A Study on Optimum Conditions of Copper Ore Leaching 255

A Study on Optimum Conditions of Copper Ore Leaching

S.M.J. Koleini* and A. Rafati**
*Assistant Prof., **Postgraduate Student, Mineral Processing Eng. Dep.,
Tarbiat Modares University, Tehran, Iran.

ABSTRACT: Increasing needs of mankind and industrial development were led to increasing consumption of
mined material. Because of decreasing mine deposits grade extraction of low grade mined material with
employing methods such as “Heap Leaching” has received more attention. The copper ore sample from Chizeh
mine was subjected to mineralogical studies. These studies have shown that major copper mineral is malachite
with very low value of sulphide mineral like covellite. To study effective parameters on copper recovery rate,
tank and column leaching tests were employed in several possible conditions. In optimum condition of column
leaching test, 80gr/Lit sulfuric acid concentration, 20 cc/min acid flow rate, 8 days leaching time and (-2794, +
1000 µm) ore particles size, the highest copper leaching rate of 92.3% was achieved.

1. INTRODUCTION estimate copper grade (Table 1). According to

atomic absorption analysis, total, oxide and
Chizeh copper mine is located at 30 Km of sulphide copper grade were respectively %2.66,
Khoramdarreh city in Zanjan Province. This %2.51 and %0.51.
area is consisting of regular sequence of
sedimentary and volcanic stones. To evaluate
average copper grade in Chizeh copper mine, 2. EXPERIMENTAL DESIGN
200 samples were prepared from exploration So far some methods are used for experimental
area. Finally average grade of copper was design. The purpose of these methods is
estimated to be %2 ± 0.3, with 5/184/000 tones decreasing number of laboratory tests and
of copper ores and 103/680 tonnes copper costs. In this study Taguchi experimental
metal. design method was used (Aghazadeh, 1381).
XRD analysis was carried out to identify Four parameters including leaching time,
ore component. These studies have shown that Sulphuric acid concentration, and acid flow
major copper mineral is malachite with very rate and particles size were determined in 3
low value of sulphide mineral like covellite. levels. Therefore L9 array of Taguchi should
According to the results it was found that ore was used in (Table 2).
is consist of Quartz, Orthoclase, Albite and The parameter level selection were based
Muscovite as tailings. on previous studies results on similar copper
Oxide copper minerals weren't detected in deposits such as Sarcheshmeh (Kerman),
XRD analysis because the grade of copper is Darreh Zereshk (Yazd) and Dechan
high (%2 ± 0.3) in this deposit. So polished (Azarbijan), and also obtained tank leaching
sections were prepared for microscopic tests were carried out on Chizeh deposit
studies. According to these studies oxide (Javadian,1381, Noorolsana, 1379, Noparast,
copper minerals present as malachite. Also low 1381, Rafati, 1382) (Table 3).
quantities of sulphide copper ores are present
as Coveline and calcosite. The main source of Table 1: Atomic absorption analyses results
oxide copper minerals was some sulphied
minerals like chalcopyrite which were changed Cu Cu
Element Al Fe SiO2
(Oxide) (Sulphide)
to oxide minerals by high oxidation in this 8
area. Grade 3.82 56.32 2.51 0.15
.01

Table 2: Taguchi L9 array design for 3levels

Atomic absorption analysis was carried out to factors
256  Mineral Processing Technology (MPT 2007)
L9 Design Experiment Design Final
RUN
1 2 3 4 Particles Acid Acid Flow copper
No. Time
1 -1 -1 -1 -1 size Conc. Rate recovery
2 -1 0 0 0 (gr/lit) (cc/min) (day) (%)
(µm)
3 -1 +1 +1 +1 -9375
4 0 -1 0 +1 1 60 10 5 50.25
+6250
5 0 0 +1 -1
-6250
6 0 +1 -1 0 2 80 20 5 76.41
+2794
7 +1 -1 +1 0
8 +1 0 -1 +1 -2794
3 100 30 5 82.14
9 +1 +1 0 -1 +1000
Table 3: Factors and its range in Taguchi -2794
4 80 10 11 84.32
experiment design. +1000
-9375
Factor Range 5 60 20 11 87.31
Time +6250
5 8 11 -6250
(day) 6 100 30 11 79.33
Particles Size +2794
-2794 -6250 -9375
(µm) -6250
7 100 10 8 50
Acid +2794
Concentration 60 80 100 -2794
(gr/lit) 8 60 20 8 82.2
+1000
Acid Flow
10 20 30 -9375
Rate (cc/min) 9 80 30 8 78.35
+6250
In column leaching test there are some
relations between column dimension,
maximum size of particles and column Table 5: Parameters effects on copper
recovery values
diameters which should be attended. Usually
the ratio of column length to diameter is 10 Parameter Level 1 Level 2 Level 3
and the ratio of column diameter to maximum Time (t) 69.6 83.65 70.18
particles size is 5 or more. In this study
Acid
columns with 13 cm diameter and 110cm 70.6 97.7 73.15
Concentration (c)
length from Plaxcy glass were employed. A 2-
3 cm layer of washed sand with a whatman Particles Size (d) 71.97 68.58 82.9
paper were putted at the end of each column to Acid Flow Rate
61.52 82.00 79.94
pregnant solution filtration. Above it was (q)
felled of 5 Kg crushed ore in each particle size According to Tagouchi tests plane (Table 3)
range. Particles size distribution each part of and daily analysis, final recovery values were
crushed ore was mixed to water in %10 weight calculated (Table 4). To determine effects of each
ratio. To uniform distribution of leaching parameter, average of final recovery values in
solution a layer of fiber-glass between two each level were calculated and results are shown
Whatman papers were used in the top of each in Table 5 and illustrated in figures 1 to 4.
column. According to column leaching tests results,
Acid sparging time was 8 hours a day. optimum values of time, Sulphuric acid
After this time acid current was cut and concentration, particle size and acid flow rate
pregnant solution was collected in a container were 8days, 80gr/lit, (-2794, + 1000) µm and 20
to prepare reagent samples to some cc/min respectively. Finally a column leaching
measurements (copper concentration). After assurance test in optimum conditions were
each test, remainder soil were washed and carried out. Daily copper recovery values are
dried in an oven to determine at least copper shown in Table 6. In These conditions final
grade and recovery valuation. copper recovery were calculated to be %92.3.

Table 4: Final recovery values of each column

A Study on Optimum Conditions of Copper Ore Leaching 257
Table 6: Daily copper recovery in optimum 100

Copper Recovery ( % )
conditions test.
80
Day Copper Recovery (%) 60

1 81.76 40
20
2 9.02
0
3 3.22 10 20 30
4 1.43
Acid Flow Rate (cc/min)
5 0.84
6 0.52
Fig. 4: Copper recovery vs. acid flow rate.
85
Copper Recovery ( % )

80
75
3. CONCLUSIONS
70
65 Mineralogy studies, microscopic review of
60 published and sections and XRD, XRF
55
50
analysis accept presence of some minerals like
60 80 100 Quartz, Orthoclase, Albite, Muscovite,
Acid conc.(gr/Lit) Dolomite, Calcite and feldesphar as gangue
mineral. Also oxide copper and sulphide
copper as Malachite with very low value of
Fig. 1: Copper recovery vs. acid concentration. Azorite.
According to atomic absorption and
analysis oxide, sulphide and total copper grade
100
respectively are %2.51, %0.15 and %2.66. So
Copper Recovery ( % )

80
sulphuric acid can be used as leaching
60
solution.
40
According to results of 9 column leaching
20 tests optimum leaching conditions are: time 9
0 days, acid sulphuric concentration 80 gr/lit,
5 8 11 and particles size (-2794, +1000) µm and acid
Time (day) flow rate 20 cc/min. In these conditions, final
copper recovery is %92.3.

Fig. 2: Copper recovery vs. time.

4. ACKNOWLEDGEMENTS
85 Authors are thankful to Tarbiat Modares
80 University and Chizeh Mine for providing
Copper Recovery(%)

75
samples and contributions.
70
65
60 5. REFERENCES
55
50 [1] Aghazadeh V., Songon Oxide Copper
2794 4794 6794 8794 Leaching, Msc Thesis, Tehran University,
1381.
Size (micron)
[2] Javadian A., Determination of Effective
Parameters in Darreh Zereshk (Yazd) Ore
Fig. 3: Copper recovery vs. particle size. Copper Leaching. Msc thesis, Tarbiat
Modarres University, 1381.
258  Mineral Processing Technology (MPT 2007)
[3] Noorolsana A., Experiments Design,
Technological Management Organization,
1379.
[4] Noparast M., Samani, B., Asgari, R., “Column
Leaching of Dechan Uranium and Copper
Ore”, Nuclear Sciences and Technologies,
No. 25, pp: 39-47, 1381.
[5] Roman, Poland J., “Column Leaching Teast-
copper Ores”, 1991.
[6] Rafati A., Determination of Optimum
Conditions of Copper Ore Leaching of Zanjan
Chizeh Mine, Msc Thesis, Tarbiat Modarres
University, 1382.
[7] Samimi A., Leaching Hydrometallurgical
Studies of Oxide Copper Ore of Sarcheshmeh
Mine, 1st Iran Non-Ferrous Metals Metallurgy,
Vol. 1, 1375.
[8] Ubaldini, S. and Piga, L., Removed of Iron
from Quartz Sands, A study by Column
Leaching Using a Complete Fractional
Designed, Hydrometallurgy, Vol. 40, pp:369-
379, 1995.