Method for recovery of metals from metal-containing materials using medium temperature pressure leaching

Abstract

The present invention relates generally to a process for recovering copper and other metal values from metal-containing materials using controlled, super-fine grinding and medium temperature pressure leaching. Processes embodying aspects of the present invention may be beneficial for recovering a variety of metals such as copper, gold, silver, nickel, cobalt, molybdenum, rhenium, zinc, uranium, and platinum group metals, from metal-bearing materials, and find particular utility in connection with the extraction of copper from copper sulfide ores and concentrates.

1 . A method for recovering a metal value from a metal-bearing material, the method comprising the steps of:
 providing a feed stream comprising a metal-bearing material;   grinding said feed stream to form an inlet stream having a uniform ultra-fine particle size distribution;   leaching said inlet stream at a temperature of from about 140° C. to about 180° C. and at a pressure of from about 100 psi to about 750 psi to form a metal-containing solution; and   recovering at least one metal value from said metal-containing solution.   
     
     
         2 . The method according to  claim 1 , wherein said step of providing a feed stream comprising a metal-bearing material comprises providing a feed stream comprising a copper sulfide ore or concentrate. 
     
     
         3 . The method according to  claim 1 , wherein said step of grinding said feed stream comprises super-fine grinding said feed stream to form an inlet stream having a particle size distribution of P98 less than about 25 microns. 
     
     
         4 . The method according to  claim 1 , wherein said step of grinding said feed stream comprises super-fine grinding said feed stream to form an inlet stream having a particle size distribution of P98 of from about 10 to about 23 microns. 
     
     
         6 . The method according to  claim 1 , wherein said step of grinding said feed stream comprises super-fine grinding said feed stream to form an inlet stream having a particle size distribution of P98 of from about 13 to about 15 microns. 
     
     
         7 . The method according to  claim 1 , wherein said step of leaching said inlet stream comprises leaching said inlet stream at a temperature of from about 160 to about 170° C. and at a pressure of from about 100 psi to about 750 psi. 
     
     
         8 . The method according to  claim 1 , wherein said step of leaching said inlet stream comprises leaching said inlet stream in the presence of a surfactant. 
     
     
         9 . The method according to  claim 1 , wherein said step of leaching said inlet stream comprises leaching said inlet stream in the presence of calcium lignosulfonate. 
     
     
         10 . A method for recovering metal from a metal-bearing material, the method comprising the steps of:
 providing a feed stream comprising a metal-bearing material;   subjecting at least a portion of said feed stream to controlled, super-fine grinding to form an inlet stream, wherein said controlled, super-fine grinding comprises reducing the particle size of said feed stream to a P98 of less than about 25 microns;   leaching at least a portion of said inlet stream in the presence of oxygen at an elevated temperature and pressure to form a metal-bearing solution; and   recovering at least one metal value from said metal-bearing solution.   
     
     
         11 . The method according to  claim 10 , wherein said step of leaching said inlet stream comprises leaching said inlet stream at a temperature of from about 140° C. to about 180° C. and at a pressure of from about 100 psi to about 750 psi. 
     
     
         12 . The method according to  claim 10 , wherein said step of leaching said inlet stream comprises leaching said inlet stream at a temperature of from about 150° C. to about 175° C. and at a pressure of from about 100 psi to about 750 psi. 
     
     
         13 . The method according to  claim 10 , wherein said step of leaching said inlet stream further comprises leaching said inlet stream in the presence of a surfactant. 
     
     
         14 . The method according to  claim 10 , wherein said step of leaching said inlet stream further comprises leaching said inlet stream in the presence of a surfactant selected from the group consisting of lignin derivatives, orthophenylene diamine, alkyl sulfonates, and mixtures thereof. 
     
     
         15 . The method according to  claim 10 , wherein said step of providing a feed stream comprising a metal-bearing material comprises providing a feed stream comprising a copper sulfide ore or concentrate. 
     
     
         16 . A system for recovering a metal value from a metal-containing material, the system comprising:
 a feed stream comprising a metal bearing material;   a means for controlled, super-fine grinding of said feed stream to reduce the particle size of said feed stream to P98 of less than about 25 microns;   a processing device operable to receive at least a portion of said feed stream and operable to leach said portion of said feed stream in an oxidizing environment at an elevated pressure and temperature to yield a metal-bearing solution; and   a means for recovering at least one metal value from said metal-bearing solution.   
     
     
         17 . The system according to  claim 16  further comprising a means for conditioning said metal-bearing solution before said step of recovering at least one metal value. 
     
     
         18 . The system according to  claim 16 , wherein said elevated pressure is from about 100 psi to about 750 psi and said elevated temperature is from about 140° C. to about 180° C. 
     
     
         19 . The system according to  claim 16 , wherein said feed stream has a particle size of P98 from about 10 to about 23 microns. 
     
     
         20 . The system according to  claim 16 , wherein said metal-bearing material comprises at least one of copper sulfide ore and copper sulfide concentrate.