Hydrometallurgy: Yunjiao Li, Vladimiros G. Papangelakis, Ilya Perederiy
Hydrometallurgy: Yunjiao Li, Vladimiros G. Papangelakis, Ilya Perederiy
Hydrometallurgy
j o u r n a l h o m e p a g e : w w w. e l s ev i e r. c o m / l o c a t e / h yd r o m e t
High pressure oxidative acid leaching of nickel smelter slag: Characterization of feed
and residue
Yunjiao Li, Vladimiros G. Papangelakis ⁎, Ilya Perederiy
Department of Chemical Engineering and Applied Chemistry, University of Toronto, 200 College Street, Toronto, Ontario, Canada M5S 3E5
a r t i c l e i n f o a b s t r a c t
Article history: Discarded slags have potential adverse environmental impact and valuable metal contents. High pressure
Received 2 October 2008 oxidative acid leaching (HPOXAL) was employed to clean a slow-cooled copper–nickel flash smelter slag
Received in revised form 9 March 2009 containing about 1% Cu and 1% Ni and selectively leach the contained base metal values. Characterization of
Accepted 10 March 2009
the slag and leach residues was carried out using powder X-ray diffraction (PXRD), scanning electron
Available online 26 March 2009
microscopy (SEM) and particle size analysis (PSA). It was found that the copper–nickel smelter slag was
Keywords:
composed of major crystalline fayalite and minor amorphous silica phases with trace amounts of magnetite
Smelter slag and entrapped matte, existing as uneven and finely dispersed particles, which are responsible for the loss of
Pressure acid leaching base metals. Most of the copper in the slag appeared as sulfide, while most of the nickel existed in the oxide
Base metal dissolution form with a minor portion as sulfide. Cobalt and zinc phases were rarely detected because of their low
Fayalite content. During high pressure oxidative acid leaching, temperature and acidity were the key variables
Hematite controlling the leaching of the base metals and iron. At 250 °C and 20% acid addition, N 99% Ni, Co and Cu
could be extracted into solution together with 94% Zn and b 2.2% Fe. Iron and silicon were transformed into
crystalline hematite and amorphous silica in the residue. By adjusting the acidity to control the rate of
fayalite dissolution and the growth of precipitates, flower-like hematite particles associated with amorphous
silica were produced. An excellent slurry filtration rate of 0.36 m3·m− 2·h− 1 was obtained.
© 2009 Elsevier B.V. All rights reserved.
0304-386X/$ – see front matter © 2009 Elsevier B.V. All rights reserved.
doi:10.1016/j.hydromet.2009.03.007
186 Y. Li et al. / Hydrometallurgy 97 (2009) 185–193
Table 1
Chemical and mineralogical composition of slag.
process than a quenched slag with an amorphous structure. Extraction of the degree of crystallization were carried out by powder X-ray
of about 95% Ni and Co was obtained from slow-cooled converter diffraction analysis (XRD) with a Cu-Kα radiation source, using a
slags. Philips XRD system. The general morphology and approximate
In the HPOXAL process, the liberation of metals from fayalite particle size were observed using a JEOL JSM-840 scanning electron
matrix and the precipitation of hematite are two most important steps microscope (SEM) at 15 kV for scanning electron and at 20 kV for
in the selective recovery of valuable metals (Li et al., 2008). Iron backscattered electron (BSE) measurements. Powder particles were
precipitation, in particular, directly impacts the rate of solid–liquid dispersed on a conductive tape and gold coated for morphology
separation. However, few researchers focused on the characterization observation. A polished section was prepared from a slag block and
of slags and the acid-leached residues. Gbor et al. (2000a) reported on scanned across the interface to obtain phase images with back-
the characterization of smelter slags by optical microscopy, SEM/EDX scattered electrons. Energy dispersive spectrometry (EDX) micro-
and XRD, but did not give detailed information on the nature of base analysis was performed on various sample regions. Because of the
metals and/or matte droplets in the slags. Since knowledge about the very fine particle sizes and mixed structures of the materials, the X-ray
form and structure of fayalite slags and leach residues may help microanalysis was inevitably biased by the surrounding particles or
uncover the mechanism of the HPOXAL process, a detailed investiga- structures.
tion was undertaken using X-ray diffraction (XRD), scanning electron
microscopy (SEM) and particle size analysis (PSA). 3. Results and discussion
2.1. Slag preparation and leaching The chemical composition of the slag determined by ICP-AES is
shown in Table 1. Iron and silicon are, of course, the main elements
The block slag as-received from Vale Inco's nickel smelter was that occur mainly in the form of fayalite and account for 57.5 wt.% of
crushed and then ground in a ball mill, and dry-sieved to less than the slag mass. Nickel and copper each constitute around 1% of slag
150 µm. It was then separated into small portions for each experiment mass together with some cobalt (0.24 wt.%) and zinc (0.14 wt.%).
through multiple splitting. Sulfur accounts for 1.54 wt.% as sulfide phases.
Slag leaching was conducted in a 2-L titanium batch autoclave Fayalite, the main component of slag, is the iron-rich end member
(Model 4524 Reactor, Parr Instrument Company) equipped with an of olivine solid-solution with an ideal formula of Fe2SiO4 or 2FeO·SiO2.
acid injector and a water-cooled titanium sampling line with an in- It crystallizes in the orthorhombic system with cell parameters a
situ graphite filter. Temperature was controlled with an accuracy of 4.82 Å, b 10.48 Å and c 6.09 Å. Fayalite can be dissolved in acid even at
±1 °C. Oxygen was introduced through a tantalum dip tube, with its pH 2 in fully oxygenated and anoxic solutions to release iron and silica
overpressure and flow rate controlled by two Brooks pressure and (Santell et al., 2001). This property makes it ideal for the liberation of
flow controllers, model 5866RT. Details of the experimental setup and valuable encapsulated metals by acid leaching.
procedure have been given previously (Li et al., 2008). Leaching was The diffractogram shown in Fig. 1 confirmed that the slag consists
run in the restricted flow rate mode until the completion of chemical of crystalline fayalite with magnetite and some unidentified minor
reactions in order to negate the effect of overpressure fluctuations. phases. The distinctly strong and narrow fayalite peaks demonstrate a
After that oxygen overpressure was allowed to climb to the set point, high degree of crystallinity obtained during slow cooling (Baghalha
regulated by a pressure controller. Vapour pressure fluctuations taken et al., 2007; Curlook et al., 2004). The weak peaks detected at 2θ values
into account by reading temperature. Autoclave cooling was per-
formed for approximately 30 min, until the temperature dropped to
70 to 80 °C.
2.3. Characterization
of 30.22°, 35.58°, 43.30°, 57.08° and 62.70° are consistent with the Fig. 2 shows the SEM/EDX results for a block-sectioned slag sample. A
existence of spinel magnetite which is formed under high oxygen backscattered electron (BSE) image shown in Fig. 2(a) is accompanied
overpressure at a high temperature during smelting (Gilchrist, 1989). by a higher-resolution, enlarged view–Fig. 2(b). Four distinct phases,
The rough baseline in the XRD pattern shows that there are some fayalite, silica, matte and magnetite, with different colors and brightness
amorphous constituents — most likely metal oxides combined with were identified. EDX measurements were carried out on different areas
silica, such as 2MgO·SiO2. Other ferrites (minor or trace) that could be and the typical EDX spectra are shown in Fig. 2(c) to (f). The bright
present include ZnO·Fe2O3 and CaO·Fe2O3. Assuming magnetite is the white-colored small dots (Area 1), with an average particle size of
only significant phase containing Fe(III), the slag is estimated to approximately 10 μm, contain major sulfur and iron as well as trace
contain 10.6% of magnetite and 58.7% of fayalite by weight based on amounts of nickel and are entrapped matte droplets. This was confirmed
the chemical analysis shown in Table 1. Based on the silicon content, by the EDX spectrum shown in Fig. 2(c). It can be seen that the matte
20.5 wt.% is SiO2 present as free amorphous silica or metal silicates, droplets are finely and unevenly embedded in the slag in different
except for fayalite. The rest of the slag (10.2%) includes metal oxides particle sizes ranging from 2 to 20 µm (Fig. 2(a)). The large dark grey-
such as MgO, CaO, Al2O3, etc. colored region (Area 2) is fayalite. As expected, large amounts of silicon
Fig. 7. Effect of acid addition on base metal extractions. Solid loading 25%; PO2 500 kPa; Fig. 9. XRD pattern of a typical residue.
temperature 250 °C; time 120 min (adapted from Li et al., 2008).
The properties of hematite, such as particle size and morphology, From Fig. 7, it was found that acid addition which levels up to 20 wt.%
directly affect the viscosity of the slurry, its filterability and to some of slag was sufficient to extract N97% Ni, Co, Cu, as well as 95% Zn in
extent the solubility of iron. Slurry viscosity affects the mass transfer 2 h. Excessive acid addition gave no benefit in terms of enhancing base
and consequently the extraction of base metals at temperature as well metal extractions and increased lime consumption needed for
as the subsequent solid–liquid separation under ambient conditions. neutralisation downstream. Fig. 8 shows the total iron concentration
Consistent with our previous work (Li et al., 2008; Baghalha et al., at 250 °C increased roughly 30-fold from 0.04 to 1.30 g/L due to the
2007), it was found that the acidity and temperature are the key exponential increase of hematite solubility with the acid addition
factors affecting the dissolution of valuable metals and iron in either increased from 15 to 30% (Liu et al., 2003; Reid and Papangelakis,
sulfide or oxide form in the presence of oxygen. 2006). However, percentage iron dissolution remained below 1.2% at
250 °C.
3.2.1. Effect of temperature It was also noticed that there was a noticeable difference in iron
The effect of temperature on base metal extractions and iron levels before and after autoclave cooling with an acid addition level of
dissolution is shown in Figs. 5 and 6, respectively. As expected, with an 30%. Iron concentration dramatically increases from 1.3 g/L before
increase in temperature from 175° to 250 °C, base metal extractions in cooling to 8.3 g/L after cooling down to 70–80 °C (Fig. 8(b)),
2 h increase from about 90% to about 99% whilst iron exhibits a reverse corresponding to 14.5% iron dissolution due to the re-dissolution of
trend due to the decrease in hematite solubility. From Fig. 6, the total precipitated hematite (or basic ferric sulphate) which impacts the
iron concentration reduces from 4.0 to 1.1 g/L corresponding to a subsequent iron removal step.
decrease in iron dissolution from 3.8 to 1.0%. Hence, a temperature of Therefore, an acid addition level of 20% or lower is recommended
250 °C or higher is preferable in terms of leaching selectivity. for maintaining a high recovery of base metals and low iron
dissolution. Flash discharging of the autoclave slurry is assumed to
3.2.2. Effect of acid addition be capable of minimizing hematite re-dissolution.
A series of similar tests with various acid additions was previously
performed (Li et al., 2008) with the results shown in Figs. 7 and 8. 3.3. Characterization of hematite residues
Table 2
Chemical composition of residues (wt.%) produced under: acid addition 20%; solid
loading 25%; 250 °C; 120 min.
Fig. 10. SEM images and EDX spectrum of a residue obtained at 47 wt.% acid addition. Solid loading 15 wt.%; PO2 500 kPa; temperature 250 °C; time 120 min.
Fig. 11. SEM images and EDX spectrum of a residue obtained at 25 wt.% acid addition. Solid loading 25 wt.%; PO2 500 kPa; temperature 250 °C; time 120 min.
192 Y. Li et al. / Hydrometallurgy 97 (2009) 185–193
Fig. 12. SEM images and EDX spectrum of a residue obtained at 20 wt.% acid addition. Solid loading 25 wt.%; PO2 430 kPa; temperature 250 °C; time 120 min.
Y. Li et al. / Hydrometallurgy 97 (2009) 185–193 193
Compared with the residue particles in Fig. 10, the ones obtained (NSERC-I2I Program) and the kind support and supply of the slag
at a low acid addition level of 25% are more even in terms of sample from Vale Inco.
size distribution. Most of these particles are scale-like aggregates,
0.5–10 µm in size, as shown in Fig. 11 (a) and (b). But there are still References
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The authors would like to acknowledge the financial support from
the Natural Science and Engineering Research Council of Canada