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Copper Recovery Flotation: Slag Composition Loses Priority To Controlled Cooling of The Slag
Copper Recovery Flotation: Slag Composition Loses Priority To Controlled Cooling of The Slag
Laboratory Studies
Harjavalta,,4
Work at North
Flash Slags from Caucasian Min·
Furnace Converter Mednegorsk ing and Met.
Source of Slag Hitachil Naoshima" Slag Slag plant' Instituteo;
Composition of slag:
% Cu 4.0 3.0 1-1.5 4.0 2.2 3.5
% SiO. 20.0 19.1 29.0 23.0 23.4 24.8
% Fe 46.0 49.4 44.0 38.5 45.2 46.8
% Fe.O. 20 25 13 20 (est'd) 32
Cooling conditions: Cast into pigs Cast inlo pigs Slow-cooled in pits
Grinding ball mill ball mill autogenous laboratory mill laboratory mill
Fineness of grind 90% -325 rn. CO 93% - 325 rn. 90% -270 m. 98% -270 m. 97.3% -325 m.
Cu in non-magnetic concentrate 59.4
Cu in slag concentrate 24.0 21.3 18.2 20.0 27.6
Cu in tailing 0.40 0.32 0.32 0.21 0.27
Concentration ratio 5.60 7.73 6.67 9.90 8.18
% recovery of copper 94.3 92.3 90.1 91.8 93.0
In comparison, milling of the same growth of the precipitated particles tend to promote the formation of
slag after granulation by water can take place. Granulated slags the amorphous vitreous phase and
quenching resulted in a 0.7% cop- were reheated to temperatures thus inhibit the precipitation of sul-
per tailing. close to the melting range and were fide particles. Zinc content in the
The effect of cooling rate on cop- " annealed" for different periods of slag above the 4% level has a simi-
per recovery was demonstrated at time. The samples were then lar effect.
Naoshima2 by comparative grinding cooled, ground and leached in am- The silica content of the slag
and flotation tests on slowly-cooled monia to determine the amount of affects its hardness and hence the
slag and on slag which was cast in precipitated copper sulphide. Figs. grindability. Dukhanin 6 has shown
an iron mold and water-quenched; 4 and 5 show clearly the beneficial that the relative grindability of con-
the tailings contained 0.20% and effect of the annealing treatment at verter and reverberatory slags is
0.65% copper, respectively. In nor- temperatures close to the melting 1.0 and 0.77, respectively. On this
mal practice at the plant, where the range of the slag. scale, results at Noranda have
slag is cast in iron molds and air- Apart from its effect on copper shown that the grindability of a
cooled, the copper content in the recovery, slow cooling also im- chalcopyrite ore is about 2, i.e.,
tailing is 0.32% (Table I). proves the grindability of the slag. 7 converter slag is nearly twice as
Laboratory milling tests by Alim- The relative grindability of slags hard to grind as copper ore. The
baev et al. 7 have shown (Fig. 3) that cooled at different rates are shown high consumption of grinding
the copper loss in the tailing de- in Table III. Slow cooling promotes media is an important cost factor in
creases with slow cooling rates and the formation and growth of crys- slag milling , and has led to the
fineness of grind. talline phase which is easily adoption of autogenous grinding at
ground. Fast cooling renders the the Harjavalta smelter. However,
Yazawa and Kameda5 have dem- slag structure amorphous and in- the Hitachi and Naoshima smelters
onstrated that an important factor hibits fine grinding. use cast iron balls for grinding.
in the precipitation process is the
residence time of the slag at a tem- Effect of Composition
MILLING OF NORANDA PROCESS
perature just below the melting Yazawa and Kameda 5 have SLAGS
range of the slag, when maximum shown that alumina or lime in slag As noted earlier, th is study was
mainly concerned with the milling
Table II-Distribution of copper, silver, and gold in the milling products
of slags produced in the Noranda
of three smelters Process for the continuous smelting
and converting of copper concen-
Concentration trates. 9 A low-silica slag (20-24%
Distribution (%)
Copper Silver Gold - -- - -- - -- Si0 2) is produced in the converting
% glt glt Copper Silver Gold
zone of the reactor where the slag
Nippon Mining CO.\IO
Hitachi smelter is in intimate contact with high-
Converter slag 100
Non-magnetic concentrat e
4.05
44 .05
56
812
0.7
10.2 29 .7
100
39 .6
100
41.2
grade matte (77% Cu) and metallic
Flotation concentrate
Flotation tails
22.59
0.34
268
4.1
3.2
0.04
63.0
7.25
54 . 1
6.3
53. 6
5.2
copper.
Saganoseki smelter
(to March 1969)
This slag is highly oxidized and
Con verter slag
Flotation concentra te
3.64
26.41
34
240
1.4
10.4
100
91 .6
100
89.2
100
93.6
contains 20-30% Fe30 4 in soluble
Flotation tails 0.35 4.0 0.1 8.4 10.8 6.4 and entrained form. Following some
Mitsubishi Metal Mining Co. "
Naosh ima smelter settling in the slag zone, the tapped
Con verter slag 4.8 7 31 0.4 100 100 100
Flotation conc entrate 28.53 191 2.8 93.4 97.3 100 slag contains 8-12% copper. Mi-
Flotation tails 0.38 1 Trace 6.6 2.7
croscopic examination of rapidly-
50 60 70 eo 90 100
of reagents was 0.20 Ib/ton slag of
fiNE NE SS Of GR IND. %-325 MESH sodium isopropyl xanthate and an Effect of Cooling Rate on 'Sizeof Copper
equal quantity of Z-200 (isopropyl Particles in Slag
Fig. 3-Effect of cooling rate and fine- Slags produced in the 100 tpd
ness of grind on laboratory milling of
ethyl thionocarbamate); pine oil
and MISC (methyl isobutyl carbinol) pilot plant of the Noranda Process
slags .~
were found to be suitable frothers . were cast in steel molds 50 150
Pilot plant tests were conducted and 350 Ib of slag capacity. Durin~
quenched slag (granulated slag) in-
at the Noranda, Quebec, concen- solidification, the cooling rates at
dicates that the soluble copper rep-
trator at grinding 'and flotation rates various depths in the slag were
resents nearly two thirds of the
of 200 Ib slag/hr. This work was measured by means of thermo-
copper content. These results are
then followed by a full-scale mill- couples inserted through the mold
in agreement with thermodynamic
ing test at the same plant during walls. After cooling, the slag pigs
studies on the solubility of copper
were sectioned to provide samples
in slags equilibrated with metallic which 1500 tons of slag were milled
copper.1 2-14 which were representative of a par-
at the rate of 15 tph. The overall
ticular cooling rate.
The magnetite and copper con- results of this test showed that a
Pieces of each slag sample were
tent of the Noranda Process slags tailing of 0.5% Cu had been pro- mounted, polished, and examined
can be reduced to the 10-12% duced at a concentration ratio of under the microscope ; typical mi-
Fe;j0 4 and 2-3% Cu levels, by add- 4.5 :1 (Table IV).
ing concentrate and reducing gas In order to optimize the milling of
in the slag zone. However, as will Noranda Process sl·ags, the effects
be shown later, this treatment has
of cooling rate and slag composi-
little effect on the copper loss in
tion on copper recovery were in-
the tailing.
vestigated extensively. Studies
Open-circuit flotation tests were
were also made of the forms of
initially carried out to establish the
feasib ility of slag milling and to copper lost in the tailing and of the
determine the requ ired fineness of distribution of other slag con-
grind and flotation reagents. It was st ituents in the tailing and con-
found that a fine grind (about 90% centrates. The results of this work
- 325 mesh) was essential to pro- are described in the following sec-
duce an acceptable low-copper tions.
crostructuresare shown in Fig. 6. ably entrained particles in the slag conditions, the median size of cop-
The cumulative distribution of cop- as it was tapped which had no per particles was approximately a
per as a function of particle size for chance to grow during the cooling linear function of the logarithm of
various samples is shown in Fig. 7. process. the time taken to cool the slag to
Slags cooled at rates above As predicted by Yazawa and 1000°C; the most slowly cooled
1000°C/hr (Le. cooled from 1200 to Kameda,5 longer retention periods slag in these tests (center portion
1000°C in less than ten minutes) of the slag at temperatures above of the 350-lb. mold) was found to
exhibited similar size distributions 1000°C promoted the coalescence contain a median particle size of
of copper particles (Figs. 6a, 6b), and growth of particles by diffusion 87 microns. Rapid cooling below
the median size of which was about and precipitation of copper out of 1000 °C, e.g., with water sprays, re-
25 microns. These were presum- solution (Figs. 6c, 6d). Under these sulted in easier crushing of the slag
% Copper in
Copper loss in
% Fe"O, Head Concen· Concentration ratio the tailing as % of
Description of Slag in slag slag trate Tailing (head I concentrate) input to reactor
Slag milled in large scale test (ball mill grind-
ing) 20-26 11.4 51.5 0.50 4.54 1.47
Slag milled in large scale test (autogenous grind-
ing) 20-26 11.7 52.1 0.53 4.74 1.58
Slag deoxidized by anthracite addition in pilot
plant reactor 12 2.2 19.8 0.54 11.70 1.71
Slag deoxidized by silicon carbide in a crucible 6 1.4 6.1 0.44 6.10 1.25
..
oxidic copper in the tailing did not
39.
produce any meaningful results . In
75 .
the light of the electron probe re-
sults and also of leaching tests on
the tailing, which will be discussed
20
• 227.
the copper content in a 0.5% Cu Metallurgical Quarterly, Vol. 8, 1969, pp, 167-
171 .
tailing could be extracted by leach- H Johansen . E.B .• Rosenqvist, T., and Torger-
sen . P.T. ; JOURNAL OF METALS . Vol. 22 . no. 9,
0.4 L--'--_ _ ---''---_ _--L_ __ -...l
ing in ferric sulfate solution at 1970. pp, 39-47.
15 Firth . M.. McGill University; pri vate com-
70 80 90 100
70 C. However, this approach was
D
munication to Noranda Research Centre. July
% - 32~ MESH abandoned due to the fact that the 1970.
,. Nippo n Mining Company. Ltd .; pri vate com-
required regeneration of the ferric munication to Noranda Research Centre . July
Fig. 9-Effect of retention period above 1970.
1000° C and fineness of grind on tailing iron was an incomplete and slow 17 Mitsubishi Metal Mining Company. Ltd.; pri-
va te communication to Noranda Research Cen-
grade. process. tre . July 1970.