Flotation separation of iron oxide from undigested matte particles obtained from autoclave leach residues

Claim 2

In a method of leaching comminuted matte containing at least one of the metal values nickel and copper and containing iron as an impurity, wherein said matte in the form of a slurry is subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of said metal values and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte, the improvement comprising, subjecting an aqueous slurry of said autoclave leach residue to flotation in a flotation cell without the addition of a flotation reagent by bubbling air therethrough, continuing bubbling air through said aqueous slurry to float selectively undigested matte particles and form a froth containing said undigested matte particles and a tailings containing substantially this iron oxide, collecting said froth, and disposing of said iron oxide-containing tailings.

Claim 3

The method of claim 1, wherein the undigested matte particles recovered by said froth are recycled to said autoclave for further leaching thereof.

Claim 4

In a method of leaching comminuted matte containing at least one of the metal values nickel and copper and containing iron as an impurity, wherein said matte in the form of a slurry is subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of said metal values and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte by adding a flocculating agent to flocculate said residue and effect the settling thereof, the improvement which comprises, subjecting an aqueous slurry of said settled flocculated autoclave leach residue to high speed, high shear stirring sufficient to break up said flocculated residue and form a dispersion of undigested matte particles and iron oxide in said slurry, subjecting said slurry to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous slurry to float selectively said undigested matte particles and form a froth containing said particles and a tailings containing said iron oxide, collecting said froth of undigested matte particles and recycling it back into the leaching process, and disposing of said iron oxide-containing tailings.

Claim 5

In a method of leaching comminuted matte containing at least one of the metal values nickel and copper and containing iron as an impurity, wherein said matte in the form of a slurry is subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of said metal values and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte by adding a flocculating agent to flocculate said residue and effect the settling thereof, the improvement which comprises, subjecting an aqueous slurry of said settled flocculated autoclave leach residue to high speed, high shear stirring sufficient to break up said flocculated residue and form a dispersion of undigested matte particles and iron oxide in said slurry, subjecting said slurry to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous slurry to float selectively said undigested matte particles and form a froth containing said particles and a tailings containing said iron oxide, collecting said froth of undigested matte particles and recycling it back into the leaching process, and disposing of said iron oxide-containing tailings.

Claim 6

The method of claim 3, wherein said stirring is carried out with an impeller rotatng at a peripheral speed of at least about 3000 feet per minute.

Claim 7

In the acid leaching of comminuted copper nickel matte containing about 30% to 70% nickel, about 5% to 40% copper, 0.5% to 20% iron, about 5% to 25% sulfur, the sum of the nickel, copper, iron and sulfur contents being at least about 85% be weight of said matte, wherein said comminuted matte is atmospherically leached with a sulfuric acid-containing solution to effect selective dissolution of a substantial amount of nickel in said matte and provide an atmospheric leach matte residue which in the form of a slurry is thereafter subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of nickel and copper from said atmospheric leach residue and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte, the improvement comprising, subjecting an aqueous slurry of said autoclave leach residue to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous medium to float selectively said undigested matte and form a froth containing undigested matte particles and a tailings containing substantially said iron oxide, collecting said froth and disposing of said iron oxide-containing tailings.

Claim 8

In the acid leaching of comminuted copper nickel matte containing about 30% to 70% nickel, about 5% to 40% copper, 0.5% to 20% iron, about 5% to 25% sulfur, the sum of the nickel, copper, iron and sulfur contents being at least about 85% be weight of said matte, wherein said comminuted matte is atmospherically leached with a sulfuric acid-containing solution to effect selective dissolution of a substantial amount of nickel in said matte and provide an atmospheric leach matte residue which in the form of a slurry is thereafter subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of nickel and copper from said atmospheric leach residue and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte, the improvement comprising, subjecting an aqueous slurry of said autoclave leach residue to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous medium to float selectively said undigested matte and form a froth containing undigested matte particles and a tailings containing substantially said iron oxide, collecting said froth and disposing of said iron oxide-containing tailings.

Claim 9

The method of claim 5, wherein the undigested matte particles recovered by said froth are recycled to said autoclave for further leaching thereof.

Claim 10

In the leaching of comminuted copper nickel matte containing about 30% to 70% nickel, about 5% to 40 % copper, 0.5% to 20% iron, about 5% to 25% sulfur, the sum of the nickel, copper, iron and sulfur contents being at least about 85% be weight of said matte, wherein said comminuted matte is atmospherically leached with a sulfuric acid-containing solution to effect selective dissolution of a substantial amount of nickel in said matte and provide an atmospheric leach matte residue which in the form of a slurry is thereafter subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of nickel and copper from said atmospheric leach residue and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte by adding a flocculating agent to flocculate said residue and effect settling thereof, the improvement comprising, subjecting an aqueous slurry of said settled autoclave leach residue to high speed, high shear stirring sufficient to break up said flocculated residue and form a dispersion of undigested matte particles and iron oxide, subjecting said slurry dispersion to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous medium to float selectively said undigested matte particles and form a froth containing said undigested matte particles and a tailings containing substantially said iron oxide, collecting said froth and disposing of said iron oxide-containing tailings.

Claim 11

In the leaching of comminuted copper nickel matte containing about 30% to 70% nickel, about 5% to 40 % copper, 0.5% to 20% iron, about 5% to 25% sulfur, the sum of the nickel, copper, iron and sulfur contents being at least about 85% be weight of said matte, wherein said comminuted matte is atmospherically leached with a sulfuric acid-containing solution to effect selective dissolution of a substantial amount of nickel in said matte and provide an atmospheric leach matte residue which in the form of a slurry is thereafter subjected to at least one high pressure high temperature oxidation leach in an autoclave to dissolve substantial amounts of nickel and copper from said atmospheric leach residue and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue containing said iron oxide and said undigested matte by adding a flocculating agent to flocculate said residue and effect settling thereof, the improvement comprising, subjecting an aqueous slurry of said settled autoclave leach residue to high speed, high shear stirring sufficient to break up said flocculated residue and form a dispersion of undigested matte particles and iron oxide, subjecting said slurry dispersion to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous medium to float selectively said undigested matte particles and form a froth containing said undigested matte particles and a tailings containing substantially said iron oxide, collecting said froth and disposing of said iron oxide-containing tailings.

Claim 12

The method of claim 7, wherein the undigested matte particles recovered by said froth are recycled to said autoclave for further leaching thereof.

Claim 13

In the leaching of comminuted copper nickel matte containing about 30% to 70% nickel, about 5% to 40% copper, 0.5% to 20% iron, about 5% to 25% sulfur, the sum of the nickel, copper, iron and sulfur contents being at least about 85% by weight of the matte, wherein said comminuted matte is atmospherically leached with a sulfuric acid-containing solution to effect selective dissolution of a substantial amount of nickel in said matte and provide an atmospheric leach matte residue which in the form of a slurry is thereafter subjected to at least one high pressure high temperature oxidation acid leach in an autoclave at a temperature of over 100° C. at an oxygen pressure ranging from about 0.7 to 20 atm., a total pressure of about 7 to 50 atm. and a terminal pH ranging up to about 4 to dissolve substantial amounts of nickel and copper from said atmospheric leach residue and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue, the improvement comprising, subjecting an aqueous slurry of said autoclave leach residue to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous medium to float selectively undigested matte particles and form a froth containing said undigested matte particles and a tailings containing substantially said iron oxide, collecting said froth and disposing of said iron oxide-containing tailings.

Claim 14

In the leaching of comminuted copper nickel matte containing about 30% to 70% nickel, about 5% to 40% copper, 0.5% to 20% iron, about 5% to 25% sulfur, the sum of the nickel, copper, iron and sulfur contents being at least about 85% by weight of the matte, wherein said comminuted matte is atmospherically leached with a sulfuric acid-containing solution to effect selective dissolution of a substantial amount of nickel in said matte and provide an atmospheric leach matte residue which in the form of a slurry is thereafter subjected to at least one high pressure high temperature oxidation acid leach in an autoclave at a temperature of over 100° C. at an oxygen pressure ranging from about 0.7 to 20 atm., a total pressure of about 7 to 50 atm. and a terminal pH ranging up to about 4 to dissolve substantial amounts of nickel and copper from said atmospheric leach residue and provide a pregnant liquor thereof and a residue comprising undigested matte and iron oxide in flotation separable form, and wherein said slurry is subjected to liquid/solid separation to effect separation of said pregnant liquor from said residue, the improvement comprising, subjecting an aqueous slurry of said autoclave leach residue to flotation in a flotation cell without the addition of a flotation agent by bubbling air therethrough, continuing bubbling air through said aqueous medium to float selectively undigested matte particles and form a froth containing said undigested matte particles and a tailings containing substantially said iron oxide, collecting said froth and disposing of said iron oxide-containing tailings.

Claim 15

The method of claim 9, wherein the pregnant liquor is separated from said autoclave leach residue by adding a flocculating agent to flocculate said residue and effect settling thereof, and wherein prior to flotation an aqueous slurry of said flocculated residue is subjected to high speed, high shear stirring sufficient to break up said flocculated residue and form a dispersion of undigested matte particles and iron oxide.

Claim 16

The method of claim 9, wherein the undigested matte particles recovered by said froth are recycled to said autoclave for further leaching thereof.