UNIT PROCESSES IN HYDROMETALLURGY: LEACHING,

PURIFICATION OF LEACH LIQUOR

BY
SWETA SUMAN (2019UGMM030)
ADITYA KUMAR JHA (2019UGMM065)
MANTHAN HARISH BHAGAT (2019UGMM095)

Hydrometallurgy is a technique within the field of extractive metallurgy to obtain metals from
their ores. Hydrometallurgy involve the use of aqueous solutions for the recovery of metals from
ores, concentrates, and recycled of residual materials. The Unit processes of hydrometallurgy
includes the leaching of particularly low grade ores for the recovery of metals, the separation of
leaching solution from the ore and also the recovery of the dissolved metal from the solution.

STEPS INVOLVED IN HYDROMETALLURGICAL PROCESS:

1. Leaching:- Leaching is the process in which desired elements in the ore are selectively
dissolved in an appropriate solvent known as leaching reagent. Proper leaching may involve
preliminary ore preparation opertaion such as grinding, sizing, physical benefication, roasting
etc.

2.Separation of leach liquor:- In this step, the solution i.e. leach liquor is separated from solid
residues by one of the methods of material separation. ex: settling, thickening, filtration etc.

3.Recovery of metal from the leach liquor:-The metal in the elemental form is obtained in the
recovery step. Methods employed to treat enriched liquor include evaporation, distillation,
precipitation, cementation, electrolysis, ion exchange, solvent extraction etc.

4. Reagent Recovery:- The leaching reagent is generally recycled after purification and
readjustment of composition.

ADVANTAGES OF HYDROMETALLURGY:
1. Ideally suited for lean and complex ores. With gradual depletion of rich ore deposits, it is
becoming increasingly difficult in many situations to apply conventional pyrometallurgical
methods for metal extraction.

2. Greater control over every step of processing resulting in recovery of valuable by-products.
Handling of material is also easier.

3. It is preferable in the point of view of reducing environmental pollution.

4. A hydrometallurgical process avoid use of coke, an increasingly costly reducing agent.

5.Waste liquor from final recovery step can be recycled.

6. A hydrometallurgical process may start on the small scale and expand as required. However, a
pyrometallurgical process usually must be designed as a large scale operation for reason of
process economy.

DISADVANTAGES OF HYDROMETALLURGY:

1. Large amount of water used, so greater potential for contamination.

2. Chances of corrosion and erosion in handling equipment.

3. Time needed for high metal recovery.

4. Impurities problem in purification process.

LEACHING:
Leaching is a process widely used in extractive metallurgy where ore is treated with chemicals
to convert the valuable metals within into soluble salts while impurity remain insoluble. In
preparation for leaching, the ore is usually reduced to a small size by crushing and grinding to
attain suitable fineness. This increases the surface area of particles and, therefore, the reaction
rate. In some cases, preliminary may be necessary.
There are four types of leaching:
1.Cyanide leaching (e.g. gold ore)
2.Ammonia leaching (e.g. crushed ore)
3.Alkali leaching (e.g. bauxite ore)
4.Acid leaching (e.g. sulfide ore)

The choice of a leaching agent depends on the following factors:

• Chemical and physical character of the material to be leached.
• Cost of the reagent.
• Corroding action of the reagent and the materials of construction of construction
required.
• Selectivity of the leaching agent for the desired constituent to be leached.
• Ability to be regenerated.
LEACHING REAGENTS
The common categories of leaching reagents are:

1 WATER – Some compounds, e.g. CuSO4, ZnSO4, most compounds of alkali metals dissolve
in water readily. Some poor grade copper sulphide ores transform slowly into water soluble
sulphate.
2 ACIDS – Mineral acids, chiefly sulphuric acids, are the most common leaching agents.
3 BASES – Several bases like, NaOH solution or NH4OH are routinely employed in many
leaching operations. Bauxite is leached by hot concentrated NaOH solution under pressure,
ammonia solution is used in the leaching of native copper, copper ores, NiS and Cu2S.
4 AQUEOUS SALT SOLUTIONS – The most important example of a salt solution as a
leachant is seen in the dissolution of gold during its extraction from veins in silica rock.
Gold is dissolved by a solution of NaCN. The reaction is,
4Au(s) + 8NaCN(aq.) + O2(g) + 2H2O(aq.) ⇋ 4NaAu(CN)2(aq.) + NaOH(aq.)

LEACHING TECHNIQUES

IN-SITU LEACHING
• It is also known as solution mining.
• It is a mining process used to recover minerals such as copper and uranium
through boreholes drilled into a deposit.
• The process initially involves the drilling of holes into the ore deposit. Leaching solution
is pumped into the deposit where it makes contact with the ore. The solution bearing the
dissolved ore content is then pumped to the surface and processed.
• Solvent is injected through a set of pipes drilled down in the ore. Resulting liquor is
removed through different set of pipe shape drills.
• Through these pipe shaped drills, solvent flow down and is penetrated in to ore body for
leaching. Solvent moves through the pipe shaped drills and ore body and solute is
leached.

HEAP LEACHING
• It is an industrial mining process to extract precious metals, copper, uranium and other
compounds from ore via a series of chemical reactions that absorb specific minerals and
then re-separates them after their division from other earth materials.
• Heap leaching mining places ore on a liner, then adds the chemicals via drip systems to
the ore.
• In heap leaching, ore is digged and prepared in the form of very large size heap.
• A pond is prepared at the top of the heap for placing solvent in it.
• Solvent is pumped over the ore through these pipe shaped drills and is flown down and
is penetrated in the ore body for leaching.
• Solvent moves through the pipe shaped drills and ore body and solute is leached.
• Whole solution is collected as it drains from the heap.
VAT LEACHING
 • The ore meant to be leached is loaded into vats that are typically made up of concrete.
When leaching has been completed, the residual solid are dug out of the vat and replaced
by fresh batch of ore.
• Suitable for porous and sandy materials.
• Commonly used for gold and silver ore.
AGITATION LEACHING
• A process where soil is slurried with the extraction of fluid for a period of time. When
equilibrium between the metals on the soil surface and metal contained by the solution is
approached, the solubilization of metal in the soil is slowed and extraction is considered
to be complete.
AUTOCLAVE LEACHING
• Autoclave reactors are used for reactions at higher temperatures, which can enhance the
rate of reaction. Autoclave enable the use of gaseous reagents in the system.

SEPARATION OF LEACH LIQUOR:

Practically all hydrometallurgical processes involve leaching of solids to dissolve valuable
constituents. This usually is followed by a solid-liquid separation before producing the final
product. In this step, the solution of leach liquor is separated from solid residues by one or more
of various methods of material separation. Leach liquor is separated from the residue by
process such as:

(a)Washing: This method is based on the difference in densities of the metallic ore and
impurities. ore is treated with a stream of running water when the lighter impurities are washed
away and heavier ore particles are left behind.

(b)Filtration: Filtration is the separation of a suspension into a solid filter cake and a liquid
filtrate by passing it through a permeable filtering material. Important factors in this process are
the properties of the suspension (e.g., size distribution, concentration), the properties of the
filtering materials (e.g., the width and shape of pores), and the forces applied to the suspension.

(c)Thickening: Thickening is a process where a slurry or solid-liquid mixture is separated to a

dense slurry containing most of the solids and an overflow of liquor in leaching processes. The
solids in a suspension settle under the influence of gravity in a tank and form a thick pulp. This
pulp, and the clear liquid at the top of the tank, can be removed continuously or intermittently.

(d)Settling: In this method of solid-liquid separation, the leachate obtained after leaching is
neutralized and this neutralized slurry is separated and removed by adding flocculants(A
flocculant is a chemical that can be added to the water to help colloids and any other suspended
solids bind together and form heavier particles)

METAL RECOVERY:
Metal recovery is the final step in a hydrometallurgical process. Metals suitable for sale as raw
materials are often directly produced in the metal recovery step. Sometimes, however, further
refining is required if ultra-high purity metals are to be produced. The primary types of metal
recovery processes are:

(a) Precipitation: Precipitation is the selective removal of a compound of the targeted metal or
removal of a major impurity by precipitation of one of its compounds. The principle technology
to recover or remove metals from a solution is by chemical precipitation. Chemical precipitation
is one of the most widely adopted methodologies that have been employed for heavy metal
removal from inorganic effluents in industries. It principally involves the transformation of a
soluble compound into an insoluble form (insoluble precipitates of heavy metals as hydroxide,
sulfide, carbonate, and phosphate) via the addition of chemicals (precipitants). Once the heavy
metals precipitate to form solids, they can be removed easily.

(b) Cementation: Cementation is a type of precipitation, a heterogeneous process in which ions

are reduced to zero valence at a solid metallic interface. It is the process of extracting the
metals from a solution based on the electrochemical reaction between the cementing metal and
the ion of the precipitated metal. The precipitation of the metal is accompanied obviously by a
change of its concentration of the solution, and consequently, of its potential. When the
equilibrium values are reached, the process stops.

(c) Electrowinning: Electrowinning is the electrodeposition of metals from their ores that have
been put in a solution. It is also called as electro extraction. It is most commonly used to
recover metals like gold, silver, copper, zinc etc. because of their high electropotential values.
In electrowinning process, current is passed from an inert anode through a liquid leach solution
containing the metal so that the metal is extracted as it gets deposited on the cathode.
Electrowinning cells provide a low-cost option for producers and higher efficiency. In addition,
electrowinning produces a very clean products.

(d)Ion exchange: Ion exchange has traditionally been employed for the purification of water and
the removal of metal contaminants from dilute waste streams. More recently, its use in removing
trace metallic impurities from hydrometallurgical process streams (with typical background
metal concentrations of 50–100 g/L) has increased substantially. It is also used as a primary
recovery and concentration unit operation for certain commodities, where both technical and
cost advantages become apparent for complex flow sheets. This overview discusses selected
modern applications of ion exchange in hydrometallurgical processes for uranium, precious
metals, copper, cobalt, nickel and zinc, and identifies some opportunities for the future.

EXAMPLE:-
GOLD EXTRACTION:-

Gold extraction refers to the processes required to extract gold from its ores. Ores in
which gold occurs in chemical composition with other elements are comparatively rare.
They include calaverite, sylvanite, nagyagite, petzite, krennerite.
 Fig: extraction of gold

Gold cyanidation:
It is the most commonly used leaching process for gold extraction. More gold is recovered by
cyanidation than by any other process. In cyanidation, metallic gold is oxidized and
dissolved in an alkaline cyanide solution. The oxidant employed is atmospheric oxygen,
which, in the presence of an aqueous solution of sodium cyanide, causes the dissolution
of gold and the formation of sodium cyanoaurite and sodium hydroxide.
The chemical reaction for the dissolution of gold
4 Au(s) + 8 NaCN(aq) + O2(g) + 2H2O(l)→ 4 Na[Au(CN)2](aq) + 4 NaOH(aq)
When gold dissolution is complete, the gold-bearing solution is separated from the
solids.
• With ores of higher gold content (greater than 20grams of gold per ton of ore),

cyanidation is accomplished by vat leaching, which involves holding a slurry of

ore and solvent for several hours in large tanks equipped with agitators.

• For extracting gold from low-grade ores heapleaching is practiced. The huge

heaps described above are sprayed with a dilute solution of sodium cyanide, and

this percolate down through the piled ore, dissolving gold.

Recovery of gold from cyanide solution:-

The common processes for recovery of the solubilized gold from solution are :
1. Carbon in pulp: Carbon in a pulp is an extraction technique of recovery of gold

which has been liberated in a cyanide solution as a part of gold cyanidation process.

Carbon in Pulp is regarded as a simple and cheap process. As such it is used in most

industrial applications where the presence of competing silver or copper does not

prohibit its use. Leached pulp and carbon are transferred in a counter current flow

arrangement between a series of tanks, usually numbering 4 to 6. In the final tank, fresh

or barren carbon is put in contact with low grade or tailing solution. At this tank the

fresh carbon has a high activity and can remove trace amounts of gold. As it moves up

the train, the carbon loads to higher and higher concentrations of gold, as it comes in

contact with higher grade solutions. Typically concentrations as high as 4000 to

8000gramsof gold per tonne of carbon (g/t Au) can be achieved on the final loaded

carbon, as it comes in contact with freshly leached ore and leach liquor solution. This

can be measured by comparing the amount of gold extracted from the carbon to the

amount of carbon used.

The final loaded carbon then is removed and washed before undergoing desorption of

gold cyanide at high temperature and pH. Ethanol can also be used to desorb gold from

activated carbon.

2. Merrill crowe process: The Merrill crowe process is a separation technique for

removing gold from solution obtained by leaching of gold ore. The solution is separated

from the ore by methods such as filtration(e.g. vertical leaf type clarifier filters) and

counter current decanation. Afterwards a very clear solution is achieved by using pre-

coated filters applying diatomaceous earth. Oxygen is then removed by passing the

solution through a vacuum de-aeration column. Zinc dust is added to the clarified, de-

aerated solution which precipitates the gold. Zinc having the high affinity to cyanide

than gold. The gold precipitate (mixed with zinc dust) is then filtered out of the solution,

and the zinc dust and gold are mixed with sulphuric acid to dissolve the zinc. The

solution is filtered, and the remaining solids are smelted to a gold bar. These bars are
 sent to a refinery to remove the copper and silver, the specific process used depending

upon the impurities in the gold.

3. Electrowinning: Electrowinning is a process used to recover metals(e.g. silver and

gold) from concentrated solution by applying a voltage across electrodes immersed in a

concentrated solution. The positive terminal from the rectifier is connected to the anode

where the oxidation reaction occur and electrons are generated. These generated

electrons are consumed at cathode which is connected to the negative terminal of the

rectifier. The reduction reaction results in the deposition of metal on the cathode .The

following reduction reactions takes place during electrolysis of the alkaline gold cyanide

solution:

Cathode: Au (CN)¯² + e¯ → Au + 2CN¯

Anode: 2H₂O →4H+ + O2 + 4ē¯

In cyanide solution, gold is present as stable auro-cyanide complex ion with a relatively

high cathodic potential. The cathodic shift demand higher cell voltage and consequently

other cathodic reaction like formation of H2 and reduction of O2 can also occur.

Refining of gold:

Gold extracted by cyanidation contains a variety of impurities, including zinc, copper,

silver, and iron. Two methods are commonly employed for purification: The Miller

process, Wohlwil process,

1. The Miller process is based on the fact that virtually all the impurities present in gold

combine with gaseous chlorine more readily than gold does at temperatures equal to or

greater than the melting point of gold. The impure gold is therefore melted and gaseous

chlorine is blown into the resulting liquid. The impurities form chloride compounds that

separate into a layer on the surface of the molten gold.

2. Wohlwil process, in this process, a casting of impure gold is lowered into an electrolyte

solution of hydrochloric acid and gold chloride. Under the influence of an electric

current the casting functions as a positively charged electrode, or anode. The anode

dissolves, and the impurities either pass into solution or report to the bottom of the

electro refining tank as an insoluble slime. The gold migrates under the influence of the

electric field to a negatively charged electrode called the cathode, where it is restored to

a highly pure metallic state.

Other Methods of refining of gold:

• USING ACID: This is the most common method to purify gold. In this method, strong

acids are used as a means of dissolving impurities. Hydrochloric acid and nitric acid are

the acids used in this process. When gold is added to the solution containing the acids,

impurities separate from the gold. After removing the other substances, the precipitate

that remains is 99.999% gold.

• USING FIRE: Another process that is used to refine gold involves the application of

heat. This is the oldest method of obtaining pure gold. Gold scraps are placed in a

crucible (a container that can withstand very high temperatures). This crucible is then

placed in a furnace which is heated up to almost 2,000 degrees Fahrenheit. The gold

melts at such a high temperature. It is then transferred to another container, leaving the

impurities and other substances floating at the surface.

• CUPELLATION: Cupellation is a process that purifies ores by separating gold and

silver from base metals and other impurities. The process makes use of a cupel – a high

temperature resistant flat bowl. The ore is placed in this cupel which is put in a special

furnace. Hot air is then passed through it to remove the impurities. The impurities and

other metals either vaporise or are oxidised or absorbed by the cupel.

• The gold that refining companies receive for purification is called ‘dor̕e form of gold’. A

dor̕e bar is basically an alloy of gold and some other metals. This is re-liquified in a
 furnace. The gold is separated from impurities and other metals when borax and soda ash

is added to the mix. And this is how pure gold is obtained.

• It is also possible to refine gold without any large-scale equipment. In this process, nitric

acid is first added to the gold that needs purification. Then, Hydrochloric acid or

Muriatic acid is added to the mixture. Once the mixture settles, impurities are removed

by filtering the solution. Since a lot of acids were added, the remains are treated to

neutralise those acids. Once all this is done, the resultant muddy precipitate is gold! This

muddy substance is then rinsed thoroughly in water and treated with aqueous ammonia.

White vapours form because of the treatment. After rinsing once again and allowing it to

dry, refined gold is obtained.

APPLICATION OF GOLD:

➢ Gold is considered as the best filling for cavities and crowns, bridges and other

orthodontic appliances because the metal is ductile and can easily take shapes. It is also

chemically passive and doesn't react easily when missed with other metals. It is also easy

to insert and is non-allergic. Dentists have used gold as the best substitute for misplaced/

dislocated teeth for ages.

➢ Gold is of the top metals when it comes to being good conductors of electricity. It is able

to carry electrical charges easily and because of this property, this metal is found in

small portions in many electrical devices like mobile phones. Television sets, GPS

devices. It is also sometimes found in computers and laptops for transferring data

quickly.

➢ Gold is considered as a highly auspicious and precious metal it is used in the making of

winning medals for popular world games, championships and awards. Its beauty holds

significance and a permanent place in the human eye. Because of its exceptional

magnificence, it is also used in the making of religious statues and Idols.

 ➢ As per statistics, about 80% of gold is converted into jewellery. It is the most standard

use if gold and is common amongst all cultures.

REFERENCE:

1. Brent Hiskey "Metallurgy, Survey" in Kirk-Othmer Encyclopedia of Chemical

Technology, 2000, Wiley-VCH, Weinheim

.doi:10.1002/0471238961.1921182208091911.a01

2. Recent Trends in Extractive Metallurgy" Journal of Mining and Metallurgy,

Section B: Metallurgy 2009, Volume 45, pp. 1- 13.

3. Adams, Mike D. (2005-12-02). Advances in Gold Ore Processing.

4. "Dictionary of Mining, Mineral, and Related Terms". Hacettepe University. Archived

from the original on 9 June 2011. Retrieved 10 September 2010 .

5. Alexander Watt, Electro-Deposition a Practical Treatise, Read Books (2008), p. 395.

ISBN 1-4437-6683-6