Preliminary study of oxide copper fine particle agglomeration at a laboratory scale

Kssio S. Santos, Luciana de C. Maia, Bruno S. Mosso & ilton P. Sou!a

Faculty of Environmental and Mining Engineering, Universidade Federal do Par, Marab, Brazil, Graduaing of Environmental and Mining Engineer, kssio_ !"#otmail$com Faculty of Environmental and Mining Engineering, Universidade Federal do Par, Marab, Brazil, Graduate of Enviromental and Mining Engineering, lucianacmaia"#otmail$com Faculty of Environmental and Mining Engineering, Universidade Federal do Par, Marab, Brazil, Graduating of Faculty of Environmental and Mining Engineering, Bruno_r%_&'"#otmail$com Faculty of Environmental and Mining Engineering, Universidade Federal do Par, Marab, Brazil, Graduating of Enviromental and Mining Engineering, ailton%anto(a"live$com
"eginaldo S. #e Pai$a

Faculty of Environmental and Mining Engineering, Universidade Federal do Par, Marab, Brazil, Professor at Faculty of Environmental and Mining Engineering, regisabo"uf%a$br BS%" C%
The Sossego Mine at Cana dos Carajs, state of Para, has about 60% of oxide copper and due to its lo grade and the difficulties of the flotation process it is considered as an exploration aste! The heap leaching is currentl" considered the #ost efficient #ethod to extract the copper fro# lo grade ore! The #ain ad$antage of this process is its lo capital and operating cost! To achie$e an efficient heap leaching process, ho e$er, creating a porous heap ith high per#eabilit" is essential! The ore s#all particles affect the heap per#eabilit", pre$ent the efficient distribution of the leach solution and because of this, the #etal reco$er" is lo ! This proble# #a" be #itigated trough the agglo#eration of the fine particles! %n this stud", to deter#ine the conditions here the agglo#erate achie$es the best &ualit" at the lo est cost, dru# agglo#eration studies ere perfor#ed at a laborator" scale ith the oxide copper fine particles, using sulfuric acid as binder agent! %n this stud", the relation bet een acid and ater at the agglo#eration process, the ore total #oisture and the influence of the speed rotation ere anal"'ed! To e$aluate the agglo#erate that as for#ed $isual aspect, granule si'e distribution, resistance and integrit" tests ere studied!

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The oxidi'ed copper #a(es up about 60% of the deposits of the Mine of Sossego) Cana do Carajs*P+) and because its lo le$el and difficult" processing b" flotation is considered residue exploitation! The heap leaching is currentl" considered the #ost efficacious route of processing for extracting copper fro# lo content ores, the #ain ad$antage of this process the lo capital cost and operation! The h"dro#etallurgical route allo s treating ores b" leaching ith lo le$els, and co#pared to p"ro#etallurgical has the ad$antage of re&uiring little in$est#ent, ha$e lo operating costs and be #ore sustainable features, it reduces en$iron#ental i#pacts fro# discharges of S,- in the at#osphere and allo s recirculation of the reactants reducing the production of effluent .Pai$a et al -0//0! Therefore, it is done to the agglo#eration of fine ore prior to pile construction that offers se$eral benefits, such as increased per#eabilit", rapid and unifor# flo of leaching solution through the stac(, increasing #etal reco$er", shorter leach c"cle and conse&uentl", increased producti$it" and lo er cost per ton .1odali et al, -0//0! The agglo#eration dru# allo s for consolidation of fine solid particles into larger granules using a binding agent and #oderate shear! The solution of sulfuric acid is the #ost idel" used binders in the agglo#eration of oxidi'ed copper ore and hat is #ost cost effecti$e! Subse&uentl" the agglo#erated, as is con$entionall" called the fines that pass through the agglo#eration process is ta(en to leach colu#n test si#ulating hat occurs in cells! The influence of rotational speed, of the total #oisture in the ore and the acid * ater ratio in the agglo#eration process as anal"'ed! To e$aluate the &ualit" of agglo#erates for#ed, be"ond the $isual aspect, particle si'e distribution, strength and integrit" tests ere done! %n addition to results prepared at a laborator" scale, in order to obtain ph"sical para#eters present in the leaching process colu#n! Si#ulating the heap leaching, using oxidi'ed copper Sossego of Canaan Pa)#ine and entered into a proposed #athe#atical #odel to predict the opti#al height of the fluid in the colu#n!

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The sa#ple as oxidi'ed copper fro# the Sossego2s Mine, locate in Cana dos Carajs, Southeast of Par! The sa#ple as crushed, sie$ed, ho#ogeni'ed and di$ided b" four to separate ali&uots of /!6 (g of ore! The si'e fraction used in the tests as belo 3 ##, being 4!36% passes in -00 5 .6437#0! The densit" and ater content of the sa#ple are, respecti$el", -!348% and -!39 g*c#8!

%rial testing0 gglomeration of %1in

The tests ere conducted in a plastic dru# laborator" scale .-9 c# dia#eter and -4 c# high0 ith $ariable speeds in a ind#ill pitchers! :eeding ore and sintering ti#e 80 #inutes did constant! + suitable rotation speed of the agglo#eration as deter#ined b" anal"'ing the beha$ior of the ore inside the dru# at $arious speeds fro# /0 to 80rp#! To e$aluate the influence of the ater * acid and total #oisture in the process, se$eral tests ere perfor#ed! The results that stood out for their results ith the follo ing para#eters; Test /0; /4!3% <-S,= and /-!3% of ater> Test //; /6% <-S,= and /8!3% of ater> Test /-; /6% to //% ater <-S,=e> Test /8; /4!3% <-S,= and //% ater! Considering the hu#idit" of the sa#ple, -!39% et basis, as spra"ed ater on the ore to adjust hu#idit"! Then, the #ixed acid directl" into the dru# in rotation, the acid through a pipe e&uall" distributed throughout the length, i#pro$ing the ho#ogeni'ation! The #ounting of the dru# agglo#eration is sho n in :igure /!

2igure 3 dru# agglo#eration!

Particle Size Analysis, Integrity and Strength of Particleboard

The particle si'e anal"sis as done of the agglo#erates in each test series of the follo ing sie$es; =, 9, /and T"ler Series -9 5 * Mesh, for co#parison purposes the particle si'e of the product to the particle si'e of the feed! The #ethod for deter#ining the integrit" of the agglo#erated is to sub#erge it in a li&uid solution and record the ti#e and the beha$ior of its total disintegration! +s ?osrati et al! .-0//0, the ti#e it ta(es for the pellet to disintegrate gi$es an indication of the strength of re) hu#idif"! The co#pressi$e strength of the agglo#erates as #easured b" deter#ining the li#it of resistance to co#pression! The test consisted of appl"ing a co#pressi$e load in one direction on the agglo#erated!

Preliminary tests Column0 2lo4 %est

The flo test as perfor#ed ith the aid of a peristaltic #etering pu#p! @ith the pre$iousl" prepared filter la"er and filled ith ore colu#n, it ta(es the sa#e to a stand here he as seated and properl" positioned for recei$ing the fluid! +t the trial, there as the ti#e that the li&uid ca#e into contact ith the sa#ple, then bro(ered the flo rate output and hen the li&uid reaches the height of the colu#n! The colu#n as identified ith those heights fro# the filter la"er! :igure - illustrates the #etering pu#p and identification for control flo !

2igure 5 Colu#n used in flo control

Sets, the #etering pu#p, the input flo in the li&uid colu#n to stabili'e the height of -0c#! This control is i#portant to pre$ent an" o$erflo of the fluid, particularl" ith the use of acid solution! "esults and #iscussion nlise .ranulom6trica, &ntegridade e "esist7ncia do glomerado The results of particle si'e anal"sis of the feed and product agglo#eration of the assa"s are sho n in :igure 8! :ro# these results e can see that in all trials particles s#aller than /!9 ## ere all lu#ped! The anal"sis confir#s hat as found in the $isual assess#ent; The test // had the best result and the test /8 as the least efficient!

2igure 80 Cur$e of particle si'e anal"sis of food and cro ding!

The result of the co#pressi$e strength and integrit" of the pellets are sho n in Tables / and -, respecti$el"! The co#pressi$e strength results sho that the test pellets // had the best results ith A/!A0 (Pa! %n integrit" test agglo#erateds the test /0 had the best result and the disintegration ti#e as 6= #in! %able 3 Co#pressi$e Strength of +gglo#erates :or#ed in Bach Test! %est 35 33 38 3> 9 of -5S(: /6% /6% /4,30% /4,30% 9 of gua //% /8,30% //% /-,30% Compression strengt1 of t1e agglomerated ;<Pa= 3A,-A/,A 30,-A ==,0= %ime of total disintegration 8A #in 39,= #in 8A #in 6= #in

Tests for co#pressi$e strength and integrit" are i#portant to predict the beha$ior of the agglo#erated in the heap leach! These tests gi$e an idea of the pressure the cro ded stand in a pile and leaching ti#e as he ould begin to fall apart! %nterestingl", the pellet is dissol$ed easil", the per#eabilit" of the cell ill be co#pro#ised, hich is totall" the opposite of the function of the agglo#eration! Leac1ing test 4it1 crus1ed ore and agglomerated gglomerate Tests using onl" the agglo#erated of fine particles sho ed $er" lo $alues in the output flo , close to 'ero, causing proble#s in the control of fluid flo , see Table 8! 2L(? &' C(L)M' :lo of initial entr" :lo initial output :lo final entr" :lo of final output %able 8 "esults of t1e agglomerated flo4 ore @ L), ;LA-= =,- C*< 0,3 C*< 0,/ C*< 0,0-4 C*<

The $alue of 0,0-4 C * < flo in the final output is justified b" the lo ti#e integrit" of the #aterial to brea( up caused the rapid decrease in porosit" and clogging the filter la"er b" fine particles! +lso difficult to control the stabili'ation of the net -0 c# in height, as can be seen in figure 6 belo !

2igure B Delationship bet een the <-, le$el height in the colu#n ith the ti#e ) Particleboard

:igure 6 sho s that at the ti#e of 68 #inutes approxi#atel" / hour at output flo sho ed al#ost constant at 0!0-4 C * <! Eelo in :igure 4 one can see $ariations in flo rates of entr" and exit controlled in an atte#pt to find the flo that ill stabili'e the li&uid at the ideal height!

2igura C Controle de Fa'o G aglo#erado

Crus1ed 4it1 agglomerated This #ixture of crushed #aterial to the agglo#erated, the flo test, sho ed good results, both in control and in the flo of final output! The results of the flo are sho n in table =! %able : Desults of sa#ple flo .30% crushed H30% agglo#erate= 2L(? &' C(L)M' @ L), ;LA-= :lo of initial entr" 3,/ :lo initial output 0,9 :lo final entr" /,69 :lo of final output /,4 %nicial#ento the output flo presented belo the input flo due to the creation of preferential flo for fluid flo $alues, but in the ti#e of -8/ #inutes about = hours the li&uid stabili'ed in the bed height of the sa#ple at a rate of /!4 I * <! The $ariation of the rise of li&uid in the colu#n until it stabili'es can be seen in :igure 9

2igure D The relationship bet een the height le$el in the colu#n ith <-, ti#e ) 30% crushed H 30% agglo#erated!

%n the graph abo$e it appears that the li&uid, after adjusting the fluid le$el has decreased, this is due to the excessi$e rise in porosit" ith reduced frag#entation of the agglo#erate #aterial! +fter /30 #inutes Manteu li&uid le$el constant at -0 c# height! The changes in control flo pre$iousl" said can be seen in :igure A! %n this it appears that the output flo reached a pea( of -!63 C * < for an input flo of -!0= C * <, but the balanced flo in a flo rate of /!4 C * <!

2igure E :lo Control of the sa#ple .30% crushed H 30% agglo#erated0

This flo of /!4 C * <, hich is an inter#ediate flo in the other t o tests, sho s that the #ixture of crushed #aterial ith the agglo#erated #aterial can bring good results in the leaching process in cells, because the proble#s addressed in the test ith crushed, as the non)use of fines and ti#e of leaching li&uid residence can be #itigated or sol$ed using the t o sa#ples together!

Proposed Model
The control of the li&uid le$el height in the colu#n as a function of ti#e as obtained ith the experi#ental data and the obser$ation e&uation of the ph"sical para#eters of in$erse Caplace transfor# #ethod! + #odel as generated to esti#ate the height of the li&uid la"er in function of ti#e .e&uation /0! H(t) = ,stimates of t1e Constants The constants in the e&uation ./0 ere obtained b" nonlinear regression #ethod using the data obtained experi#entall" in the colu#n! Eeing, Particleboard .Test -0 and crushed ith Particleboard the rate of 30% .Test 80! ns4er %1eoretical and ,xperimental The figures /0 and // sho s the co#parison bet een the theoretical cur$es obtained ith the e&uation ./0 obtained in practice and the tests ith the crushed and agglo#erated ore! .e&uation /0

2igure 3> Practical and theoretical cur$e after cur$e fit .test -0!

2igure 33 Practical and theoretical cur$e after cur$e fit .test 80!

The theoretical cur$e fits the experi#ental cur$e sho ing possible to control the height of the li&uid la"er in the leaching colu#n!

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%s it possible to perfor# clustering of copper ores in plastic dru#s, including on its interior surface, rails in straight lines in the direction trans$erse to the #o$e#ent of the dru# to cause the Jsno ball effectJ and ha$e controlled as a function of the height of the dia#eters rails! There is an opti#i'ed linear distance bet een these rails! To dru# -9c# in dia#eter, t o trac(s of linear distance of about =3c# as the best that for#ed clusters! The obser$ations sho ed that belo /=!6 rp# speed of rotation causes the effect of Jslip particlesJ, so ithout the for#ation of agglo#erates! Since the abo$e /9 rp# as $erified the JcascadeJ effect, and therefore, the brea(do n of the agglo#erates ere present! The speed of rotation that is best suited to testing as /4!3 rp#, "ielding #ore balanced clusters of di#ensions! Tests for co#pressi$e strength and ph"sical integrit" executed ith clusters sho ed that the test // sho ed the best perfor#ance because of agglo#eration in order to $ie leaching in fixed beds, ie in colu#ns or cells, a cluster ith greater resistance to both co#pression and ph"sical integrit", i#plies a better extraction efficienc"! B&uation /, sho n to be a possible tool to control the fluid height in the leaching colu#n, enabling predictions regarding the ti#e re&uired for half saturation occurs! Kuring the leaching process it is necessar" to #a(e specific adjust#ents to the input flo to a$oid o$erflo ! This is a #easure of control in order to reach e&uilibriu#, this occurs hen the flo of output approaches the input $alue!

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