Professional Documents
Culture Documents
Processing
Technologies for
Treating High Arsenic
Copper Concentrates
Patrick R. Taylor
G.S. Ansell Distinguished Professor of
Chemical Metallurgy
Director, Kroll Institute for Extractive
Metallurgy
Colorado School of Mines
Introduction
Conventional methods to
extract copper from sulfide
ores using pyrometallurgy
have been used for decades
and more than 75% of
primary copper is recovered
using these methods.
Even though conventional
processing is highly efficient,
the depletion of clean
copper sulfide ore reserves
requires new strategies to
extract the copper with
certain levels of impurities.
Converter Aisle
Introduction
Group 15 elements (As, Sb and
Bi) are difficult to handle in
conventional copper smelting.
Environmental regulations
have resulted in avoidance of
high-arsenic copper sulfide
concentrates and led to
increased smelter penalties
and lower acceptable amounts
of arsenic in the concentrates
treated.
An example from the US is
presented:
Arsenic Plant
Element
Alumina
Iron
Penalty Formula
$0.50 ea 0.1% > 5%
> 15% = increased treatment charge
for more flux needed
$0.50/lb > 1% (20 lb) OR 2$/dt ea
Arsenic
0.1% > 0.1% Max 0.2%
Barium
0.5 to 1% limit
Beryllium < 10 ppm limit
($1.10 to $7.50) /dt ea 0.1% > (0.1%
Bismuth
to 0.4%) Max 0.4 %
Cyanide
< 10 ppm !
Cadmium ($2.20 to $7.50) /dt ea 0.1% >
(0.05% to 0.2%) Max 0.4 %
Chloride
BAD PLAYER, DO NOT WANT ANY
Cobalt
0.5% limit
Chromium $0.50 dt ea 0.1% > 3% no hex
chrome, 5% max on tri v Cr
$5 dt ea 0.1% > 0.2%
0.5%
Fluoride
max
Hydrometallurgy
After more than 50 years of
using hydrometallurgy to
recover copper from low
grade ores, certain problems
and issues are still a concern,
especially for the treatment
of high arsenic bearing ores or
concentrates.
Various hydrometallurgical
methods have been proposed
for treating high arsenic
copper ores and concentrates.
This is not covered in this talk.
Dump Leach - Morenci
Arsenic?
Arsenic in copper presents
several problems.
In the final product, cracks
appear during the forming
process and reduces the
electrical conductivity of
copper.
The maximum allowable
arsenic concentration in
copper for electrical
applications is set at 1 ppm.
Arsenic?
A main objectives for the
control of arsenic in mineral
processing and extractive
metallurgy operations is to
avoid its emissions in either
the gaseous and aqueous
phases.
This is addressed through
arsenic removal and
converting it to a disposable,
environmentally acceptable
stable compound.
Arsenic?
There is a small market for
arsenic currently.
The El Indio operations is one
example of this, the
operations separated and
recovered arsenic as the
commodity As2O3 until 2002,
at which time operations
were closed due a
combination of factors,
including the lack of a
market for this arsenic
product.
Tons
Process Options
Both pyrometallurgical and
hydrometallurgical processes
have been evaluated for the
extraction of copper from
enargite concentrates.
Most research has focused
on hydrometallurgical
methods, as they are
generally thought to be more
environmentally benign and
less capital intensive.
Multi-hearth Furnace
Pyrometallurgy
High arsenic content represents
a barrier to direct smelting of
enargite concentrates and makes
the value of the concentrates
greatly diminished.
For those reasons, the arsenic
must be minimized before
smelting to obviate the need to
collect and treat volatile arsenic
compounds and to decrease slag
Pyrometallurgy
During the pyrometallurgical processing of
primary and secondary materials, arsenic
represents a risk and most countries require its
removal from the processing residues.
Controlled oxidation roasting is one of the
options for pyrometallurgical pre-treatment to
remove the arsenic from enargite concentrates
by volatilization.
The final product of the arsenic must be in a
stable disposable form.
Pyrometallurgy
Numerous studies on the use of roasting and
smelting have been published for enargite
concentrate treatment.
Several very good review papers have been
published on this topic.
Several of the operating and potential
processes will be discussed in this
presentation.
Pyrometallurgy
Enargite can be decomposed through
roasting methods.
The mechanisms for decomposition of
enargite are known.
Padilla (1997) showed that enargite
decomposition starts at about 525C, but
maximum arsenic removal occurred between
700C and 750C.
(g)
Lime Roasting
Lime roasting was investigated by Terry et al. (1994).
The arsenic and sulfur can be captured during roasting,
where As2O3 and SO2 gases react with CaO.
Rapid oxidation of As2S3 gas upon contacting with CaO was
estimated to be the mechanism of arsenic fixation (Igiehon
et al. 1994a).
As2S3 (g) + 3CaO (s) 1/2As4O6 (g) + 3CaS (s)
The reaction of As4O6 gas with CaO results in the formation
of calcium arsenite as showed in reaction. This reaction
happened with the absence of oxygen.
3CaO (s) + 1/2As4O6 (g) Ca3(AsO3)2 (s)
Lime Roasting
Liu et al. (2000) performed research regarding lime roasting
on a refractory gold concentrate.
The SO2 and As2O3 gases were fixed based on the following
reactions below:
2CaO (s) + 2SO2 (g) + O2 (g) 2CaSO4 (s)
3CaO (s) + As2O3 (g) + O2 (g) Ca3(AsO4)2 (s)
Lime Roasting
Taylor et. al (1991) conducted test work on
lime roasting of refractory precious metal
ores.
This study used hydrated lime to react with
arsenic and sulfur under typical roasting
conditions.
The results showed more than 99.9% of the
arsenic and 98% of the sulfur were retained
in the calcine when roasting.
Lime Roasting
The problem with lime roasting for industrial
application is that the arsenic reacted with lime
stays in the solid calcine and is very difficult to
remove.
One possible approach would be to do this reaction
in another reactor where the arsenic off gas is
contacted with lime at elevated temperature.
The question of the acceptability of this product for
disposal would have to be addressed.
Concentrator Bin
(Cu3AsS4)
Gas CO2
Na2CO3
Preliminary
Proposed
Flowsheet
Exhaust
Water
Pelletizer
Roasted
Product Bin
Rotary Kiln
Leached
Solution
Leached
Product
Fe2(SO4)3
As Precipitation
(Solid-Liquid Separation)
Filtering
Thickener
Solid
Disposal
Tank
Leached
Solid
Product
Solutio
n
Tank
Filtering
SMELTER
Na2CO3
Bleed or EDU
for Reagent Regeneration
H2SO4
El Indio
The enargite concentrate (23
wt.% Cu, 15 wt.% Fe, 35 wt.%
S, 10 wt.% As and 0.8 wt.%
Sb).
Treated in a 14-hearth 6.5 m
diameter NicholasHerreschoff roaster in the
temperature range 500C 700C with an oxygen
amount of less than 0.5%.
This made the process
essentially a neutral roasting.
El Indio
The residence time of the feed was about 3
hours.
The outlet gases were captured in two
cyclones, where the collected dust was fed
back to the roaster and the un-oxidized gases
(sulfur and arsenic trisulfide) were oxidized in
a combustion chamber with excess air
through an exothermic reaction at a
temperature of 750 25C
El Indio
Then the oxidized gases were cooled down to 350C 400C in a heat exchanger and directed to an
electrostatic precipitator.
The dust, which contained high precious metal values,
was mixed with flotation concentrates.
The dust free gases were further quenched down to
120 5C with cold air in which a major part of the
arsenic was condensed and removed from the gas
phase as arsenic trioxide (white powder).
The final gas stream was released to the atmosphere.
Sulfation Roast
B. Chambers (2012) evaluated sulfation roasting of
enargite
Calcines produced at two temperatures, 500 and 750 C.
They indicated that while high copper extraction and
arsenic fixation rates could be achieved, the sulfation
roasting reactions are highly exothermic and significant
cooling water would need to be added.
Due to these issues, it is likely that partial roasting
operations would not be economically favorable in
greenfield operations.
However, niche applications of this process in operations
with existing copper SX/EW facilities in good acid markets,
have the potential to be economically favorable.
Ministro Hales
Codelco and Outotec (very little public information)
The treatment of Ministro Hales deposit in Chile by
Codelco (McElroy et al. 2008; Mayhew et al. 2011), which
will start in 2013, expects a yearly throughput of 550,000
tonnes of copper concentrate and 250,000 tonnes of
sulfuric acid production.
Controlled oxidation (or neutral roast) to remove arsenic
as a vapor compound.
Arsenic dust is collected and converted to disposable form
or stockpiled.
Outotec in Frankfurt, Germany is operating a 25 kg per
hour pilot plant that uses the roasting method to treat
copper concentrate (Ondrey, 2012).
Smelters
The ASARCO smelter at El Paso, Texas gives a
maximum of 0.2% As in the copper concentrate
that can be the feed (ASARCO El Paso Smelting
Processes, 2010).
Enargite concentrates are smelted directly by a
few copper smelters but most smelters limit
their arsenic input for environmental reasons
and only process clean copper concentrates,
containing less than about 0.5% As (Peacey et
al., 2010).
Smelters
The Lepanto roaster at Lepanto Consolidated
Mining Company, Philippines treated about 180
tpd of enargite concentrates containing 11% As,
31% Cu, 15% Fe, 34% S and produced calcine
containing 0.3% As, 43% Cu, 23% Fe, and 20% S.
The Boliden roaster at Boliden Oy, Finland, with
a capacity of up to 800 tpd concentrate, treated
concentrates containing 1-2% As and typically
produced a calcine containing about 0.1% As (
Peacey et al., 2010).
Smelters
Dundee Precious Metals Inc. from Chelopec,
Bulgaria transports the enargite concentrates
(175,000 t/a) to the NCS smelter in Tsumeb,
Namibia.
This smelter can treat high arsenic and lead
bearing copper concentrate.
Not many smelters in the world can do that.
Copper blister and arsenic trioxide (As2O3) were
produced from this smelter (Dundee Precious
Metals Inc. 2012a).
Arsenic Collection
As4O6 or As2S3 vapors is the gas phase may be
present in some streams when extracting the
copper.
Electrostatic precipitators or wet gas
scrubbers, are used to collect As2O3 dusts.
As2O3 dust cannot be stockpiled because of
the long term problems associated with the
high solubility in water and toxicity.
Smelter Arsenic
The Horne smelter in Rouyn-Noranda, Quebec has
developed its own process for the precipitation of arsenic in
its effluent treatment plant.
The process is using the AMD (acid mine drainage) as the
agent and produce arsenical ferrihydrite.
The process is increasing the pH to about 4-5 and oxygen
injected to oxidize ferrous to ferric ion, the second stage
reaction tank, the pH is increased to about 9 to precipitate
arsenic to 0.5 ppm (from 2500 ppm).
This is a well proven process in the field, and the product is
stored in a monitored pond.
Smelter Arsenic
Incos Copper Cliff Smelter in Sudbury installed a weak acid
treatment process that also precipitates arsenic as arsenical
ferrihydrites using SO2 and H2SO4 respectively, the process has
been conducted for 30 years.
The Saganoseki copper smelter in Japan precipitates the arsenic in
solution, from its converter dust leach and its acid plant weak acid
bleed, as arsenic sulfide using sodium hydrosulfide.
Codelco has conducted bench scale tests using pyrite and low
grade copper concentrates and pilot plant runs were carried out at
SGS Lakefield treating a weak acid containing 14.8 g/L As and 26
g/L H2SO4. The arsenic precipitated out of solution quickly down
to about 1.5 g/L As. Stable material produced and stored in a
concrete pit on site (Peacey et al., 2010).
Ferrihydrate Precipitation
Co-precipitation removal of arsenic by ferrihydrite
precipitation from solutions containing both dissolved
iron and arsenic species.
Post-precipitation is removal of arsenic from solutions
by the addition of a solution of aqueous ferric bearing
species at a pH where ferrihydrite forms (usually at
pH 7 to 8) adsorption is removal of arsenic from
solutions by exposing arsenic bearing solutions to a
previously precipitated ferrihydrite solid.
The precipitation depends on time, temperature, pH,
Fe/As mole ratio, agitation rate, arsenic valence state,
associated ion, etc (Patnaik, 2004).
Ferric Precipitation
The precipitation of dissolved arsenic with ferric ions
has been declared by The United States
Environmental Protection Agency (EPA) as The Best
Demonstrated Available Technology (BDAT) (Riveros
et al. 2001; Rosengrant and Fargo 1990).
Several factors that have influences on the stability of
any disposed arsenic compound: characteristics of
the disposal location, crystallinity and size
distribution of the compound, and the presence of
oxygen or any complexing agents.
Ferric Precipitation
Arsenic ferrihydrite compounds is formed at low temperatures
and atmospheric pressure and it is amorphous and voluminous.
According to the EPA, arsenic ferrihydrite compounds are
acceptable for practical arsenic disposal operations, releasing less
arsenic than the mandatory requirements in many countries.
Scorodite was formed at high temperature and pressure
conditions.
It produces a low-volume, dense, crystalline precipitate that has
lower solubility (less than 1 mg/L As at pH 5) than arsenical
ferrihydrite.
However, recent research shows the possibility of scorodite
formation under atmospheric pressure conditions; but the
industrial application of this process has not yet been reported.
Factors in Processing
Some general difficulties of applying certain
arsenic treatment method are:
A wide range of arsenic concentrations
Effects of other elements and their variable
concentrations in the solution
The need to adjust pH for optimal removal
Optimized dose
Proper operation and maintenance
Safe disposal of solid arsenic waste
Conclusions
Smelters generally accept copper concentrates
with low arsenic levels (less than 0.2% to 0.5%)
due to environmental and product purity
concerns.
Treating the waste stream from high arsenic
copper concentrates requires significant
investment.
The separation and collection of arsenic as
arsenic trioxide is problematic, primarily due to
its toxicity and lack of market value.
Conclusions
Pyrometallurgical processing has several concerns:
- the strict environmental regulations on arsenic release
- the complexity of gas/dust capture
- separation facilities
- and the stabilization of the final arsenic compound
Recent application in the industry to treat high
arsenic concentrate (enargite) were Barrick's El Indio
smelter in Chile and Xstrata's Home smelter in
Canada.
Both employed reductive roasting-smelting process
for the treatment of enargite concentrates.
Conclusions
Despite the perceived shortcomings for roasting to
selectively volatilize arsenic, the process could an
option under specific conditions, provided that a
arsenic precipitation process is possible.
Roasting is the only process that has been operated
commercially for enargite concentrates; therefore the
level of project risk is lower, i.e. based on past
commercial experience.
Another advantage of roasting is it is less sensitive to
feed mineralogy than hydrometallurgical options and
arsenic disposal as a compact crystalline compound
with low solubility would appear possible.
Thank you!!!
It has been a pleasure to be at
PERUMIN again.