Effect of Ultrasound on the Oxidative Copper Leaching from Chalcopyrite in Acidic Ferric Sulfate Media

Ultrasound effects on restricted silica gelation during silica extraction from Pyro-Metallurgical copper slag under acidifying conditions

Pyro-metallurgical copper slag (CS) waste was used as the source material for ultrasound (US) silica extraction under acidification processes with 26 kHz with HCl, HNO₃, and H₂SO₄ at different concentrations at 100, 300, and 600 W. During acidifying extraction processes, US irradiation inhibited silica gel formation under acidic conditions, especially at lower acid concentrations of less than 6 M, whereas a lack of US irradiation led to enhanced gelation. When US stopped, gelation occurred to a considerable degree, suggesting that the gel particle size distribution was aggregated in the 3-400 µm size range. However, with US, the size was mainly in the 1-10 µm range. Results of elemental analysis indicated that US treatment decreased the co-precipitation of other metal ions such as Fe, Cu, and Al sourced from CS for lower acidic medium, whereas the higher concentration medium accelerated silica gelation and the co-precipitation of other metals. With acids of HCl and HNO₃, and H₂SO₄, the gelations were less likely to occur at 6 M and 3 M during US irradiation, but acidic extraction without US was efficient for silica gelation and co-precipitation of other metals in the purified silica. The silica extraction yield with H₂SO₄ concentration of 3 M was 80% with 0.04% of Fe, whereas the silica product from HCl 6 M had a 90% extraction yield with only 0.08% of Fe impurity. In contrast, even though the non-US system of HCl 6 M had a higher yield at 96%, the final product had 0.5% Fe impurity, which was much higher than the US system. Consequently, the US extraction process was quite noticeable for silica recovery from CS waste.

Effect of ultrasound power on HCl leaching kinetics of impurity removal of aphanitic graphite

This study aimed to investigate the effect of ultrasonic power and temperature on the impurity removal rate during conventional and ultrasonic-assisted leaching of aphanitic graphite. The results showed that the ash removal rate increased gradually (∼50 %) with the increase in ultrasonic power and temperature but deteriorated at high power and temperature. The unreacted shrinkage core model was found to fit the experimental results better than other models. The Arrhenius equation was used to calculate the finger front factor and activation energy under different ultrasonic power conditions. The ultrasonic leaching process was significantly influenced by temperature, and the enhancement of the leaching reaction rate constant by ultrasound was mainly reflected in the increase of the pre-exponential factor A. Ultrasound treatment improved the efficiency of impurity mineral removal by destroying the inert layer formed on the graphite surface, promoting particle fragmentation, and generating oxidation radicals. The poor reactivity of hydrochloric acid with quartz and some silicate minerals is a bottleneck limiting the further improvement of impurity removal efficiency in ultrasound-assisted aphanitic graphite. Finally, the study suggests that introducing fluoride salts may be a promising method for deep impurity removal in the ultrasound-assisted hydrochloric acid leaching process of aphanitic graphite.

Effect of Power Ultrasound on Wettability and Collector-Less Floatability of Chalcopyrite, Pyrite and Quartz

Numerous studies have addressed the role of ultrasonication on floatability of minerals macroscopically. However, the impact of acoustic waves on the mineral hydrophobicity and its physicochemical aspects were entirely overlooked in the literature. This paper mainly investigates the impact of ultrasonic power and its time on the wettability and floatability of chalcopyrite, pyrite and quartz. For this purpose, contact angle and collectorless microflotation tests were implemented on the ultrasonic-pretreated and non-treated chalcopyrite, pyrite and quartz minerals. The ultrasonic process was carried out by a probe-type ultrasound (Sonopuls, 20 kHz and 60 W) at various ultrasonication time (0.5–30 min) and power (0–180 W) while the dissolved oxygen (DO), liquid temperature, conductivity (CD) and pH were continuously monitored. Comparative assessment of wettabilities in the presence of a constant low-powered (60 W) acoustic pre-treatment uncovered that surface of all three minerals became relatively hydrophilic. Meanwhile, increasing sonication intensity enhanced their hydrophilicities to some extent except for quartz at the highest power-level. This was mainly related to generation of hydroxyl radicals, iron-deficient chalcopyrite and elemental sulfur (for chalcopyrite), formation of OH and H radicals together with H2O2 (for pyrite) and creation of SiOH (silanol) groups and hydrogen bond with water dipoles (for quartz). Finally, it was also found that increasing sonication time led to enhancement of liquid temperature and conductivity but diminished pH and degree of dissolved oxygen, which indirectly influenced the mineral wettabilities and floatabilities. Although quartz and pyrite ultrasound-treated micro-flotation recoveries were lower than that of conventional ones, an optimum power-level of 60–90 W was identified for maximizing chalcopyrite recovery.