Pyrite Catalyst Leaching Copper Arsenic Sulfosalt Minerals

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Solution Overview

Problem

Copper recovery from copper arsenic sulfosalt and copper antimony sulfosalt minerals is challenging due to their resistance to conventional leaching processes, making existing methods economically unviable, especially for minerals like enargite which requires high-pressure oxidation.

Innovation Solution

A hydrometallurgical method using pyrite (FeS2) as a catalyst in an acidic sulfate leach solution with an oxidizing agent, such as oxygen, under controlled conditions to leach copper from copper sulfide concentrates, maintaining pyrite in a substantially unoxidized state to facilitate copper ion production.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If conventional leaching processes are used on copper arsenic sulfosalt and copper antimony sulfosalt minerals, then the process is simple and economically viable, but copper recovery is ineffective due to mineral resistance

Engineering Contradiction:

Improvecopper recovery effectivenessVSAvoidprocess complexity

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

Pyrite is introduced as an intermediary catalyst that mediates between the ferric sulfate leach solution and the resistant copper sulfosalt minerals. The pyrite surface facilitates electron transfer and enhances the leaching reaction kinetics, enabling effective copper recovery from minerals that are otherwise resistant to conventional leaching processes

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The invention changes the chemical parameters of the leaching system by introducing pyrite particles and controlling the ferric sulfate concentration and pH conditions. These parameter changes transform the leaching environment to one that is effective against resistant copper sulfosalt minerals, achieving high copper recovery without requiring high-pressure oxidation

Inventive Principle:

Principle #35Parameter changes

2Productivity

If high pressure oxidation in autoclaves is used for enargite, then copper recovery is effective, but the process cost increases significantly

Engineering Contradiction:

Improvecopper recovery effectivenessVSAvoidprocess cost

Core Design Contradiction:

ProductivityVSLoss of energy

Solution Approach 1:

Pyrite particles are used as a inexpensive, easily obtainable catalyst that replaces the need for expensive high-pressure autoclave equipment. The pyrite can be added in particulate form and does not require recovery, functioning as a disposable catalyst that dramatically reduces process costs while maintaining effective copper recovery from enargite

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Solution Approach 2:

The invention replaces the mechanical high-pressure oxidation system with a chemical catalysis system using pyrite and ferric sulfate at ambient or near-ambient conditions. This substitution eliminates the need for expensive autoclave equipment and high-energy input while achieving comparable or superior copper recovery effectiveness

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Productivity

If pyrite is added as a catalyst, then copper leaching effectiveness improves, but pyrite oxidation consumes oxygen and may reduce leaching efficiency

Engineering Contradiction:

Improvecopper leaching rateVSAvoidpyrite oxidation side reaction

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The invention controls the pH and potential parameters of the leach solution to maintain conditions where pyrite remains stable and catalytically active without oxidizing. By adjusting these parameters, the system maximizes copper leaching rate while minimizing the harmful side reaction of pyrite oxidation that would consume oxygen and reduce leaching efficiency

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This method effectively recovers copper from copper sulfide concentrates, allowing for subsequent recovery through conventional methods like solvent extraction and electrowinning, improving the economic viability of copper extraction from previously resistant minerals.

Implementation Method 1

uses pyrite (FeS2) as a catalyst for the leaching reaction

Methodology Applied

Scientific EffectCatalysis: Catalysis

Implementation Method 2

The process includes the application of an oxidizing agent, e.g. oxygen in the form of air or oxygen gas

Methodology Applied

Scientific EffectOxidation: Oxidation

Data Source

PatentUS8277539B2Leaching process for copper concentrates containing arsenic and antimony compounds

Publication Date: 2012.10.02 THE UNIV OF BRITISH COLUMBIA

AI summary

A method of recovering copper from a copper sulfide concentrate comprising a copper arsenic sulfosalt or a copper antimony sulfosalt, using pyrite as a catalyst. The concentrate and pyrite are added to an acidic sulfate leach solution. The copper is leached from the concentrate, in the presence of an oxygen-containing gas, under conditions whereby the pyrite is substantially unoxidized. The pyrite:copper sulfide ratio of the pyrite being added to the copper sulfide present in the concentrate being added is at least 1:3. The pyrite may be maintained at a concentration in the leach solution of at least 9 grams per liter. The leached copper is recovered from the solution by conventional methods.