Autoclave oxidation leaching of sulfide materials containing copper, nickel and/or cobalt

Claim 2

A process for treating a finely ground matte containing copper and sulfur values and at least one of the metal values nickel and cobalt, and which may also contain iron values, to effect selective extraction of nickel and/or cobalt from copper and, if present, iron values, comprising: forming an aqueous slurry comprising ground matte, said slurry having a sulfur content, apart from elemental sulfur, substantially equivalent on a molar basis to the nickel and cobalt plus about 35% to about 70% of the copper in said slurry; subjecting said slurry to a single stage oxidative pressure leach in a continuous manner in the presence of copper in the aqueous phase of the slurry for a period of time necessary to convert substantially all of the sulfidic sulfur in the slurry to the sulfate form, and allowing the pH of the slurry to drop to a level of below about 4 but not below about 3; separating the leach liquor from the leach residue; and thereby obtaining a leach liquor containing a preponderant amount of the nickel and cobalt values and a minor amount of the copper values and a copper sulfate hydrate containing leach residue containing a preponderant amount of the copper and substantially all the iron values.

Claim 3

A process of claim 1, wherein the oxidative pressure leach is carried out at elevated temperature up to about 130° C.

Claim 4

A process of claim 1, wherein the oxidative pressure leach is carried out at temperatures in the range of about 110° C. up to about 130° C.

Claim 5

A process of claim 1, wherein the oxygen partial pressure of the oxidative pressure leach is at least about 0.25 MPa.

Claim 6

A process of claim 4, wherein the oxygen partial pressure is about 0.5 to about 1.5 MPa.

Claim 7

A process of claim 1, wherein the copper level in the aqueous phase of the slurry is at least about 0.5 gram per liter.

Claim 8

A process of claim 6, wherein the copper level is at least about 1 gram per liter.

Claim 9

A process according to claim 1, wherein the leach liquor is treated with ground matte under oxidizing conditions to effect precipitation of copper from the liquor.

Claim 10

A process according to claim 8, wherein said liquor is treated with ground matte at a temperature of about 60° C. to about 85° C. at atmospheric pressure.

Claim 11

A process according to claim 8, wherein the residual matte obtained after treatment of the leach liquor is recirculated and forms at least a part of the matte which is subjected to the oxidative pressure leach.

Claim 12

A process according to claim 1, wherein the leach residue is treated in a copper-containing solution at a controlled pH of about 2.0 to about 2.8 and at a temperature below the boiling point to solubulize selectively nonferrous metals and to separate them from the undissolved iron in said residue.

Claim 13

A process according to claim 11, wherein the pH is about 2.2 to about 2.5.

Claim 14

A process according to claim 1, wherein copper in said leach residue is solubilized to form a copper-containing solution and copper is recovered by a method comprising electrowinning of copper.

Claim 15

A process according to claim 13, wherein at least a part of the spent electrolyte is circulated back to the oxidative leach slurry to adjust the sulfur content of the slurry.

Claim 16

A process according to claim 13, wherein at least a part of the spent solution of the electrowinning step is used as at least part of the leachant of the autoclave leach residue.

Claim 17

A process according to claim 1, wherein the conversion of sulfidic sulfur in the slurry to sulfate form is at least about 92%.

Claim 18

A process for treating a finely ground matte containing copper and sulfur values and at least one of the metal values nickel and cobalt, and which may also contain iron values, to effect separation of nickel and/or cobalt from copper, if present, iron values, comprising: forming an aqueous slurry comprising ground matte, said slurry having a sulfur content, apart from elemental sulfur, equivalent on a molar basis to the nickel and cobalt plus about 35% to about 70% of the copper in said slurry; subjecting said slurry to a single stage oxidative pressure leach in a continuous manner at an elevated temperature up to about 130° C. and a pressure of at least about 0.25 MPa in the presence of at least about 0.5 gram per liter of copper in the aqueous phase of the slurry for a period of time necessary to convert substantially all the sulfidic sulfur in the slurry to the sulfate form and allowing the pH of the slurry to drop to a level of below about 4 but not less than about 3, separating the leach liquor from the leach residue, and thereby obtaining a leach liquor containing a preponderant amount of the nickel and cobalt values and a minor amount of the copper values and a copper sulfate hydrate containing leach residue containing a preponderant amount of the copper and substantially all the iron values.

Claim 19

A process for treating a finely ground matte containing copper and sulfur values and at least one of the metal values nickel and cobalt, and which may also contain iron values, to effect separation of nickel and/or cobalt from copper, if present, iron values, comprising: forming an aqueous slurry comprising ground matte, said slurry having a sulfur content, apart from elemental sulfur, equivalent on a molar basis to the nickel and cobalt plus about 35% to about 70% of the copper in said slurry; subjecting said slurry to a single stage oxidative pressure leach in a continuous manner at an elevated temperature up to about 130° C. and a pressure of at least about 0.25 MPa in the presence of at least about 0.5 gram per liter of copper in the aqueous phase of the slurry for a period of time necessary to convert substantially all the sulfidic sulfur in the slurry to the sulfate form and allowing the pH of the slurry to drop to a level of below about 4 but not less than about 3, separating the leach liquor from the leach residue, and thereby obtaining a leach liquor containing a preponderant amount of the nickel and cobalt values and a minor amount of the copper values and a copper sulfate hydrate containing leach residue containing a preponderant amount of the copper and substantially all the iron values.

Claim 20

A process according to claim 17, wherein the copper level in the leach liquor is reduced to less than about 0.01 gram per liter and at least one of the metals nickel or cobalt is recovered from the copper depleted solution.

Claim 21

A process according to claim 17, wherein copper is extracted from the leach residue.

Claim 22

A process according to claim 19, wherein the copper is extracted by forming a copper-containing solution and copper is electrowon from such solution.

Claim 23

A process for treating a finely ground matte containing copper and sulfur values and at least one of the metal values nickel and cobalt, and which may also contain iron values, to effect separation of nickel and/or cobalt from copper and, if present, iron values, comprising: forming an aqueous slurry comprising ground matte, said slurry having a sulfur content, apart from elemental sulfur, equivalent on a molar basis to the nickel and cobalt plus about 35% to about 70% of the copper in said slurry; subjecting said slurry to a single stage oxidative pressure leach in a continuous manner at an elevated temperature up to about 130° C. and a pressure of at least about 0.25 MPa in the presence of at least about 0.5 gram per liter of copper in the aqueous phase of the slurry for a period of time necessary to convert substantially all the sulfidic sulfur in the slurry to the sulfate form and allowing the pH of the slurry to drop to a level of below about 4 but not less than about 3; separating the leach liquor from the leach residue, and thereby obtaining a leach liquor containing a preponderant amount of the nickel and cobalt values and a minor amount of the copper values and a copper sulfate hydrate containing leach residue containing a preponderant amount of the copper and substantially all the iron values; treating the leach liquor with ground fresh matte under oxidizing conditions at a temperature of about 60° C. to about 85° C. to precipitate copper from the leach liquor; separating the copper-depleted leach liquor from the solids containing the precipitated copper, and recovering at least one of the metals nickel or cobalt from the copper-depleted leach liquor.

Claim 24

A process for treating a finely ground matte containing copper and sulfur values and at least one of the metal values nickel and cobalt, and which may also contain iron values, to effect separation of nickel and/or cobalt from copper and, if present, iron values, comprising: forming an aqueous slurry comprising ground matte, said slurry having a sulfur content, apart from elemental sulfur, equivalent on a molar basis to the nickel and cobalt plus about 35% to about 70% of the copper in said slurry; subjecting said slurry to a single stage oxidative pressure leach in a continuous manner at an elevated temperature up to about 130° C. and a pressure of at least about 0.25 MPa in the presence of at least about 0.5 gram per liter of copper in the aqueous phase of the slurry for a period of time necessary to convert substantially all the sulfidic sulfur in the slurry to the sulfate form and allowing the pH of the slurry to drop to a level of below about 4 but not less than about 3; separating the leach liquor from the leach residue, and thereby obtaining a leach liquor containing a preponderant amount of the nickel and cobalt values and a minor amount of the copper values and a copper sulfate hydrate containing leach residue containing a preponderant amount of the copper and substantially all the iron values; treating the leach liquor with ground fresh matte under oxidizing conditions at a temperature of about 60° C. to about 85° C. to precipitate copper from the leach liquor; separating the copper-depleted leach liquor from the solids containing the precipitated copper, and recovering at least one of the metals nickel or cobalt from the copper-depleted leach liquor.

Claim 25

A process according to claim 21, wherein the solids containing precipitated copper comprises at least a part of the slurry which is subjected to the oxidative pressure leach.

Claim 26

A process according to claim 21, wherein the leach residue is treated in a copper-containing leach solution at a controlled pH of about 2.0 to about 2.8 and at a temperature below the boiling point to solubilize selectively nonferrous metals.

Claim 27

A process according to claim 23, wherein copper is recovered from the resultant solution by means of an electrowinning method.