The SAIMM Southern · PDF fileS47 Fourth Southern African Base Metals Conference ‘Africa...

THE SOUTHERN AFRICAN INSTITUTE OF MINING AND METALLURGYJOHANNESBURG 2008

SYMPOSIUM SERIES S54

The SAIMM Southern African

HYDROMETALLURGY CONFERENCE 2009

24–26 February 2009

MISTY HILLS, MULDERSDRIFT, GAUTENG

i-xii:PRELIMS 2/16/09 12:08 PM

SAIMM PUBLICATIONS

THE MONOGRAPH SERIES

Ml Lognormal-De Wijsian Geostatistics for Ore Evaluation(2nd ed 1981) D.G. Krige

M2 An Introduction to Geostatistical Methods of Mineral Evaluation(2nd ed 1981) J.-M.M. Rendu

M3 Principles of Flotation(1982) (3rd imp. 1986) Edited by R.P. King

M4 Increased Underground Extraction of Coal(1982) Edited by C.J. Fauconnier and R.W.O. Kersten

M5 Rock Mechanics in Mining Practice(1983) (3rd imp. 1986) Edited by S. Budavari

M6 Assay and Analytical Practice in the South African Mining Industry(1986) W.C. Lenahan and R. de L. Murray-Smith

M7 The Extractive Metallurgy of Gold in South Africa,2 volumes (1987) Edited by G.G Stanley

M8 Mineral and Metal Extraction — An Overview(1994) L.C. Woollacott and R.H. Eric

M9 Rock Fracture and Rockbursts—an illustrative study(1997) Edited by W.D. Ortlepp

THE SPECIAL PUBLICATIONS SERIES

SPI Proceedings, Underground Transport Symposium(1986) Edited by R.C.R. Edgar

SP2 Backfill in South African Mines (1988)

SP3 Treatment and Re-use of Water in the Minerals Industry (1989)

SP4 COREX Symposium 1990(1990) Edited by H.M.W. Delport and P.J. Holaschke

SP5 Measurement, Control, and Optimization in Mineral Processing(1994) Edited by H.W. Glen

SP6 Handbook on Hard-rock Strata Control(1994) A.J.S. Spearing

SP7 Rock Engineering for underground coal mining(2002) J. Nielen van der Merwe and Bernard J. Madden

SUPPLEMENT TO THE SAIMM JOURNAL

The Metals and Minerals Industry in South Africa - Part 1 (1989)Edited by H.W. Glen


THE SYMPOSIUM SERIES S1 Mathematical Statistics and Computer Applications in Ore Valuation (1966)S2 Planning Open Pit Mines (1970) (4th imp.) Edited by P.W.J. van RensburgS3 Application of Computer Methods in the Mineral Industry (APCOM 1973) Edited by M.D.G. SalamonS4 Infacon 1974 Edited by H.W. GlenS5 Proceedings of the 12th CMMI Congress 2 volumes (1982) Edited by H.W. GlenS6 Rockbursts and Seismicity in Mines (1984) Edited by N.C. Gay and E.H. WainwrightS7 The Planning and Operation of Open Pit and Strip Mines (1986) Edited by J.P. DeetlefsS8 GOLD 100: Proceedings of the International Conference on Gold (1986)

Volume 1: Gold Mining Technology Edited by H. Wagner and R.P. KingVolume 2: Extractive Metallurgy of Gold Edited by C.E. Fivaz and R.P. KingVolume 3: Industrial Uses of Gold Edited by G. Gafner and R.P. King

S9 APCOM 87: Proceedings of the Twentieth International Symposium on theApplication of Computers and Mathematics in the Mineral Industries (1987)

Volume 1: Mining Edited by L. Wade, R.W.O. Kersten and J.R. CutlandVolume 2: Metallurgy Edited by R.P. King and I.J. BarkerVolume 3: Geostatistics Edited by I.C. Lemmer, H. Schaum and F.A.G.M. Camisani-Calzolari

S10 International Deep Mining Conference (1990)Volume 1: Innovations in Metallurgical Plant Edited by G.A. Brown and P. Smith and Application of Materials Engineering in the Mining Industry Edited by B. MetcalfeVolume 2: Technical Challenges in Deep Level Mining Edited by D.A.J. Ross-Watt and P.D.K. Robinson

S11 Infacon 6 ( Incorporating Incsac) (1992) Edited by H.W. GlenS12 Massmin 92 Edited by H.W. Glen (out of print)S13 Minefill 93 Edited by H.W. GlenS14 XVth CMMI Congress Publications (1994)

Volume 1: Mining Edited by H.W. GlenVolume 2: Metals Technology and Extractive Metallurgy (1994) Edited by H.W. Glen

S15 Surface Mining 1996 Edited by H.W. GlenS16 Hidden Wealth (1996) Edited by H.W. GlenS17 Heavy Minerals 1997 Edited by R.E. RobinsonS18 The 8th International Platinum Symposium (1998)S19 Mining in Africa ’98S20 Extraction Metallurgy Africa ’98S21 Sixth International Symposium for Rock Fragmentation by Blasting (1999)S22 Metallurgy Africa ’99S23 Heavy Minerals 1999 Edited by R.G. StimsonS24 Tunnels under Pressure Technical Editor T.R. StaceyS25 Mine Hoisting 2000S26 Coal–The Future (2000)S27 The Fifth International Symposium on Rockburst and Seismicity in Mines (RaSim 5) (2001)S28 6th International Symposium on Mine Mechanization and Automation (2001)S29 XIV International Coal Preparation Congress and ExhibitionS30 Surface Mining 2002—Modern Developments for the New MillenniumS31 IFSA 2002, Industrial Fluidization South AfricaS31A APCOM 2003—Application of Computers and Operations Research in the Minerals IndustriesS32 ISSA/Chamber of Mines Conference—Mines and Quarries: Prevention of Occupational Injury and DiseaseS33 ISRM—Technology Roadmap for Rock MechanicsS34 Heavy Minerals Conference 2003S35 Safety in Mines Research Institutes (2003)S36 VII International Conference on Molten Slags, Fluxes & Salts (2004)

Tenth International Ferroalloys Congress INFACONX 2004S37 Deep and high stress mining 2004S38 ‘Platinum adding value’ 2004S39 Base Metals—Southern Africa’s response to changing global base metals market dynamics 2005S40 Strategic versus Tactical approaches in mining 2005S41 Best practices in rock engineering SARES 2005S42 IFSA 2005 (Mintek)S43 Southern African Pyrometallurgy 2006 International ConferenceS44 Stability of rock slopes in open pit mining and civil engineering situationsS45 ‘Platinum Surges Ahead’ 2006S46 Hydraulic Transport of Solids - Hydrotransport 17 (2007)S47 Fourth Southern African Base Metals Conference ‘Africa’s base metals resurgence’S48 Heavy Minerals Conference, 2007S49 Cave Mining Conference, 2007S50 International Symposium on Lead and Zinc processing – Lead & Zinc 2008S51 Surface Mining 2008S52 Hydrometallurgy Conference 2009S53 IFSA 2008


Published by The Southern African Institute of Mining and MetallurgyFifth Floor, Chamber of Mines Building, 5 Hollard Street, Johannesburg, 2107

Republic of South Africa

© The Southern African Institute of Mining and Metallurgy, 2008

ISBN 978-1-920211-22-6

The papers in this volume have been for the most part prepared from files supplied by the authors, with additional typesetting and formatting by The Southern African Institute of Mining and Metallurgy.

All papers included in this volume were subjected to review.A technical and critical review of each paper was carried out by one technical reviewer.

Printed by Camera Press, Johannesburg


FOREWORD

For the first time a conference is being staged that covers the true diversity of theapplication of hydrometallurgy in Southern Africa. This conference will bringtogether operating hydrometallurgical facilities, research organisations, academic

organisations, project companies, technology and equipment suppliers, and reagentsuppliers, encompassing a wide range of commodities and unit operations.

The SAIMM Southern African Hydrometallurgy conference 2009 will cover anoverview of a significant number of currently operating hydrometallurgical facilities inSouthern Africa. These overviews will encompass a description of the facility, thetechnical challenges facing the operation, and any future process improvements,debottlenecking or expansions envisaged. The conference wil l highlighthydrometallurgy research being conducted by Southern African academic institutionsand by mining companies. The conference will also highlight developments beingundertaken by technology suppliers, equipment suppliers and reagent suppliers.

Some of the countries included are South Africa, Namibia, Botswana, Zimbabwe,Zambia and the Democratic Republic of Congo. Some of the commodities covered willbe copper, nickel, zinc, cobalt, uranium, gold and PGMs. A wide range of unitprocesses will be featured, including, atmospheric leaching, pressure leaching,biological leaching, precipitation, cementation, crystallization, solvent extraction, ionexchange and electrowinning.

I believe that the papers and presentations submitted for this conference willprovide a valuable future reference for hydrometallurgy, thus making the work of all thecontributors to this conference highly rewarding and worthwhile.

Marek DworzanowskiChairman

Organising Committee


ContentsPage No.

ATMOSPHERIC LEACHINGLeaching of the arsenopyrite/pyrite flotation concentrates using metallic iron in a hydrochloric acid mediumT. MAHLANGU, F.P. GUDYANGA, and D.J. SIMBI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Base metals recovery from zinc hydrometallurgical plant residues by digestion methodR.B. NGENDA, L. SEGERS, and P.K. KONGOLO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

The progression of metallurgical testwork during heap leach designS.W. ROBERTSON and P.J. VAN STADEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

PRESSURE LEACHINGIncreasing the capacity of existing and new exothermic autoclave circuitsG.M. DUNN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Stress development in refractory due to the rate of temperature change: a pressure vessel refractory lining design considerationP. LAUZON, A. KONING, and I. DONOHUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Mixing system design for the Tati Activox® autoclaveM. NICOLLE, G. NEL, T. PLIKAS, U. SHAH, L. ZUNTI, M. BELLINO, and H.J.H. PIETERSE . . . . . . . . . 65

Stabilization of supersonic vent gas from autoclave pressure oxidationM. FRANCESCHINI and J. WOLOSHYN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

BIOLOGICAL LEACHINGIndigenous microorganism strains as bio-extractants of Ca, Fe, and Mg from metallurgical and mine drainagesA.F. MULABA-BAFUBIANDI, E. FOSSO-KANKEU, and B.B. MAMBA . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Biosorption of cobalt and copper from hydrometallurgical solutions mediated by Pseudomona sppA.F. MULABA-BAFUBIANDI, N.P. DLAMINI, and B.B. MAMBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

An investigation into fungal strains bio-extraction of metal impurities from aqueous effluents emanating from Ekhuruleni (Gauteng, South Africa) metallurgical and mining operationsM. MWANZA and A.F. MULABA-BAFUBIANDI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Integrated piloting of a thermophilic bioleaching process for the treatment of a low-grade nickel-copper sulphide concentrateJ.W. NEALE, S.W. ROBERTSON, H.H. MULLER, and M. GERICKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

The effect of elemental sulphur and pyrite on the leaching of nickel laterites using chemolithotrophic bacteriaG.S. SIMATE, S. NDLOVU, and M. GERICKE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Recent advances in BIOX® technologyJ. VAN NIEKERK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Systematic characterization of the mixing process for the BIOX® reactorR. VAN DEVENTER, W. KELLER, M. OOSTHUIZEN, and J. STAPELBERG . . . . . . . . . . . . . . . . . . . . . . . 177

Keynote address: Hydrometallurgical process development for complex ores and concentratesD. DREISINGER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

SOLVENT EXTRACTION AND ELECTROWINNINGCopper electrowinning: theoretical and practical designN.T. BEUKES and J. BADENHORST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Developments in organic holding tank structure for solvent extraction processesH.T. LAITALA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 241


Contents (Continued)

Page No.

SOLVENT EXTRACTION AND ELECTROWINNING (Continued)

The next generation of permanent cathode and lead anode technologyT. MARSDEN and J. JICKLING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 249

Solvent extraction design consideration for the Tati Activox® plantE. ROBLES, I. CRONJE, and G. NEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

The ACORGA® OPT series: comparative studies against aldoxime: ketoxime reagentsO. TINKLER, D. SHIELS, and M. SODERSTROM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273

Solvent extraction (SX) reagent selection for high temperature, acid, chloride and Cu PLS at Port Pirie and its impact on electrowinning (EW)P. CRANE, M. URBANI, K. DUDLEY, A. HORNER, and M. VIRNIG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Organic degradation in uranium and cobalt solvent extraction: the case for aliphatic diluents and antioxidantsD.M. VAN RENSBURG, B. MUNYUNGANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 295

BASE METALS REFINERIESDevelopment of the Tati Activox® BMR ammonia recovery circuitD.A. VAN DEN BERG, P. MARÉ, and G.J. NEL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

pH advanced process control solution for Impala BMR first stage high pressure acid-oxygen leachA.F. KHAN, T. SPANDIEL, T. VAN SCHALKWYK, and J.A.M. RADEMAN . . . . . . . . . . . . . . . . . . . . . . . . 313

COPPER, COBALT, NICKEL, ZINC HYDROMETALLURGYA cobalt solvent extraction investigation in Africa’s Copper BeltT. KÖNIGHOFER, S.J. ARCHER, and L. BRADFORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Oxidative precipitation of Mn(II) from cobalt leach solutions using dilute SO2/air mixtureN. MULAUDZI and T. MAHLANGU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Soluble metal recovery improvement using high density thickeners in a CCD circuit: Ruashi II a case studyM.C. MULLIGAN and L. BRADFORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Optimizing acid utilization and metal recovery in African Cu/Co flowsheetsM. REOLON, T. GAZIS, and S. AMOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

Processing considerations for cobalt recovery from Congolese copperbelt oresB. SWARTZ, S. DONEGAN, and S. AMOS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385

GENERAL HYDROMETALLURGYKinetic modelling of chemical processes in acid solution at t ≤ 200°C i. thermodynamics and speciation in H2SO4-metal (ii) SO4-H2O systemJ.D.T. STEYL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401

The evaluation of various oxidants used in acid leaching of uraniumR. VENTER and M. BOYLETT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 445Application of redox titration techniques for analysis of hydrometallurgical solutionsO. BAZHKO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 457

Investigation of granular activated carbon from peach stones for gold adsorption in acidic thioureaT.T. MASIYA and F.P. GUDYANGA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 465

Elution behaviour of metals from carbonM. JEFFREY, R. PLEYSIER, and K. BUNNEY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 475


i-xii:PRELIMS 2/16/09 12:08 PM Page 11

The organisers of the conference wish tothank the following sponsors for their support

-oOo-

Premier

FLSmidth Minerals Impala Platinum Protea Mining Chemicals

Exhibitors

Mintek MIP Process Technologies

Roymec Technologies Air Liquide

Sponsors

Anglo Operations

ChemQuest Africa

Csiro Minerals

Cytec Industries

Hatch

Purolite International

i-xii:PRELIMS 2/16/09 12:08 PM Page 10

HYDROMETALLURGY CONFERENCE 2009

Organising Committee

M. Dworzanowski (Chairman)

P. Maré S. Ndlovu

T. Thulare B. McGeorge

J. van Huysteen T. Claasens

K. Manyukwi L. van Dyk


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