressure with respect to the
vapour pressure of water at constant temperature.
Extractive metallurgy by Prof R K Amankwah

Calcination

Heating a substance (ore) above its

decomposition temperature
Causes decomposition of the material and
removal of chemical and mechanically
(physically) held water and volatile components
Involves dehydration and dehydroxylation
e.g.

MnCO3

MnO + CO2

Extractive metallurgy by Prof R K Amankwah

Roasting

Involves the heating of a substance or an ore

below its fusion temperature
Presence of air or other gases
Leads to decomposition of the material or
changes in the physical and chemical properties
to make it suitable for subsequent process(es)
Types oxidizing, chlorodising, sulphating,
magnetizing and reducing
Extractive metallurgy by Prof R K Amankwah

Factors that affect roasting

Particles should be relatively small (but not

over-ground) to increase rate of reaction
The correct temperature should be ensured and
maintained to prevent melting and formation of
unwanted product.
The charge should have the right composition
and good contact with the hot air.

Extractive metallurgy by Prof R K Amankwah

Smelting

Melting process

Flux addition

Acidic

Basic

Neutral

Higher affinity for waste, lowering melting point,

protection of crucibles, slag fluidity

Layers obtained
Extractive metallurgy by Prof R K Amankwah

Electrometallurgy
Electrometallurgy is the branch of
electrochemical engineering, which deals with
the extraction, and refining of metals from
aqueous and molten solutions

Key components of the operation;

Electrolyte,

Electrodes,

Cell.
Extractive metallurgy by Prof R K Amankwah

Electrolyte
Any compound which in solution or in fused state
conduct electric current and can be decomposed by
it, is called an electrolyte

An electrolyte contains free ions

The passage of current depends on the number of the
ions present and their mobility and speed
In strong electrolytes, ionisation is complete but
ionic movement is hindered by interference
In weak electrolytes the degree of ionisation
increases as dilution increases
Extractive metallurgy by Prof R K Amankwah

Electrolysis
Electrolysis is the decomposition of an electrolyte
by the passage of an electric current.

current is led in and out of the electrolyte through

immersed electrodes
anions move to the anode to give up electrons and
cations to the cathode to take up electrons
AA + eC+ + e-

Extractive metallurgy by Prof R K Amankwah

Simple electrolytic cell

Electrolyte

Anode

Cathode

Extractive metallurgy by Prof R K Amankwah

Faradays first law

The mass of substance liberated is a proportional to the

quantity of electricity passing through the electrolyte
M Q and Q = It therefore M = ZIt
Q quantity of electricity, M mass, I current, t time
Z electrochemical equivalent of the element (Mass in gram of
an element liberated by a Coulomb of electricity)

Z = a/FC
F Faradays Const = 96500 C or 96500 A.s or 26.8 A.h or 96.5 K
J/v
C- Charge on the ion, a atomic mass
Extractive metallurgy by Prof R K Amankwah

Faradays second law

If the same quantity of electricity is passed through a

number of different electrolytes, the masses of the
substance liberated are proportional to their respective
chemical equivalent
ma/mb = za/zb
Al3+
Cu2+
Ag+
2O2-

3F
2F
1F
O2 + 4e-

4F

Extractive metallurgy by Prof R K Amankwah

27 g
63.5 g
107.9 g
32 g

Electroplating
It is the process of depositing a sound metallic coating
with the required characteristics onto a conducting
surface by means of electrolysis

immerse the item to be plated in solution of the metal

to be plated on it
pass a direct current between the part and another
electrode to produce a thin smooth sound metallic
deposit
item to be coated is made the cathode
it should thoroughly be cleansed of grease and dirt by
dipping it in acid and alkaline cleaning solutions
Extractive metallurgy by Prof R K Amankwah

Electroplating
It can be used to;

improve the nature and appearance of metallic and

non-metallic materials

improve the abrasion resistance of steel balls

restore worn out parts

provide protection against corrosion

Extractive metallurgy by Prof R K Amankwah

Electrowinning
It is the electrolytic extraction of metal from an
electrolyte containing metal ions by the passage of
current

the metal may be electrowon either from aqueous

solution or fused salts
the electrodes may be active or inert
electropositive metals like aluminium, sodium,
potassium and magnesium are electrowon from fused
salts
others like gold and copper are won from aqueous
media
Extractive metallurgy by Prof R K Amankwah

Electrorefining

Used in purifying impure metals

Impure metal is made the anode of the cell

A pure strip of the metal is made the cathode

The anode reduces in weight as the cathode

builds up
Behaviour of impurities

Extractive metallurgy by Prof R K Amankwah

Process variables

Decomposition potential

Overpotential

Polarisation

Current density

Current efficiency

Energy efficiency

Extractive metallurgy by Prof R K Amankwah