Cobalt extraction refers to the techniques used to extract cobalt from its ores and other compound ores. Several methods exist for the separation of cobalt from copper and nickel. They depend on the concentration of cobalt and the exact composition of the ore used.
The ores are treated by a sulfatizing roast in a fluidized bed furnace to convert copper and cobalt sulfides into soluble sulfates and iron into insoluble hematite. The calcine is subsequently leached with sulfuric acid from the spent copper recovery electrolyte. Oxide concentrates are introduced at this leaching step to maintain the acid balance in the circuit. Iron and aluminum are removed from the leach solution by the addition of lime, and copper is electrowon on copper cathodes. A part of the spent electrolyte enters the cobalt recovery circuit and is purified by the removal of iron, copper, nickel, and zinc prior to the precipitation of cobalt as its hydroxide. This is accomplished by the addition of more lime to raise the pH until the remaining copper precipitates. This copper is sent back to the copper circuit. As more lime is then added, a copper-cobaltite precipitates and is fed back to the leaching process. Sodium hydrosulfide (NaHS) is added (along with some metallic cobalt as a catalyst) to precipitate nickel sulfide (NiS). Hydrogen sulfide (H2S) and sodium carbonate (Na2CO3) are then added to precipitate zinc sulfide (ZnS). Lime is then added to saturation to precipitate cobalt(II) hydroxide (Co(OH)2). In the final stages, this cobalt hydroxide is redissolved and the metal is refined by electrolysis. The resulting cobalt cathodes are crushed and vacuum degassed to obtain a pure cobalt metal.
The Sherritt process is a hydrometallurgical process named for Sherritt Gordon Mines Ltd. (now Sherritt International) of Sherridon and Lynn Lake Manitoba Canada, based on the older Forward process developed by Dr. Frank Forward for the recovery of copper and nickel from those same mines. Nickel sulfide concentrates can be treated by either roasting or flash smelting to produce matte from which nickel and cobalt can be recovered hydrometallurgically, or they may be treated by an ammonia solution pressure leach. The residue is removed. A feed of matte and sulfide concentrate containing approximately 0.4% cobalt and 30% sulfur is pressure leached at elevated temperature and pressure in an ammoniacal solution to produce a solution of nickel, copper and cobalt. By boiling away the ammonia; copper is precipitated as a sulfide and sent to a smelter. Hydrogen sulfide is added to the autoclave to remove nickel sulfide and copper sulfide which is fed back to the leaching process. Air is then passed through the solution in the autoclave for oxyhydrolysis. The solution is then reduced with hydrogen, again at high temperature and pressure, to precipitate nickel powder (>99%). The remaining solution (containing approximately equal proportions of nickel and cobalt sulfides), is then adjusted (to a lower temperature and pressure) to precipitate the mixed sulfides and the fluid is concentrated and crystallized into ammonium sulfate ((NH4)2SO4). The mixed sulfides are pressure leached with air and sulfuric acid. Ammonia is then added to remove potassium and iron as jarosite (KFe3+
3 (OH)6(SO4)2). More ammonia and air is added for oxidation. The solution is removed from the autoclave and sulfuric acid added to remove nickel as nickel(II) sulfate-ammonium sulfate hexahydrate ([NiSO4]•[(NH4)2SO4]•6H2O) which is then sent to have its nickel recovered. The solution is then further reduced with more sulfuric acid and cobalt metal powder is added to aid in the nucleation of precipitants (seeding). Addition of hydrogen gas to saturation precipitates cobalt powder with a purity of approximately 99.6%.
The ore is comminuted and the cobalt rich oxides are separated by froth flotation. The cobalt-bearing concentrate is then mixed with lime and coal, and then melted in a reducing atmosphere. Iron and lighter impurities float to the surface as solid dross or are expelled from the melt as gas. The remaining liquid is composed of a heavier copper smelt containing approximately 5% cobalt that is processed for its copper and a lighter slag that is approximately 40% cobalt that is further refined by hydrometallurgical and electrolytic processing. Concentrations of cobalt oxide (Co3O4) may also be reduced by the aluminothermic reaction or with carbon in a blast furnace. [1]
Nickel-cobalt lateritic ores can be treated by either hydrometallurgical processes or pyrometallurgical processes, such as matte or ferronickel smelting, which require the entire ore to be melted and the metal values to be separated from the residual components of the ore. The hydrometallurgical process for laterite ore can use sulfuric acid or ammonia leach solutions. [2]
Arsenic containing concentrates are roasted in a fluidized bed to remove 60% to 70% of the arsenic present as arsenic oxide (As2O5). The roasted ores can be treated with hydrochloric acid and chlorine or with sulfuric acid to give a leach solution that can be purified by hydrometallurgical methods and from which cobalt can be recovered by electro refining or by carbonate precipitation. [3] If hydrochloric acid is used then cobalt may be extracted using alamine 336 in meta -xylene. [4] Cobalt can be extracted also using dialkylphosphinic acid. When cobalt carbonate (CoCO3) is heated (calcined) above 400 °C it decomposes into carbon dioxide (CO2) and cobalt(II) oxide (CoO) and can be refined as an oxide concentrate (see above).
When purifying by electrolysis, an aqueous sulfate solution at 50 to 70 °C is typically used with a lead anode (corrosion products from which will not contaminate the cobalt oxy-hydroxide (CoOOH) electrolyte solution) and a stainless steel cathode which will allow for the easy removal of the deposited cobalt. [5] Electro refining in a chloride or sulfate medium at −0.3 V will make a cathode coating of 99.98% cobalt.
Bioleaching is the extraction or liberation of metals from their ores through the use of living organisms. Bioleaching is one of several applications within biohydrometallurgy and several methods are used to treat ores or concentrates containing copper, zinc, lead, arsenic, antimony, nickel, molybdenum, gold, silver, and cobalt.
Smelting is a process of applying heat and a chemical reducing agent to an ore to extract a desired base metal product. It is a form of extractive metallurgy that is used to obtain many metals such as iron, copper, silver, tin, lead and zinc. Smelting uses heat and a chemical reducing agent to decompose the ore, driving off other elements as gases or slag and leaving the metal behind. The reducing agent is commonly a fossil fuel source of carbon, such as carbon monoxide from incomplete combustion of coke—or, in earlier times, of charcoal. The oxygen in the ore binds to carbon at high temperatures as the chemical potential energy of the bonds in carbon dioxide is lower than that of the bonds in the ore.
Extractive metallurgy is a branch of metallurgical engineering wherein process and methods of extraction of metals from their natural mineral deposits are studied. The field is a materials science, covering all aspects of the types of ore, washing, concentration, separation, chemical processes and extraction of pure metal and their alloying to suit various applications, sometimes for direct use as a finished product, but more often in a form that requires further working to achieve the given properties to suit the applications.
Chalcopyrite ( KAL-kə-PY-ryte, -koh-) is a copper iron sulfide mineral and the most abundant copper ore mineral. It has the chemical formula CuFeS2 and crystallizes in the tetragonal system. It has a brassy to golden yellow color and a hardness of 3.5 to 4 on the Mohs scale. Its streak is diagnostic as green-tinged black.
Malachite is a copper carbonate hydroxide mineral, with the formula Cu2CO3(OH)2. This opaque, green-banded mineral crystallizes in the monoclinic crystal system, and most often forms botryoidal, fibrous, or stalagmitic masses, in fractures and deep, underground spaces, where the water table and hydrothermal fluids provide the means for chemical precipitation. Individual crystals are rare, but occur as slender to acicular prisms. Pseudomorphs after more tabular or blocky azurite crystals also occur.
Copper extraction refers to the methods used to obtain copper from its ores. The conversion of copper ores consists of a series of physical, chemical and electrochemical processes. Methods have evolved and vary with country depending on the ore source, local environmental regulations, and other factors.
Bacteria biooxidation is an oxidation process caused by microbes where the valuable metal remains in the solid phase. In this process, the metal remains in the solid phase and the liquid can be discarded. Bacterial oxidation is a biohydrometallurgical process developed for pre-cyanidation treatment of refractory gold ores or concentrates. The bacterial culture is a mixed culture of Acidithiobacillus ferrooxidans, Acidithiobacillus thiooxidans and Leptospirillum ferrooxidans. The bacterial oxidation process comprises contacting refractory sulfide ROM ore or concentrate with a strain of the bacterial culture for a suitable treatment period under an optimum operating environment. The bacteria oxidise the sulfide minerals, thus liberating the occluded gold for subsequent recovery via cyanidation.
Classical qualitative inorganic analysis is a method of analytical chemistry which seeks to find the elemental composition of inorganic compounds. It is mainly focused on detecting ions in an aqueous solution, therefore materials in other forms may need to be brought to this state before using standard methods. The solution is then treated with various reagents to test for reactions characteristic of certain ions, which may cause color change, precipitation and other visible changes.
Hydrometallurgy is a technique within the field of extractive metallurgy, the obtaining of metals from their ores. Hydrometallurgy involve the use of aqueous solutions for the recovery of metals from ores, concentrates, and recycled or residual materials. Processing techniques that complement hydrometallurgy are pyrometallurgy, vapour metallurgy, and molten salt electrometallurgy. Hydrometallurgy is typically divided into three general areas:
Pyrometallurgy is a branch of extractive metallurgy. It consists of the thermal treatment of minerals and metallurgical ores and concentrates to bring about physical and chemical transformations in the materials to enable recovery of valuable metals. Pyrometallurgical treatment may produce products able to be sold such as pure metals, or intermediate compounds or alloys, suitable as feed for further processing. Examples of elements extracted by pyrometallurgical processes include the oxides of less reactive elements like iron, copper, zinc, chromium, tin, and manganese.
Electrowinning, also called electroextraction, is the electrodeposition of metals from their ores that have been put in solution via a process commonly referred to as leaching. Electrorefining uses a similar process to remove impurities from a metal. Both processes use electroplating on a large scale and are important techniques for the economical and straightforward purification of non-ferrous metals. The resulting metals are said to be electrowon.
Heap leaching is an industrial mining process used to extract precious metals, copper, uranium, and other compounds from ore using a series of chemical reactions that absorb specific minerals and re-separate them after their division from other earth materials. Similar to in situ mining, heap leach mining differs in that it places ore on a liner, then adds the chemicals via drip systems to the ore, whereas in situ mining lacks these liners and pulls pregnant solution up to obtain the minerals. Heap leaching is widely used in modern large-scale mining operations as it produces the desired concentrates at a lower cost compared to conventional processing methods such as flotation, agitation, and vat leaching.
Lateritic nickel ore deposits are surficial, weathered rinds formed on ultramafic rocks. They account for 73% of the continental world nickel resources and will be in the future the dominant source for the mining of nickel.
Zinc smelting is the process of converting zinc concentrates into pure zinc. Zinc smelting has historically been more difficult than the smelting of other metals, e.g. iron, because in contrast, zinc has a low boiling point. At temperatures typically used for smelting metals, zinc is a gas that will escape from a furnace with the flue gas and be lost, unless specific measures are taken to prevent it.
Leviathan Mine is a United States superfund site at an abandoned open-pit sulfur mine located in Alpine County, California. The mine is located on the eastern slope of the Sierra Nevada at about 7,000-foot (2,100 m) elevation, 6 miles (9.7 km) east of Markleeville and 24 miles (39 km) southeast of Lake Tahoe. The mine site comprises approximately 250 acres (100 ha) of land surrounded by the Toiyabe National Forest, which is only accessible a few months a year. The approximately 22 million tons of sulfur ore-containing crushed rock at the mine are responsible for contaminating the Leviathan and Aspen Creek, which join with Mountaineer Creek to form Bryant Creek which ultimately empties into the East Fork of the Carson River. These water bodies are listed as 303(d) impaired. The site location is seismically active.
Mopani Copper Mines PLC is a Zambian company owned by ZCCM Investment Holdings.
A nickel mine is a mine that produces nickel. Some mines produce nickel primarily, while some mines produce nickel as a side-product of some other metal that has a higher concentration in the ore.
Huayou Cobalt Co., Ltd primarily operates as a supplier of cobalt and its associated products, such as cobalt tetroxide, cobalt oxide, cobalt carbonate, cobalt hydroxide, cobalt oxalate, cobalt sulfate, and cobalt monoxide. The company is headquartered in the Tongxiang Economic Development Zone of Zhejiang, China.
Chevreul's salt (copper(I,II) sulfite dihydrate, Cu2SO3•CuSO3•2H2O or Cu3(SO3)2•2H2O), is a copper salt which was prepared for the first time by a French chemist Michel Eugène Chevreul in 1812. Its unusual property is that it contains copper in both of its common oxidation states, making it a mixed-valence complex. It is insoluble in water and stable in air. What was known as Rogojski's salt is a mixture of Chevreul's salt and metallic copper.