The Extraction of Zinc from Secondary Zinc Minerals
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THE EXTRACTION OF ZINC FROM SECONDARY ZINC MINERALS WITH AQUEOUS SODIUM CYANIDE SOLUTIONS by Steve Bogdan Kesler, B. Sc(Eng), Ä. R. S. M. April, 1976 A thesis submitted for the degree of Doctor of Philosophy of the University of London and for the Diploma of Imperial College. Department of Mining and Mineral Technology, Imperial College, London S. W. 7. Dvý`- -1- ACKNOWLEDGEMENTS I should like to thank Professor E. Cohen, all the staff and research students of the Department for their helpful discussions and the technical staff for their patience in building and repairing apparatus. In particular, I thank my colleagues Mr. R. F. Dougill for all his valuable time spent on my computing problems and Mr. J. R. J. Burley for his advice on mineralogy. The willingness of Mr. A. Read of Warren Spring and the Institute of Geological Sciences to spare me some of their time was also much appreciated. Above all I thank Dr. H. L. Shergold, my supervisor, for his constant advice, tact and understanding and without whom this work could not have been accomplished. I should also like to thank the Science Research Council for providing the financial assistance to enable me to carry out this research and last, but not least, Miss Christine Ball, for volunteering to type this thesis even after she had'seen my appalling handwriting. -2- ABSTRACT The possibility of recovering zinc from zinc oxide material with a sodium cyanide leaching stage has been investigated. Zinc oxide and the secondary zinc minerals all dissolve stoichiometrically in cyanide solutions. The predominant species in cyanide solutions saturated with smithsonite or hemimorphite is the Zn(CN)42 complex, and a cyanide to zinc molar ratio close to 4/1 is obtained. A lower ratio results from cyanide solutions saturated with zinc oxide or hydrozincite because of the formation of zinc hydroxy complexes. The dissolution of smithsonite and hemimorphite is mass transfer controlled, the former by transfer either of cyanide ion to or, more probably, Zn(CN)42 away from the reaction interface whilst the latter is controlled by the diffusion of zinc cyanide complexes through a thin silica surface layer. The dissolution reactions follow heterogeneous reaction theory and empirical reaction models have been derived. Dissolution of smithsonite and hemimorphite is very anisotropic the reactions being initiated at high energy surface sites. Preferential dissolution at sub-grain boundaries results in the disintegration of the smithsonite particles. -3- The addition of sodium hydroxide to the cyanide solution increases the rate of dissolution of hemimorphite by thinning or removing the surface silica film. Roasting the hemimorphite removed compositional water from channels in the crystal structure and produced an increased reaction surface area. Zinc and free cyanide can be recovered from cyanide solutions containing dissolved zinc oxide by electrolysis but part of the cyanide is oxidised to cyanate at the anode. The recovery of zinc from cyanide solutions containing dissolved smithsonite, hemimorphite or hydrozincite is possible by precipitation as the cyanide. The precipitate can be dissolved in spent electrolyte from zinc sulphate electrolysis allowing cyanide recovery and electrodeposition of zinc from the electrolyte. Reagent losses as cyanide or sodium hydroxide are substantial but a cyanide leaching process might be economically viable if cyanide oxidation during electrolysis can be minimised and if cheap supplies of sodium hydroxide are available. -4- CONTENTS Page Acknowledgements. 1 Abstract. 2 Contents. 4 Chapter INTRODUCTION 6 1.1. Occurrence of zinc oxide minerals 6 1.2. Conventional zinc mineral processing. 8 1.3. Alkaline leaching of zinc oxide material. 11 1.4. Reactions between cyanide and the zinc minerals. 18 2 EXPERIMENTAL 32 2.1. Materials. 32 2.2. Analytical techniques. 44 2.2.1. Zinc analysis. 44 2.2.2. Cyanide analysis. 45 2.2.3. Cyanide ion-selective electrode. 47 2.2.4. Potentiometric titrations. 55 2.2.5. Ultra-violet absorption spectrophotometry. 70 2.2.6. Conclusion. 75 2.2.7. Determination of the free cyanide concentration of leach liquors. 76 3 THE SOLUBILITY OF THE SECONDARY ZINC MINERALS IN AQUEOUS CYANIDE SOLUTIONS 82 3.1. Experimental procedure. 82 3.2. Results. 86 3.2.1. Influence of cyanide concentration. 86 3.2.2. Influence of temperature. 92 3.2.3. Influence of sodium hydroxide addition. 93 3.3. Discussion. 98 4 KINETIC STUDIES 112 4.1. Introduction. 112 4.2. Agitation system. 118 4.3. Experimental technique and data analysis. 120 4.4. The influence of agitation rate on the rate of dissolution of the secondary zinc minerals. 122 4.5. The influence of particle size on the rate of dissolution of smithsonite and hemimorphite in cyanide solutions. 132 -5- Chapter Page 4.6. The influence of cyanide concentration on the rate of dissolution of the secondary zinc minerals. 139 4.7. The influence of temperature on the rate of dissolution of smithsonite and hemimorphite. 148 4.8. General rate equations for the dissolution of smithsonite and hemimorphite in cyanide. 154 4.9. Scanning electron microscope examination of smithsonite and hemimorphite after leaching in sodium cyanide. 156 4.10. Surface area changes during smithsonite dissolution. 179 4.11. Further dissolution studies on hemimorphite. 182 4.12. Addition of sodium hydroxide to the cyanide leach solvent. 185 4.13. Roasting of hemimorphite. 194 5 DISCUSSION OF KINETIC RESULTS. 204 5.1. Comparison of rate equations with the experimental results. 224 6 METAL AND SOLVENT RECOVERY 228 6.1. Introduction 228 6.2. Solution purification. 235 6.2.1. Experimental. 240 6.2.2. Results. 241 6.2.3. Conclusions. 242 6.3. Electrodeposition of zinc from cyanide solutions. 244 6.3.1. Experimental. 251 6.3.2. Results. 254 6.3.3. Discussion. 275 6.4. Zinc cyanide precipitation. 283 6.4.1. Experimental. 283 6.4.2. Results. 285 6.4.3. Discussion. 292 6.4.4. Conclusions. 295 7 PROCESS EVALUATION. 297 7.1. Direct electrolysis of zinc cyanide solution. 297 7.2. Precipitation of zinc as zinc cyanide. 302 8 FINAL CONCLUSIONS. 307 REFERENCES 312 -6- 1. INTRODUCTION 1.1. Occurrence of zinc oxide minerals The major source of zinc is the sulphide minerals sphalerite and wurtzite, however, significant amounts have and are being recovered from zinc carbonate and zinc silicate minerals. These latter minerals, known as calamine ores, originated through the weathering and oxidation of the primary sulphide deposits resulting in the formation of a zinc sulphate solution which precipitated on encountering carbonate rocks or available silica. Many primary zinc deposits are, therefore, capped by oxidised zinc ores containing smithsonite (zinc carbonate), hydrozincite (basic zinc carbonate) and hemimorphite (zinc silicate). In some cases, oxidised. zinc deposits occur alone either as a result of the complete oxidation of the sulphide minerals or the transport of the zinc sulphate solution some distance from the original primary ore body before precipitating. The zinc minerals of commercial interest are shown in Table 1.1. -? - Table 1.1. Zinc minerals of commercial interest I--- - T Composition Mineral Formula rTn(%)_ I Si(%) Sphalerite ZnS 67.1 ý - Wurtzite ZnS 67.1 - Smithsonite ZnCO3 52.1 - H d i i te I 2Z 3 Z 59.6 y roz nc nC(ý . n(OH) 2 - H em i morp hi te Zn Si Cý (OH) H 54.3 11.7 62722 .O 180.3 ý Zincite* Zn - Willemite Zn SiO 58.7 12.6 (Fe, Franklinite* Mn Zn)(Fe, Mn)204 15-20 - m Zincite and franklinite only occur in quantity at Franklin, New Jersey(, ). The zinc sulphide minerals are generally associated with lead minerals such as galena and cerussite, other sulphides like pyrite and chalcopyrite, silver minerals and less commonly gold, the latter two greatly adding to the value of the ore. The most common gangue minerals associated with zinc deposits are calcite and dolomite with fluorite, quartz and limonite. A number of metals are commonly found substituted for zinc in the oxide zinc minerals and these include copper, cobalt, cadmium, manganese, lead, magnesium and iron, although usually only to a small extent (less than 1%). The most important of these substituted metals is cadmium which rarely -8- occurs as a natural cadmium mineral and, indeed, most of the world's production of this metal comes as a by-product from the processing of zinc ores. 1,2, Conventional zinc mineral processin The zinc sulphide minerals are conveniently concentrated by normal sulphide flotation methods and the zinc oxide minerals are often recovered by flotation with a dodecylamine/fuel oil emulsion(2) a fatty acid(3) Flotation the or after sulphidisation(4) . of zinc oxide minerals, however, generally results in a poor concentrate grade and recovery because the reagents are not selective enough. More recently work has been conducted whereby the zinc oxide minerals are floated by the use ofchelating agents(5) which enable more selective flotation. However, flotation is made difficult by the similarity in the surface properties of the zinc oxide minerals and the gangue and by the presence of hydrated iron oxide slimes which coat both gangue and zinc minerals alike. Zinc has a low boiling point (9030 C) and is often recovered from oxidised zinc deposits of sufficiently high grade by fuming in retorts after roasting or calcining. This process, however, has many disadvantages not least being the requirement -9- of a cheap source of fuel. The reduction can be summarised by the following two gas-solid reactions. Zn0(s) + CO(g) -s Zn(g) + C02(g) (1, la) C02(g) C(s) 2CO(g) (1. lb) + r- Zinc oxide is relatively stable, however, and the reduction reaction is only thermospontaneous at 950°C. On condensing the zinc, therefore, the reaction given by Equation 1.1 tends to reverse and large amounts of the zinc revert to zinc oxide.