Process for recovering metal values from materials containing arsenic

Claim 2

A process for separating arsenic from a material containing arsenic and one or more metal values selected from the group consisting of copper, cadmium, zinc and germanium, comprising: (a) leaching the material to solubilize arsenic and the other metal values; (b) contacting the leach solution with ferric ions to precipitate arsenic as a ferric-arsenic compound; (c) retaining the leach solution in contact with the ferric ions for a sufficient period of time to precipitate substantially all the arsenic present in solution; (d) performing a liquid-solid separation; and (e) neutralizing the liquid of step (d) to a pH of about 3 to precipitate a substantial portion of the remaining arsenic.

Claim 3

The process of claim 1 wherein the retention time of step (c) is at least one hour.

Claim 4

The process of claim 1 wherein the leach solution contains sulfate, the liquid-solid separation of step (d) is accomplished by filtration, and between steps (c) and (d) the leach materials are partially neutralized with calcium carbonate to generate gypsum.

Claim 5

A process for recovering metals selected from the group consisting of copper, cadmium, zinc, germanium, indium, antimony, bismuth, lead, silver and gold from a copper smelter flue dust containing arsenic which comprises: (a) leaching the flue dust with sulfuric acid at a pH of 0.1-1.5 under oxidizing conditions to convert substantially all of the arsenic to pentavalent arsenic while contacting the leach solution with ferric ions in an amount to precipitate substantially all of the arsenic as a ferric-arsenic compound and to solubilize metals selected from the group consisting of copper, zinc, cadmium, indium and germanium; (b) performing a liquids-solids separation on the slurry of step (a) to separate the solids from the solution; (c) adjusting the pH of the solution of step (b) to a pH of at least 3 to precipitate the remainder of the arsenic as ferric arsenate and reduce the arsenic content of the solution to no more than about 100 ppm; (d) removing the arsenic precipitate from the solution of step (c); (e) recovering the metals solubilized in step (a) from the solution of step (d) in substantially arsenic-free form; (f) leaching the residue of step (b) with a brine leach in the presence of the ferric-arsenic precipitate to solubilize metals selected from the group consisting of antimony, bismuth, lead, silver and gold; (g) performing a liquid-solids separation on the slurry of step (f) to separate the solids from the solution, and (h) recovering the metals solubilized in step (f) from the solution of step (g) in substantially arsenic-free form.

Claim 6

A process for recovering metals selected from the group consisting of copper, cadmium, zinc, germanium, indium, antimony, bismuth, lead, silver and gold from a copper smelter flue dust containing arsenic which comprises: (a) leaching the flue dust with sulfuric acid at a pH of 0.1-1.5 under oxidizing conditions to convert substantially all of the arsenic to pentavalent arsenic while contacting the leach solution with ferric ions in an amount to precipitate substantially all of the arsenic as a ferric-arsenic compound and to solubilize metals selected from the group consisting of copper, zinc, cadmium, indium and germanium; (b) performing a liquids-solids separation on the slurry of step (a) to separate the solids from the solution; (c) adjusting the pH of the solution of step (b) to a pH of at least 3 to precipitate the remainder of the arsenic as ferric arsenate and reduce the arsenic content of the solution to no more than about 100 ppm; (d) removing the arsenic precipitate from the solution of step (c); (e) recovering the metals solubilized in step (a) from the solution of step (d) in substantially arsenic-free form; (f) leaching the residue of step (b) with a brine leach in the presence of the ferric-arsenic precipitate to solubilize metals selected from the group consisting of antimony, bismuth, lead, silver and gold; (g) performing a liquid-solids separation on the slurry of step (f) to separate the solids from the solution, and (h) recovering the metals solubilized in step (f) from the solution of step (g) in substantially arsenic-free form.

Claim 7

The process of claim 4 wherein the ferric ions of step (a) are generated during the leach from ferrous ions.

Claim 8

The process of claim 5 wherein the leach of step (a) is performed under an oxygen pressure of between about 25 and about 75 psi.

Claim 9

The process of claim 5 wherein the leach of step (a) is performed under an oxygen pressure of between about 45 and 55 psi.

Claim 10

The process of claim 4 wherein the leach of step (a) is performed at a temperature of between about 90° C. and about 130° C.

Claim 11

The process of claim 4 wherein the leach of step (a) is performed at a temperature of between about 105° C. and about 115° C.

Claim 12

The process of claim 4 wherein arsenic is recovered from the residue of step (b) by means of a hot caustic leach with subsequent crystallization of a soluble arsenic salt from the leach liquor.

Claim 13

The process of claim 4 wherein the ferric ion is oxidized in situ from ferrous sulfate added to produce ferric ion in solution in excess of stoichiometric amounts to precipitate the arsenic as a ferric-arsenic compound.

Claim 14

The process of claim 4 wherein the emf is adjusted to between about -400 and about -500 mv in the leach.

Claim 15

The process of claim 4 wherein the solids of step (b) are further processed to recover arsenic in soluble form.

Claim 16

The process of claim 13 wherein arsenic is recovered by means of the following steps: (a) leaching the solids of step (d) with a strong, basic solution in excess of stoichiometric amounts to solubilize the arsenic; (b) performing a liquid-solid separation on the material of step (a); and (c) crystallizing sodium arsenate from the liquid of step (b).

Claim 17

A process for recovering at least one of the metals copper, cadmium, zinc, indium and germanium from arsenic-containing flue dust resulting from the pyrometallurgical processing of copper ores comprising: (a) leaching the feed material with sulfuric acid at a pH approximately 0.5, at a temperature between about 90° C. and about 130° C. to dissolve the aforesaid metal values, in the presence of oxygen under pressure of between about 25 and about 75 psi to adjust the emf of the system to between about -400 and about -500 mv and sufficient ferric ions to insolubilize all the arsenic as a ferric-arsenic compound; (b) allowing the leach materials of step (b) to remain in contact for a period of about 1 to about 3 hours to allow precipitation of arsenic as a ferric arsenic compound; (c) filtering the leach materials of step (b); (d) neutralizing the liquid of step (c) with calcium carbonate to pH at least about 3.0 and cooling for about one-half hour to precipitate out additional arsenates; (e) recovering a metal value or values selected from the group comprising copper, germanium, cadmium, zinc, and indium from the liquid of step (d).

Claim 18

A process for recovering at least one of the metals copper, cadmium, zinc, indium and germanium from arsenic-containing flue dust resulting from the pyrometallurgical processing of copper ores comprising: (a) leaching the feed material with sulfuric acid at a pH approximately 0.5, at a temperature between about 90° C. and about 130° C. to dissolve the aforesaid metal values, in the presence of oxygen under pressure of between about 25 and about 75 psi to adjust the emf of the system to between about -400 and about -500 mv and sufficient ferric ions to insolubilize all the arsenic as a ferric-arsenic compound; (b) allowing the leach materials of step (b) to remain in contact for a period of about 1 to about 3 hours to allow precipitation of arsenic as a ferric arsenic compound; (c) filtering the leach materials of step (b); (d) neutralizing the liquid of step (c) with calcium carbonate to pH at least about 3.0 and cooling for about one-half hour to precipitate out additional arsenates; (e) recovering a metal value or values selected from the group comprising copper, germanium, cadmium, zinc, and indium from the liquid of step (d).

Claim 19

The process of claim 15 wherein valuable metals are recovered by means of the following additional steps: (f) leaching the solid residue of step (c) with a mixture of sodium chloride and calcium chloride, in the presence of ferric ions at a concentration of approximately 3 g/l ferric for about an hour at a pH of about 0.5 adjusted with sulfuric acid at a temperature of between about 95° C. and about 100° C. in the presence of an oxidizing agent to maintain the emf at up to about -700 mv, in order to solubilize at least one of the metals lead, silver, gold, bismuth and antimony, and leave the ferric-arsenic compound undissolved; (g) performing a liquid-solid separation on the leach materials of step (f); and (h) recovering at least one of the metal values from the liquid of step (g).

Claim 20

A process for recovering metals selected from the group consisting of copper, zinc, cadmium, indium and germanium from a copper smelter flue dust containing arsenic which comprises: (a) leaching the flue dust with sulfuric acid at a pH of 0.1-1.5 under oxidizing conditions to convert substantially all of the arsenic to pentavalent arsenic while contacting the leach solution with ferric ions in an amount to precipitate substantially all of the arsenic as a ferric-arsenic compound, and to solubilize said metals; (b) performing a liquid-solids separation on the slurry of step (a) to separate the solids from the solution; (c) adjusting the pH of the solution of step (b) to a pH of at least 3 to precipitate the remainder of the arsenic as a ferric-arsenic compound and reduce the arsenic content of the solution to no more than about 100 ppm; (d) removing the arsenic precipitate from the solution of step (c); and (d) recovering the metals solubilized in step (a) from the solution of step (b) in substantially arsenic-free form.

Claim 21

A process for recovering metals selected from the group consisting of copper, zinc, cadmium, indium and germanium from a copper smelter flue dust containing arsenic which comprises: (a) leaching the flue dust with sulfuric acid at a pH of 0.1-1.5 under oxidizing conditions to convert substantially all of the arsenic to pentavalent arsenic while contacting the leach solution with ferric ions in an amount to precipitate substantially all of the arsenic as a ferric-arsenic compound, and to solubilize said metals; (b) performing a liquid-solids separation on the slurry of step (a) to separate the solids from the solution; (c) adjusting the pH of the solution of step (b) to a pH of at least 3 to precipitate the remainder of the arsenic as a ferric-arsenic compound and reduce the arsenic content of the solution to no more than about 100 ppm; (d) removing the arsenic precipitate from the solution of step (c); and (d) recovering the metals solubilized in step (a) from the solution of step (b) in substantially arsenic-free form.

Claim 22

A process for recovering metals selected from the group consisting of antimony, bismuth, lead, silver and gold from a copper smelter flue dust containing arsenic which comprises: (a) leaching the flue dust with sulfuric acid at a pH of 0.1-1.5 under oxidizing conditions to convert substantially all of the arsenic to pentavalent arsenic while contacting the leach solution with ferric ions in an amount to precipitate substantially all of the arsenic as a ferric-arsenic compound, and to solubilize said metals; (b) performing a liquid-solids separation on the slurry of step (a) to separate the solids from the solution; (c) leaching the residue of step (b) with a brine leach in the presence of a ferric-arsenic precipitate to solubilize metals selected from the group consisting of antimony, bismuth, lead, silver and gold; (d) performing a liquid-solids separation on the slurry of step (c) to separate to solids from the liquids; and (e) recovering the metals solubilized in step (c) from the solution of step (d) in substantially arsenic-free form.

Claim 23

A process for recovering metals selected from the group consisting of antimony, bismuth, lead, silver and gold from a copper smelter flue dust containing arsenic which comprises: (a) leaching the flue dust with sulfuric acid at a pH of 0.1-1.5 under oxidizing conditions to convert substantially all of the arsenic to pentavalent arsenic while contacting the leach solution with ferric ions in an amount to precipitate substantially all of the arsenic as a ferric-arsenic compound, and to solubilize said metals; (b) performing a liquid-solids separation on the slurry of step (a) to separate the solids from the solution; (c) leaching the residue of step (b) with a brine leach in the presence of a ferric-arsenic precipitate to solubilize metals selected from the group consisting of antimony, bismuth, lead, silver and gold; (d) performing a liquid-solids separation on the slurry of step (c) to separate to solids from the liquids; and (e) recovering the metals solubilized in step (c) from the solution of step (d) in substantially arsenic-free form.