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Sullivan 1931
Sullivan 1931
The largest confined leaching plants of the world and their approximate
daily capacity in tons of ore treated are: Calumet and Hecla, Michigan,
5100; Bwana M'Kubwa, Africa, 1000; Kennecott, Alaska, 800; Chu-
quicamata, Chile, 20,000; Andes, Chile, 7500; New Cornelia, Arizona,
1500; Katanga, Africa (Belgian Congo), 1400; and Inspiration, Arizona,
9000. The largest plant leaching in place is that of the Ohio Copper
Co., Bingham, Utah; and the largest heap-leaching plants are a t Warren
isbe bee), Arizona, and Rio Tinto, Spain. Other leaching plants of smaller
capacities are found in the United States and in foreign countries.
Later in this paper (see page 842 et seq.) a typical leaching plant and
cycle will be described.
Principles Underlying Leaching Processes
Four factors are essential to the successful leaching of any copper-bearing
ores: (1) a solution that will attack the copper minerals must get into
the body of the particle of ore, (2) the minerals must be dissolved by the
chemical action of that solvent, (3) the solution containing the dissolved
copper must find its way out of the voids of the rock into the main solution
stream, and (4) the copper in solution must be recovered by some means of
precipitation. In leaching a given ore the rate of extraction is not instan-
taneous but goes on slowly and the factors of penetration, dissolution, and
di5usion go on simultaneously and not in successive steps.
834 JOURNAL OF CHEMICAL EDUCATION MAY.1931
concentrates aud containing five per cent or less of sulfur dioxide is passed
in the form of small bubbles through a solution of ferrous sulfate, the iron
is oxidized to the ferric condition. The final reaction may he written:
When nearly all the iron is oxidized, sulfuric acid is formed according to the
final reaction which may be written:
are spaced four and one-half inches from center of cathode to center of cath-
ode, is about two and one-fourth volts. Theoretically 1.186 grams of cop-
per should be deposited by one ampere hour of electric current when the
copper is in the cupric condition. Owing to impurities in the solution the
ampere efficiency a t Inspiration is only slightly above sixty per cent. The
current efficiency is somewhat higher in other plants not requiring so high a
concentration of ferric iron.
Construction and Operation of a Confined Percolation Leaching Plant
The operations are widely different in the various methods of leachine.
The scope and length of
this article p r o h i b i t s
giving details of all
types of leaching. As
confined percolation
leaching is the most
important of the meth-
ods now in use, a brief
description of the con-
struction and operation
of such a plant will be
given. The sizes of
vats, etc.,are given for a
plant of approximately
0000 tons daily capac-
ity, and leaching oxi-
dized ore with sulfuric
acid. The practice at
any given plant may
differ from the follow-
ing outline, but the
practice in general will
be virtually the same.
The ore as it comes
from the mine is first
broken in primary
crushers either of the
jaw or gyratory type.
Primary crushing may
reduce the ore to about
three-inch size. The
ore is then passed over
vibrating screens with
VOL. 8, NO. 5 LEACHING COPPER FROM ITS ORES 843
suitable openings to remove the fine sizes. The undersize goes directly
to the leaching vats, and the oversize goes to the secondary crushers.
Secondary crushers are usually rolls. A common size of roll is seventy-eight
inches in diameter with a twenty-four-inch face. Ordinarily two sets of
rolls are used, the second being set closer than the first. The discharge
from the first passes over vibrating screens, the undersize goes to the leach-
ing vats and the oversize to the second set of rolls where it is reduced to
proper size for leaching. The undersize from the coarse and fine crushing
operations now all being crushed to approximately three-eighths of an inch
is conveyed to the leaching plant. The conveying system, which is shown
under the roof in Figures 3 and 4, consists of an endless rubber belt that
carries the ore to the loading bridge where i t is automatically dumped into
the leaching vats.
Leaching vats are made of concrete and are lead lined. (In plants of
small capacity the vats might be constructed of wood.) A vat one hundred
seventy-five feet long by sixty-eight feet wide by eighteen feet deep has a
capacity of about 9000 tons of ore. The lead on the side walls is protected
by a covering of two-inch planks. The bottom of the tank is protected
with filter boards of two-inch material and having about fifteen three-
eighths-inch holes per square foot. A lead pipe of twelve or fourteen
inches diameter is burned to the lead lining at the bottom of each vat a t
one end. This pipe acts both as a solution entry and exit tube. All
solutions are carried to and from the vats in lead pipes. The lead used
in leaching plants contains about three per cent of antimony. The ore, af-
ter bedding, is covered with a solution strong enough in acidity to prevent
neutralization; otherwise basic salts may precipitate. Solution is usually
Frcune LEA LEACHING VATS FLOODFD
WITH SOLUTION
VOL. 8, NO. 5 LEACHING COPPER FROM ITS ORES 845
percolated upward through the ore and ovenlows a t one end of the vat into
a launder from whence it goes to the suction of the pump serving the next
tank, thus permitting the vats under acid treatment to be in series. If
the entire leaching plant has thirteen tanks, eight will probably be under
acid treatment a t all times, three will be washing, one being excavated,
and one being charged.
The strongest solution is added to the oldest ore under treatment. The
solution travels from tank to tank, constantly being reduced in reagent
strength and finally emerges from the newest ore from whence i t flows
to the electrolytic tank-house. The leached residue is then washed. Ordi-
narily the first washes will contain acid, and are systematically advanced,
the first wash goes with the main solution stream, the second wash becomes
the first wash on thenext tank to be washed, and so on. The washes,
especially the last ones, may be batch washes; that is, the entire solution
is pumped onto the ore and after a given time the solution is drained off,and
the next wash is added. If ten washes are used, the last five will probably
go to iron-precipitation
launders to recover the
soluble copper and will
not join the main solu-
tion stream. The last
wash will be water.
Solution sumps are nec-
essary to store solutions
that are not on the ore
or in the tankhouse or
iron launders. They
may be seen near the
center of Figure 3.
The tailings from a
leaching vat are dis-
charged with a "clam-
shell" bucket, shown in
Figure 3, into cars, and
dumped in a tailings
pile. Figure 11 shows
a discharging mecha-
nism in operation.
The pregnant solu-
tion from the leaching
vats will go to the tank-
house where the copper
is precipitated electro-
lytically using lead an-
odes and copper cath-
odes. Figure 10 shows
t h e interior of t h e
tank-house of the In-
spiration Consolidated Copper Co. The cathode starting sheets are made
by plating copper on plates of rolled copper. The starting sheets are
stripped from the plates and a copper loop is riveted onto the top to hang
them from bus bars. If the solution entering the tank-house contains thirty
grams of copper per liter, about six grams will be plated out. The solution
from the tank-house containing the remaining twenty-four grams of copper
VOL.8, NO. 5 LEACHING COPPER FROM ITS ORES 847
per liter, after adding new acid if necessary, joins the regular circuit as
leaching solution. Sulfuric acid is produced simultaneously with the
precipitation of copper. Electrolytic copper produced from leach liquors
is quite pure, often containing as much as ninety-nine and seven-tenths per
cent of copper. The metal itself is as pure as that produced by refining
anodes, and the impurities are largely slimes that have been mechanically
attached to the cathodes.
Future of Leaching
The production of copper is increasing and simultaneously the nation's
total tonnage of high-grade sul6de ores is decreasing. As the tonnage of
ores amenable to concentration decreases, more and more attention will be
paid to hydrometallurgical processes for recovering the metal values from
low-grade disseminated ores carrying both oxidized and sulfide minerals.
The success of leaching so-called waste dumps has indicated that many
mine dumps now termed as waste will he leached as heaps. Eventually
nearly every mine will be leached in place. When the grade of ore becomes
so low that mining is unprofitable, the ore remaining in the mine in a broken
condition will he leached. The future outlook for leaching is bright.
Acknowledgment
Figures 1 , 2, and 9 were made availabk to the author through the courtesy
of 0. E. SIMMONS, foreman, Copper Queen Heap Leaching Plant, Warren.
Arizona; Figures 3, 4, and 10, by H . W. ALD~ICH, assistant general super-
intendent, Inspiration Consolidaled Coper Co., Ins@ration, Arizona; and
Figures 11 to 16, inclusive, by G . A. BELL,chief chemist, New Cornelia Mines
01the Calumet and Arizona Mining Co., Ajo, Arizonu.
Literature Cited
( I ) "Mineral Resources of the United States," 1927, part 1, p. 691.
( 2 ) SIMMONS, 0 . E., "Leaching and Cementation of the Copper Queen Branch Phelps
Dodge Corporation." Paper presented before the Arizona Chapter of American
Mining Congress in April, 1930,and published by the Mining Congress Journal. 1930.
(3) SULLIVAN, J. D., W. E. KECK,and G. L. OLDR~GHT, "Factors Governing the
Entry of Solutions into Ores During Leaching," Tech. Paper 441, Bureau of
Mines, 1929, 38 pp.; SULLIVAN, J. D., and E. OSTREA, "Factors Governing the
Entry of Solutions into Ores during Leaching, 11." Tah. Paper 498, Bureau of
Mines, in press.
( 4 ) BENEDICT, C. H., "Milling Methods and Costs at the Conglomerate M i of the
Calumet and Hecla Consolidated Copper Co.," Bureau of Mines Informlion
Circzrlar 6364, 1930, 22 pp.
(5) SULLIVAN, J. D.. ''Chemistw of Leaching Chalcocite," Tech. Paper 473, Bureau
of Mines, 1930, 24 pp.; "Chemistry of Leaching Bornite," Tech. Paper 486,
Bureau of Mines. 1931, 20 pp.; "Chemistry of Leaching Co.rellite." Tech. Paper
487, Bureau of Mines, 1931, 18 pp.
( 6 ) RALsroN, 0 . C , "The Ferric SulfateSulfuric Acid Process." Bull. 260, Bureau
of Mines, 1927, 122 pp.