RECOVERY OF METALS FROM METALLIC OR METAL-BEARING MATERIALS

FIELD OF THE INVENTION

THE INVENTION relates to the recovery of metals from solid metallic or metal-bearing materials. The invention provides a method of treating a solid metallic or metal-bearing material, to recover one or more metals from the metallic or metal-bearing material via a chloride medium. In this sense, “metal” has a broad meaning, including both metals in elemental metallic form and metal compounds. The invention extends to a process for performing the method.

BACKGROUND TO THE INVENTION

IN MANY MINERAL CONCENTRATES, and other metallic and metal-bearing materials, iron is a major contaminant. Dealing with iron generally results in high acid consumption and waste generation when such materials are beneficiated using hydrometallurgical processes. The present invention seeks to provide a more efficient and cost-effective approach, while not limiting itself to the beneficiation iron-contaminated metallic and metal-bearing materials.

OBJECT OF THE INVENTION

IT IS AN OBJECT OF THE INVENTION to provide for the treatment of metallic or metal bearing materials that contain metals other than iron and, optionally, also contain iron, the iron then typically being comprised by a matrix containing the other metals, to liberate such metals other than iron from such matrices. In this sense, again, “metal” has a broad meaning, including both metals in elemental metallic form and metal compounds. In respect of metal compounds, it is envisaged that such compounds would be in a form that may be more readily beneficiated than the original form in which such metals manifested in the metallic or metal-bearing material.

SUMMARY OF THE INVENTION

IN THIS SPECIFICATION the provision of features in parenthesis contribute to the substantive content of the specification and therefore to the characterisation of the invention. In particular, in cases in which generic chemical formulae and numerical values for symbols of such generic formulae are provided in parenthesis, this should be interpreted as contributing substantively to the characterisation of the invention. IN ACCORDANCE WITH A FIRST ASPECT OF THE INVENTION IS PROVIDED a method of treating a solid metallic or metal-bearing material, comprising one or more metals in metallic or compound form, to recover one or more of the metals from the metallic or metal bearing material in metallic or compound form, the method including, in an oxidative or reductive digestion step, producing a ferrous chloride (FeCI ₂ ) solution by contacting the metallic or metal-bearing material with a digestion reagent selected from ferric chloride (FeCI ₃ ), typically in aqueous solution, gaseous hydrochloric acid (HCI),

HCI, in aqueous solution, and optionally, a combination or any two or more thereof, and reducing any FeCI ₃ in solution, produced from the contacting of the metallic or metal-bearing material with the digestion reagent, to FeCI ₂ in solution.

The contacting of the metallic or metal-bearing material with the digestion reagent may be performed in aqueous medium. Thus, the FeCI ₂ solution may be an aqueous FeCI ₂ solution.

When the digestion reagent is HCI, contacting the metallic or metal-bearing material with the HCI may include contacting the metallic or metal-bearing material directly with gaseous HCI (i.e. not in the form of an aqueous HCI solution); or contacting the metallic or metal-bearing material with HCI in aqueous solution, preferably of a concentration above 30% v/v, e.g. between 30% and 36% v/v, e.g. 33% v/v.

When contacting the metallic or metal-bearing material with gaseous HCI, the metallic or metal-bearing material may, in particular, be a hydrous ore material, which may be an ore material comprising chemically bound water (as opposed to “free water”, i.e. not chemically bound water), typically in a range of from about 5% to about 70% by weight, e.g. in the form of metal hydrates and/or metal hydroxides. Optionally, such a hydrous ore material may be slightly wetted with free water, e.g. up to about 5% by mass of the mass of the hydrous ore, before being subjected to digestion in the digestion step.

The gaseous HCI may, preferably, be anhydrous gaseous HCI, e.g. produced according to the third aspect of the invention.

When contacting the metallic or metal-bearing material with an aqueous HCI solution, the method may include preparing an aqueous HCI solution by scrubbing gaseous HCI with water, and contacting the metallic or metal-bearing material with the aqueous HCI solution thus prepared; or preparing an aqueous suspension or slurry of the metallic or metal-bearing material and scrubbing gaseous HCI with the suspension or slurry of the metallic or metal-bearing material.

The gaseous HCI may, in particular, be gaseous HCI, and more specifically anhydrous gaseous HCI, produced according to the third aspect of the invention.

Reducing FeCI ₃ produced from the contacting of the metallic or metal-bearing material with the digestion reagent to FeC may be effected using a reducing agent, e.g. metallic iron (Fe).

Depending on the composition of the metallic or metal-bearing material, contacting the metallic or metal-bearing material with the digestion reagent may produce a solution of FeCI ₃ to the exclusion of FeCh or a solution comprising both FeCI ₃ and FeC , which would thus require reduction of the FeCI ₃ to be effected using the reducing agent.

It is also possible that a solution comprising no FeCI ₃ would be produced, in which case no reduction would be required.

It will be appreciated that reduction is therefore only required if the digestion of the metallic or metal-bearing material produces FeCI ₃

The digestion reagent may therefore, for example, be gaseous HCI, e.g. produced in accordance with the third aspect of the invention; an aqueous solution of HCI, e.g. produced by scrubbing gaseous HCI produced in accordance with the third aspect of the invention with water; an aqueous solution of HCI, e.g. produced by scrubbing gaseous HCI e.g. produced in accordance with the third aspect of the invention with an aqueous suspension or slurry of the solid metallic or metal-bearing material; an aqueous solution of FeCI ₃ , e.g. produced by contacting solid hematite (Fe ₂ 0 ₃ ), e.g. produced in accordance with the third aspect of the invention, with an aqueous solution of HCI produced by scrubbing gaseous HCI e.g. produced in accordance with the third aspect of the invention with water; or is an aqueous solution of FeCI ₃ , e.g. produced by scrubbing gaseous HCI e.g. produced in accordance with the third aspect of the invention with an aqueous suspension of solid Fe ₂ 0 ₃ , e.g. produced in accordance with the third aspect of the invention.

When the metallic or metal-bearing material comprises iron, in metallic or compound form, such iron would be converted to ferrous chloride as described above and thus be present as ferrous chloride in the FeCI ₂ solution. When the metallic or metal-bearing material comprises metals (M) other than iron, in metallic or compound form, then at least some such metals other than iron would advantageously also be converted to soluble, e.g. divalent, chlorides (M ²⁺ CI ₂ ) thereof.

IN ACCORDANCE WITH A SECOND ASPECT OF THE INVENTION IS PROVIDED a method of treating a solid metallic or metal-bearing material, comprising one or more metals in metallic or compound form, to recover one or more of the metals from the metallic or metal-bearing material in metallic or compound form, the method including, in a displacement crystallisation step, contacting a FeCI ₂ solution, typically an aqueous FeCI ₂ solution, produced by oxidative/reductive digestion of the metallic or metal-bearing material, with a displacement crystallisation reagent, preferably HCI, most preferably gaseous HCI, that displaces FeCI ₂ from the FeCI ₂ solution and thus produces a solid ferrous chloride hydrate (FeCI ₂ xH ₂ 0, wherein x>1 , more preferably x>1), typically solid ferrous chloride tetrahydrate (FeCI ₂ -4H ₂ 0, i.e. x=4).

The HCI in gaseous form may be anhydrous gaseous HCI.

The HCI in gaseous form that may be used in effecting the displacement crystallisation may, in particular, be HCI in gaseous form, and more specifically anhydrous HCI in gaseous form, produced in accordance with the third aspect of the invention.

Producing the FeCI ₂ solution by oxidative/reductive digestion of the metallic or metal-bearing material may have included contacting the metallic or metal-bearing material with a digestion reagent selected from

FeCI ₃ , typically in aqueous solution, gaseous HCI,

HCI, in aqueous solution, and optionally, a combination of any two or more thereof, and reducing any FeCI ₃ in solution, produced from the contacting of the metallic or metal-bearing material with the digestion reagent, to FeCI ₂ .

The FeCI ₂ solution may, for example, be a FeCI ₂ solution that has been produced according to the digestion step of the first aspect of the invention.

As noted above, the FeCI ₂ xH ₂ 0 may, in particular, be FeCI ₂ -4H ₂ 0, i.e. x=4.

The displacement crystallisation step may include, or may more typically be followed by, a dehydration (i.e. drying) step, which may include subjecting the FeCI ₂ xH ₂ 0 to temperature treatment to produce a dehydrated solid ferrous chloride hydrate (FeCI ₂ yH20, wherein x>y>0). The FeCI ₂ yH ₂ 0 may, in particular, be FeCI ₂ H ₂ 0 (ferrous chloride monohydrate), i.e. y=1 .

In the sense used in this specification, in the context of the dehydration step, the terms “dehydration” and “dehydrated” therefore do not require complete dehydration, to provide an anhydrous form, although that possibility is included within the meaning of the word. The dehydration step may therefore more accurately be characterised as a “partial” dehydration step, at least in terms of the change in the hydration of the ferrous chloride.

The temperature treatment to which the FeCI ₂ .xH ₂ 0 is subjected in the dehydration step, may include subjecting the FeCI ₂ .xH ₂ 0 to a temperature in a range of from 70°C to 200°C, more preferably in a range of from 70°C to less than 200°C, i.e. at a temperature less than 200°C but not lower than 70°C. For example, the temperature may be in a range of from 70°C to 150°C.

The dehydration step may be performed under non-oxidising conditions, i.e. under conditions that avoid oxidation of the FeCI ₂ .xH ₂ 0. This may include avoiding, or at least limiting, the presence of exogenous oxygen in the dehydration step. This may, in turn, include performing the dehydration step under positive pressure in a steam environment, which steam may be that which is produced as a result of the dehydration of the FeCI ₂ xH ₂ 0.

When crystallisation is effected by means of displacement crystallisation, the digestion reagent would typically not be, or be produced using, gaseous HCI produced in the decomposition step, then rather being or being produced using the aqueous HCI solution produced in the displacement crystallisation step. When the metallic or metal-bearing material comprises iron, in metallic or compound form, such iron would be converted to ferrous chloride in the digestion step and then displaced as ferrous chloride hydrate from the FeCI ₂ solution in the displacement crystallisation step.

When the metallic or metal-bearing material comprises metals (M) other than iron, in metallic or compound form, then at least some such metals other than iron would advantageously also be converted to soluble, e.g. divalent, chlorides (M ²⁺ Cl2) thereof in the digestion step and would then also, advantageously, be displaced from solution as divalent metal chloride hydrates (M ²⁺ CI ₂ .zH ₂ 0, wherein z>0) thereof in the displacement crystallisation step.

IN ACCORDANCE WITH A THIRD ASPECT OF THE INVENTION IS PROVIDED a method of treating a solid metallic or metal-bearing material, comprising one or more metals in metallic or compound form, to recover one or more of the metals from the metallic or metal bearing material in metallic or compound form, the method including, in a thermal decomposition step, subjecting FeCI ₂ xH ₂ 0, wherein x>1 , more preferably x>1 , x most preferably being 4, produced by crystallisation thereof from a FeCI ₂ solution produced by oxidative/reductive digestion of the metallic or metal-bearing material, and/or FeCI ₂ yH ₂ 0, wherein x>y>0, y preferably being 1 , produced by subjecting the FeCI ₂ xH ₂ 0 to dehydration, to temperature treatment, thus decomposing the FeCI ₂ xH ₂ 0 or FeCI ₂ yH ₂ 0 to produce solid ferric oxide (Fe ₂ 03) and gaseous HCI.

The gaseous HCI may, in particular, be anhydrous gaseous HCI.

It is noted that, in the context of the thermal decomposition step and the invention generally, it is preferred that it is FeCI ₂ .xH ₂ 0 or FeCI ₂ .yH ₂ 0 that is subjected to thermal decomposition, to the exclusion of FeCh. This is since FeCh would, when subjected to thermal decomposition, not decompose to produce gaseous HCI and Fe ₂ 03, but would instead sublimate.

Producing the FeCI ₂ solution by oxidative/reductive digestion of the metallic or metal-bearing material may have included contacting the metallic or metal-bearing material with a digestion reagent selected from

FeCI ₃ , typically in aqueous solution, gaseous HCI,

HCI in aqueous solution, and optionally, a combination thereof, and reducing any FeCI ₃ in solution, produced from the contacting of the metallic or metal-bearing material with the digestion reagent, to FeCI ₂ .

The FeCI ₂ solution may, for example, be a FeCI ₂ solution that has been produced according to the method of the first aspect of the invention.

Crystallisation of FeCI ₂ .xH ₂ 0 from the FeCI ₂ solution may have been achieved by conventional methods, e.g. by means of evaporative crystallisation.

More preferably, however, crystallising the FeCI ₂ xH ₂ 0 from the FeCI ₂ solution may have been effected, in accordance with the second aspect of the invention, by displacement crystallisation from a FeCI ₂ solution, which may have included contacting a FeCI ₂ solution, produced by oxidative/reductive digestion of the metallic or metal-bearing material, with a displacement crystallisation reagent, preferably hydrochloric acid (HCI), most preferably gaseous HCI, that displaced FeCI ₂ from solution and thus produced FeCI ₂ xH ₂ 0.

The gaseous HCI may, in particular, have been anhydrous gaseous HCI, preferably produced by the thermal decomposition step of the invention.

The use of displacement crystallisation, as characterised above in accordance with the invention, over evaporative crystallisation, is preferred since, in the case of evaporative crystallisation, the pH shift that results from the evaporation of water from an FeCI ₂ solution makes the FeCI ₂ in the solution significantly more susceptible to oxidation to FeCI ₃ , which should be avoided in the context of the invention, in light thereof that, as mentioned above, FeCI ₃ sublimates when subjected to high temperatures such as those exploited by the invention in the thermal decomposition step that is described herein.

When crystallisation is effected by means of displacement crystallisation, the digestion reagent would typically not be, or would typically not be produced using, gaseous HCI produced in the decomposition step, then rather being or being produced using the aqueous HCI solution that is produced in the displacement crystallisation step.

Furthermore, producing FeCI ₂ .yH ₂ 0 through dehydration of the FeCI ₂ xH ₂ 0 and subjecting the FeCI ₂ .yH ₂ 0 to thermal decomposition, is preferred. Such dehydration may be effected, as described with reference to the second aspect of the invention, by subjecting the FeCI ₂ .xH ₂ 0 to temperature treatment, at a temperature in a range of from 70°C to 200°C, more preferably in a range of from 70°C to less than 200°C, i.e. at a temperature less than 200°C but not lower than 70°C. For example, the temperature may be in a range of from 70°C to 150°C.

It is regarded as a particular inventive advantage of the invention that by subjecting FeCI ₂ .yH ₂ 0 to thermal decomposition, an effect of producing anhydrous gaseous hydrochloric acid is inventively achieved and exploited.

The solid FeCI ₂ xH ₂ 0, or the FeCI ₂ yH ₂ 0, may, for example, be FeCI ₂ xH ₂ 0, or FeCI ₂ yH ₂ 0, that has been produced according to the method of the second aspect of the invention.

When the metallic or metal-bearing material comprises iron, in metallic or compound form, then such iron would be converted to ferrous chloride, would be displaced from solution as ferrous chloride hydrate, would be dehydrated, and would be decomposed as described.

When the metallic or metal-bearing material comprises metals (M) other than iron, in metallic or compound form, then at least some of such metals other than iron would advantageously also be converted to soluble, e.g. divalent, chlorides (M ²⁺ CI ₂ ) thereof, would be displaced from solution as divalent chloride hydrates (M ²⁺ CI ₂ .zH ₂ 0, wherein z>0) thereof, would be partially or fully dehydrated (to produce M ²⁺ CI ₂ .aH ₂ 0, wherein z>a>0), and would subjected to decomposition as described (to produce anhydrous M ²⁺ CI ₂ ).

In contrast to the ferrous chloride hydrate when subjected to decomposition, such other divalent metal chlorides or chloride hydrates would therefore not decompose. They would remain intact, at most being completely dehydrated to their anhydrous divalent chloride forms. In such forms, such metals are soluble and may thus be easily separated from the solid ferric oxide by solid-liquid separation.

IN ACCORDANCE WITH A FOURTH ASPECT OF THE INVENTION IS PROVIDED a method of treating a solid metallic or metal-bearing material, comprising one or more of the metals in metallic or compound form, to recover one or more of the metals from the metallic or metal-bearing material in metallic or compound form, the method including in an oxidative or reductive digestion step, producing a ferrous chloride (FeCI ₂ ) solution by contacting the metallic or metal-bearing material with a digestion reagent selected from ferric chloride (FeCI ₃ ), in aqueous solution gaseous hydrochloric acid (HCI),

HCI in aqueous solution, and optionally, a combination of any two or more thereof, and reducing any FeCh in solution, produced from the contacting of the metallic or metal bearing material with the digestion reagent, to FeCI ₂ in solution; in a crystallisation step, crystallising a solid ferrous chloride hydrate (FeCI ₂ xH ₂ 0, wherein x > 1 , preferably x > 1 , most preferably being 4) from the FeCI ₂ solution; optionally, in a dehydration step, subjecting the FeCI ₂ xH ₂ 0 to temperature treatment to produce dehydrated ferrous chloride hydrate (FeCI ₂ yH ₂ 0, wherein x>y>0, preferably being 1); and in a thermal decomposition step, subjecting the FeCI ₂ xH ₂ 0 and/or the FeCI ₂ yH ₂ 0 to temperature treatment and thus decomposing the FeCI ₂ xH ₂ 0 and/or the FeCI ₂ yH ₂ 0 to produce solid ferric oxide (Fe ₂ 0 ₃ ) and gaseous HCI.

The oxidative or reductive digestion step may be that of the method of the first aspect of the invention.

Crystallisation of FeCl ₂ .xH ₂ 0 from the FeCI ₂ solution may be achieved by conventional methods, e.g. by means of a evaporative crystallisation.

More preferably, however, crystallising the FeCI ₂ xH ₂ 0 from the FeCI ₂ solution may be effected by displacement crystallisation from the FeCI ₂ solution (i.e. the crystallisation step may be a displacement crystallisation step), which may include contacting, and saturating, the FeCI ₂ solution with a displacement crystallisation reagent, preferably HCI, more preferably HCI in gaseous form, most preferably HCI in anhydrous gaseous form, e.g. gaseous HCI recovered from the thermal decomposition step, thus displacing FeCI ₂ from solution and producing the FeCI ₂ xH ₂ 0.

In the displacement crystallisation step, the temperature of the FeCI ₂ solution may be from 10°C to 60°C.

When the displacement crystallisation reagent is HCI in gaseous form, the displacement crystallisation may comprise, for example, scrubbing the gaseous HCI with the FeCI ₂ solution. In the displacement crystallisation step, an aqueous solution of HCI (i.e. diluted HCI) may therefore be formed.

When displacement crystallisation is used, the method may include separating solid FeCl ₂ .xH ₂ 0, and any other solid metal chloride hydrates that crystallised along with the FeCl ₂ .H ₂ 0 in the crystallisation step (M ²⁺ CI ₂ .zH ₂ 0 wherein z>1 , as described below), from the aqueous solution of HCI thus produced; and using the aqueous solution of HCI as, or in producing, the digestion reagent in the digestion step.

The method may therefore include, in a second separation step, performed after the displacement crystallisation step and before the dehydration step, recovering solid FeCI ₂ xH ₂ 0, and any other solid metal chloride hydrates (M ²⁺ CI ₂ zH ₂ 0, as described herein) that may be present, from the resulting HCI solution by means of solid-liquid separation, thus recovering FeCI ₂ xH ₂ 0 and any solid M ²⁺ CI ₂ zH ₂ 0 that may have been present.

As mentioned above, the method may also include recycling the HCI solution produced in the displacement crystallisation step to the digestion step of the method and/or using the HCI solution to produce a FeC solution for use in the digestion step, by reaction of the HCI in the HCI solution with Fe ₂ 0 ₃ , which may be Fe ₂ 0 ₃ which is produced in the thermal decomposition step of the invention.

It is noted that recycle of the HCI solution produced in the displacement crystallisation step may include recycle of some metal chlorides not converted to metal chloride hydrates, e.g. as a result of low concentration. It is expected that build-up of such metal chloride hydrates would ultimately result in such conversion, once a sufficiently high concentration has been achieved.

The displacement crystallisation step may be that of the method of the second aspect of the invention.

The thermal decomposition step may be that of the third aspect of the invention.

The following statements apply to all of the abovementioned first to fourth aspects of the invention: The one or more metals comprised by the metallic or metal-bearing material may include one or more of chrome (Cr), copper (Cu), vanadium (V), nickel (Ni), cobalt (Co), zinc (Zn), titanium (Ti), manganese (Mn) and iron (Fe), in metallic and/or compound forms.

Typically, the metallic or metal-bearing material would include at least iron, in a metallic or compound form, and preferably at least one metal (M) other than iron, in a metallic or compound form. Such other metals (M) may for example be one or more of those listed above, other than iron.

In cases in which the metallic or metal-bearing material includes iron, in metallic or compound form, the digestion reagent may comprise at least HCI.

In some embodiments of the invention, the metallic or metal-bearing material may, for example, be one or more of a polyoxide material (containing multiple metal oxides), a polysulphide material (containing multiple metal sulphides), an alloy material, a metal slag material, a metal fines material, and a metallic material.

Thus, metals in the metallic or metal-bearing material may, for example, be in one or more of metal oxide form, metal sulphide form, and metallic from.

In one specific embodiment of the invention, the metal-bearing material may be an ore material. For example, the metal-bearing material may be a titaniferous magnetite ore material, e.g. a vanadium-containing titaniferous magnetite ore material. Generally, it is envisaged that the invention may find application to any metal sulphide and/or metal oxide bearing ore material, particularly those comprising iron in a metallic or compound form.

Depending on the composition of the metal-bearing material, the FeCh solution may therefore contain, in addition to FeCh, other metal chlorides, typically at least other divalent metal chlorides (M ²⁺ Cl ₂ ), but not excluding monovalent metal chlorides, in solution, e.g. CuCI ₂ or Cu ₂ CI ₂ .

Thus, the digestion step may have to effect that at least some metals contained in the metallic or metal-bearing material in metallic or metal compound form, are converted to metal chlorides (FeCI ₂ and, if other metals (M) are present, M ²⁺ CI ₂ ) in solution, contained in the FeCI ₂ solution. This is desired. The digestion step may be performed at a temperature of from 10°C to 120°C.

If an FeCI ₃ digestion reagent is used in the digestion step, it may be in solution. Typically, it may be in aqueous solution at a concentration of from 5wt% to 70wt%.

It is noted that in order to produce FeCh in solution for use as the digestion reagent in the digestion step, solid Fe ₂ 0 ₃ may be used in conjunction with HCI, thus producing a FeCI ₃ solution in the digestion step, instead of producing it separately as a feed to the digestion step.

HCI, when used as digestion reagent in the digestion step, may be in solution, and may be produced as described in accordance with the first aspect of the invention. Typically, it may be in aqueous solution at a concentration of from 5wt% to 40wt%, more preferably 30% to 36%, e.g. 33%.

Alternatively, the HCI, when used as digestion reagent in the digestion step, may be gaseous HCI, as described in accordance with the first aspect of the invention.

The digestion reagent may therefore be, for example, gaseous HCI, e.g. produced in the thermal decomposition step; an aqueous solution of HCI, e.g. produced by scrubbing gaseous HCI e.g. produced in the thermal decomposition step with water; an aqueous solution of HCI, e.g. produced by scrubbing gaseous HCI e.g. produced in the thermal decomposition step with an aqueous suspension or slurry of the solid metallic or metal-bearing material; an aqueous solution of FeCI ₃ , produced by contacting solid Fe ₂ 0 ₃ e.g. produced in the thermal decomposition step with an aqueous solution of HCI produced by scrubbing gaseous HCI e.g. produced in the thermal decomposition step with water; or an aqueous solution of FeCI ₃ , produced by scrubbing gaseous HCI e.g. produced in the thermal decomposition step with an aqueous suspension of solid Fe ₂ 0 ₃ e.g. produced in the thermal decomposition step.

When crystallisation is effected by means of displacement crystallisation, the digestion reagent would typically not be, or would not be produced using, gaseous HCI produced in the decomposition step, then rather being or being produced using the aqueous HCI solution produced in the displacement crystallisation step. Metallic iron may be used as the reducing agent.

In using metallic iron as the reducing agent, in addition to reduction of Fe ³⁺ to Fe ²⁺ (i.e. FeCh to FeCh), other metals may be reduced, possibly to solid metallic form, thus rendering such metals readily recoverable by solid-liquid separation.

Reduction may only be required if there is FeCh in solution that forms from treatment of the metallic or metal-bearing material with the digestion reagent.

The method may include, in a first separation step performed after the digestion step, separating solids from the FeCh solution by means of solid-liquid separation, thus recovering the FeCl2 solution (inclusive of other divalent metal chlorides in solution) substantially free of solids.

When the FeCh solution contains other metal chlorides (M ²⁺ Cl2) in solution, the crystallisation step may form, in addition to solid FeCh xFhO, other solid metal (M) chloride hydrates (M ²⁺ Ch zH 0, wherein z>0 and M may, for example, be selected from one or more of chrome (Cr), copper (Cu), vanadium (V), nickel (Ni), cobalt (Co), zinc (Zn), titanium (Ti), and manganese (Mn)).

As mentioned above with reference to the crystallisation step when the crystallisation step comprises displacement crystallisation, the method may include, in a second separation step, performed after the crystallisation step and before the dehydration step, recovering solid FeCh xFhO, and any solid M ²⁺ Ch zFhO that may be present.

The dehydration step is preferably performed.

The dehydration step may be effected, as described with reference to the second aspect of the invention, by subjecting the FeCI ₂ .xH ₂ 0, and any M ²⁺ Ch.zH ₂ 0 that may be present, to temperature treatment, at a temperature in a range of from 70°C to 200°C, more preferably in a range of from 70°C to less than 200°C, i.e. at a temperature less than 200°C but not lower than 70°C. For example, the temperature may be in a range of from 70°C to 150°C. Thus, FeCI ₂ .yH ₂ 0 and, if M ²⁺ CI ₂ .zH ₂ 0 was present, dehydrated solid divalent chloride hydrate or anhydrous solid divalent chloride of the other metal (M ²⁺ CI ₂ .aH ₂ 0 wherein z>a>0) may be produced.

The method may then comprise subjecting the FeCI ₂ .yH ₂ 0 and any M ²⁺ CI ₂ .aH ₂ 0 produced by the dehydration step, to thermal decomposition.

The dehydration step may be performed under non-oxidising conditions. This may include avoiding, or at least limiting, the presence of exogenous oxygen in the drying step. This may, in turn, include performing the dehydration step under positive pressure in a steam environment, which steam may be that which is produced as a result of the dehydration of the FeCI ₂ xH ₂ 0.

As indicated above, when solid M ²⁺ CI ₂ .zH ₂ 0, in addition to FeCI ₂ xH ₂ 0, is recovered from the crystallisation step, such solid M ²⁺ CI ₂ .zH ₂ 0 would also be subject to dehydration in the dehydration step, along with the FeCI ₂ xH ₂ 0, such that, in addition to FeCI ₂ yH ₂ 0, dehydrated solid divalent chloride hydrate and/or anhydrous solid divalent chloride of the other metal (M ²⁺ CI ₂ aH ₂ 0, wherein z>a>0, thus including anhydrous forms when a=0) are also produced in the dehydration step.

The thermal decomposition step may be performed at a temperature of from 200°C to 600°C, more preferably at a temperature above 200°C, up to 600°C.

The thermal decomposition step may be performed under oxidising conditions, i.e. in the presence of oxygen which may be supplied, for example, by air.

The gaseous HCI that is produced in the thermal decomposition step may be substantially dry, i.e. devoid of moisture (anhydrous).

Reactions that occur in the drying (dehydration) and thermal decomposition steps therefore comprise

(i) Drying (dehydration) at temperatures described above, under non-oxidising conditions

FeCI ₂ .4H ₂ 0 (s) -> FeCI ₂ .H ₂ 0 (s) + 3H ₂ 0 (g) (ii) Thermal decomposition under oxidising conditions, in the presence of oxygen (½0 ₂ ) supplied by air, at temperatures described above

2FeCI ₂ .H ₂ 0 (s) -> Fe ₂ 0 ₃ (s) + 4HCI (g)

As mentioned above, when solid M ²⁺ CI ₂ .zH ₂ 0, in addition to FeCI ₂ xH ₂ 0, is recovered from the crystallisation step, and the dehydration step is performed and, in addition to FeCI ₂ .yH ₂ 0, solid M ²⁺ CI ₂ .aH ₂ 0 is produced in the dehydration step, such solid M ²⁺ CI ₂ .zH ₂ 0 and/or M ²⁺ CI ₂ .aH ₂ 0 would be subjected to temperature treatment in the thermal decomposition step along with the FeCI ₂ xH ₂ 0 / FeCI ₂ yH ₂ 0.

Thermal decomposition of FeCI ₂ xH ₂ 0 / FeCI ₂ yH ₂ 0 would occur to the exclusion of solid M ²⁺ CI ₂ .ZH ₂ 0 and/or M ²⁺ CI ₂ .aH ₂ 0, however which M ²⁺ CI ₂ .zH ₂ 0 and/or M ²⁺ CI ₂ .aH ₂ 0 would, to the extent that they were not already fully dehydrated, become fully dehydrated in the thermal decomposition step and thus remain as fully dehydrated solid M ²⁺ CI ₂ (i.e. a=0) post thermal decomposition of the FeCI ₂ .xH ₂ 0 / FeCI ₂ yH ₂ 0 (preferably FeCI ₂ .yH ₂ 0) to Fe ₂ 0 ₃ and gaseous HCI. As will be appreciated from the foregoing discussions, however, it is preferred that only FeCI ₂ yH ₂ 0 and M ²⁺ CI ₂ .aH ₂ 0 are subjected to the thermal decomposition step, to produce ferric oxide, anhydrous HCI gas and solid M ²⁺ CI ₂ .

Therefore, the thermal decomposition step would typically produce a mixture of solid Fe ₂ 0 ₃ and solid M ²⁺ CI ₂ , in addition to gaseous HCI which is then used as described herein.

The method may then include, in a third separation step, dissolving the M ²⁺ CI ₂ in water, and performing a solid-liquid separation to recover the insoluble Fe ₂ 0 ₃ from the resulting solution of M ²⁺ CI ₂ .

In the resulting solution of M ²⁺ CI ₂ , metals (M), other than iron, that were originally contained in the metallic or metal-bearing material, have thus been liberated from the matrix in which they were held in the metallic or metal-bearing material, which matrix may have included iron. Such other metals may now be recovered by conventional methods, e.g. hydrometallurgical methods, from the resulting solution.

The method thus also produces saleable Fe ₂ 0 ₃ and products suitable for recycle to earlier method steps. For example, and significantly it is noted that the thermal decomposition of FeCI ₂ xH ₂ 0 / FeCI ₂ yH ₂ 0 (preferably FeCI ₂ .yH ₂ 0) by means of temperature treatment releases gaseous HCI, desirably in an anhydrous form particularly when FeCI ₂ .yH ₂ 0 is subjected to thermal decomposition.

The method may include recycling this HCI gas to be used in the crystallisation step, when performed as displacement crystallisation. Alternatively, it may be recycled to the digestion step, to be used as digestion reagent or in producing digestion reagent.

Furthermore, as noted earlier, the Fe ₂ 03 may be reacted with HCI solution from the displacement crystallisation step, and more specifically from the second separation step, to produce a FeCI ₃ solution for use in the digestion step.

It is regarded as a particular advantage, and inventive feature, of the invention as described, that the production of FeCI ₂ .xH ₂ 0 and subsequent dehydration to FeCI ₂ .yH ₂ 0 enables, through subsequent decomposition of the partially dehydrated FeCI ₂ .yH ₂ 0, the production of HCI in gaseous form which is, as will be appreciated, concentrated and undiluted HCI which, in addition, is in the context of the invention substantially dry, i.e. devoid of moisture (anhydrous). This is in stark contrast to conventional methods exploiting HCI in the digestion of solid metal-bearing feedstocks, which unavoidably form dilute solutions of HCI due to water balances that are unfavourable to the production of concentrated HCI, and even to the production of desired concentrations of diluted HCI. For example, while the maximum concentration of HCI at room temperature is around 33% v/v, existing methods exploiting HCI rarely achieve a regeneration of diluted HCI above 18% v/v. The present invention addresses this elegantly, by taking a route of iron precipitation as FeCI ₂ .xH ₂ 0, partial dehydration thereof to produce FeCI ₂ .yH ₂ 0, and decomposition thereof in turn to produce undiluted gaseous HCI for use in earlier method steps.

THE INVENTION EXTENDS, AS A FIFTH ASPECT THEREOF, TO a process for performing the method of the first to fourth aspects of the invention, which process includes process stages and process operations corresponding to and for performing the respective method steps.

DETAILED DESCRIPTION OF AN ILLUSTRATIVE EMBODIMENT

THE INVENTION WILL NOW BE DESCRIBED IN MORE DETAIL with reference to the accompanying diagrammatic drawing which shows a process according to the fifth aspect of the Invention. Referring to the drawing, reference numeral 10 generally indicates a process according to the fifth aspect of the Invention, for performing a method of the first to fourth aspects of the Invention.

The process 10 includes the following process stages: an oxidative/reductive digestion stage 12; a reduction stage 14; a first separation stage 16; a displacement crystallisation stage 18; a second separation stage 20; a drying stage 22; a thermal decomposition stage 24; a third separation stage 26; a ferric chloride generation stage 28; and a metals recovery stage 30.

In the process 10, the following feed, transfer, withdrawal, and recycle lines are identified: feed line 32; feed line 34 feed line 36 transfer line 38; feed line 40; transfer line 42; withdrawal line 44; transfer line 46; feed line 48; recycle line 50; transfer line 52; recycle line 54; recycle line 56; transfer line 58; transfer line 60; transfer line 62; transfer line 64; transfer line 66; recycle line 70; withdrawal line 72; feed line 74; and recycle line 76.

In using the process 10 to perform the method of the first to fourth aspects of the Invention, a metallic or metal-bearing material is fed to the digestion stage 12 along feed line 32, along with one or a combination of a solution of FeCI ₃ and a solution of HCI, respectively along feed line 34 and/or recycle line 70 and along feed line 36 and/or recycle line 54. Alternative/additional approaches to providing a solution of HCI and a solution of FeCI ₃ to the digestion stage 12, with reference to recycle lines 54, 70 and 76, are discussed below.

Oxidative/reductive digestion of the metallic or metal-bearing material proceeds in the digestion stage 12, and produces a FeCI ₂ solution, possibly containing residual FeCI ₃ , and possibly containing one or more other metal (M) chlorides, e.g. chlorides of copper (Cu), vanadium (V), nickel (Ni), cobalt (Co), zinc (Zn), titanium (Ti), and manganese (Mn).

The FeCI ₂ solution is transferred from the digestion stage 12 to the reduction stage 14 along transfer line 38, where it is contacted with a reducing agent that is fed to the reduction stage 14 along feed line 40.

The FeCI ₂ solution is then transferred from the reduction stage 14 to the first separation stage 16 along transfer line 42, where solids contained in the FeCI ₂ solution are separated from the FeCI ₂ solution and are withdrawn along withdrawal line 44.

The recovered FeCI ₂ solution is then passed from the first separation stage 16 to the displacement crystallisation stage 18 along transfer line 46. Here the FeCI ₂ solution is contacted with gaseous HCI which is fed to the displacement crystallisation stage 18 along feed line 48 and/or along recycle line 50.

Contacting the FeCI ₂ solution with gaseous HCI in the displacement crystallisation stage 18 produces solid FeCI ₂ xH ₂ 0, and solid M ²⁺ CI ₂ zH ₂ 0 if there are other metal (M) chlorides present in the FeCI ₂ solution, (x,z>1), in an aqueous solution of HCI (i.e. diluted HCI). Typically, the value of x would be 4, and therefore the solid FeCI ₂ xH ₂ 0 would be FeCI ₂ -4H ₂ 0 (i.e. ferrous chloride tetrahydrate).

The solid FeCI ₂ xH ₂ 0, solid M ²⁺ CI ₂ zH ₂ 0, if present, and aqueous solution of HCI are transferred to the second separation stage, along transfer line 52, where the solid FeCI ₂ xH ₂ 0 and solid M ²⁺ CI ₂ zH ₂ 0, if present, are separated from the aqueous solution of HCI and are withdrawn along transfer line 58. The aqueous solution of HCI is recycled along recycle line 54 to the digestion stage 12 and/or along line 56 to the FeCh generation stage 28. The solid FeCI ₂ xH ₂ 0 and solid M ²⁺ CI ₂ zH ₂ 0, if present, are transferred to the dehydration stage 22 along transfer line 58.

It is noted that recycle of the aqueous solution of HCI may include recycle of some metal chlorides not converted to metal chloride hydrates, e.g. as a result of low concentration. Build-up of such metal chloride hydrates would ultimately result in such conversion, once a sufficiently high concentration has been achieved.

In the dehydration stage 22, the solid FeCI ₂ xH ₂ 0 and solid M ²⁺ CI ₂ zH ₂ 0, if present, are subjected to dehydration in a non-oxidising environment, using temperature treatment at a temperature below 200°C but not less than 70°C, more preferably at a temperature in a range of from 70°C and 150°C, thus producing solid FeCI ₂ yH ₂ 0 and solid M ²⁺ CI ₂ aH ₂ 0, if present, (x>y>0; z>a>0).

More specifically, the solid FeCI ₂ xH ₂ 0 and solid M ²⁺ CI ₂ zH ₂ 0, if present, are fed into, and through, a non-vented vessel in which the temperature treatment is carried out, thus producing a slight positive pressure relative to atmospheric pressure inside the vessel resulting from steam that is formed inside the vessel due to the temperature treatment and the resulting dehydration of the FeCI ₂ xH ₂ 0 and M ²⁺ CI ₂ zH ₂ 0, which steam serves to displace oxygen that may be present in the vessel, e.g. in the form of air, thus avoiding oxidisation of the ferrous chloride.

The solid FeCI ₂ yH ₂ 0 and solid M ²⁺ CI ₂ aH ₂ 0 are transferred, along transfer line 60, to the thermal decomposition stage 24, in which the solid FeCI ₂ yH ₂ 0 and solid M ²⁺ CI ₂ aH ₂ 0 are subjected to temperature treatment to decompose the solid FeCI ₂ yH ₂ 0 to produce solid Fe ₂ 0 ₃ and HCI gas, to the exclusion of the solid M ²⁺ CI ₂ aH ₂ 0 which remains intact and is therefore not decomposed, but would typically be dehydrated so that in any case of M ²⁺ CI ₂ aH ₂ 0 where a>1 being present in the decomposition stage such M ²⁺ CI ₂ aH ₂ 0 would be converted to anhydrous M ²⁺ CI ₂ (i.e. a=0). The temperature treatment is effected under conditions that favour the thermal decomposition of FeCI ₂ yH ₂ 0 over that of M ²⁺ CI ₂ aH ₂ 0, and it is in fact so that no thermal decomposition of the M ²⁺ CI ₂ aH ₂ 0 (z>a>0) would take place at any temperature at which decomposition of the FeCI ₂ .yH ₂ 0 is performed. The temperature treatment in the thermal decomposition stage 24 is performed at a temperature above 200°C, but not higher than 600°C, under oxidising conditions, i.e. in the presence of oxygen, e.g. being supplied by air.

The HCI gas produced in the thermal decomposition stage 24 is recovered and is recycled along recycle line 50 to the displacement crystallisation stage 18.

To favour or effect oxidising conditions in the thermal decomposition stage, a blower may be employed to blow air into the thermal decomposition stage and thus also expel gaseous hydrochloric acid from the thermal decomposition stage, for recovery and use as described herein.

It will be appreciated that gaseous HCI is concentrated, i.e. undiluted and thus substantially pure, HCI which, in addition, is substantially dry (i.e. devoid of moisture, and thus anhydrous). Thus, the process as described enables the achievement of a favourable water balance that, in turn, enables the production of concentrated substantially dry HCI in gaseous form, for use upstream in the process. This is in contrast to existing processes that exploit HCI in metal recovery operations, which produce diluted HCI solutions, rarely at concentrations higher than 18% v/v.

In the absence of dehydration of the FeCI ₂ .xH ₂ 0, the gaseous HCI produced from the thermal decomposition stage 24 would be moist/dilute (i.e. contain water vapour), which would not be effective in displacing dissolved FeCI ₂ in the manner described in the displacement crystallisation stage 18. The inventive approach that the invention follows therefore further avoids any need for an evaporation operation to recover gaseous HCI for use in the displacement crystallisation stage 18.

The solid Fe ₂ 0 ₃ and solid M ²⁺ CI ₂ are transferred to the third separation stage 26, along transfer line 62, in which the solid M ²⁺ CI ₂ is dissolved in water to produce a M ²⁺ CI ₂ solution, and solid-liquid separation is carried out to recover the M ²⁺ CI ₂ solution and solid Fe ₂ 0 ₃ . The M ²⁺ CI ₂ solution is transferred to the metals recovery stage 30 along transfer line 64, for recovery of the metals contained therein.

The Fe ₂ 0 ₃ is withdrawn, as a saleable product, along withdrawal line 72, and/or is transferred, along transfer line 66, to the FeCh generation stage 28 where it is contacted with HCI that is fed to the generation stage 28 along feed line 74 or that is recycled to the generation stage 28 along recycle line 56, and/or is recycled to the digestion stage 12 along recycle line 76 where it is contacted with HCI to produce a FeCh solution in situ.

The generated (re-generated) FeCI ₃ is then recycled from the generation stage 28 to the digestion stage 18.

EXAMPLES

Example 1 - Beneficiation of mixed oxide and sulphide copper concentrate

The ore concentrate beneficiated in this example, has a composition as set out in Table 1 below.

1. 100g concentrate (refer to table 1) as received from the mine (milled to -75um) was digested with 250g FeCh (43 wt%) solution, 55 g HCI (33 wt%) solution and 100 ml water for 4 hours at 105°C in a reflux glass beaker.

Table 1: Chemical composition of feed

2. After oxidative digestion of the above concentrate major soluble chlorides FeCh, CuCh and Cu ₂ CI ₂ were produced in solution. Via filtration, the water-soluble fraction was separated from the insoluble fraction. The insoluble fraction comprised 51 g (30%, or 16g, moisture) and, after washing and drying at 110°C, was found to comprise sulphur, silicates and other insolubles (refer to table 2). Referring to the chemical composition of the insoluble fraction, it follows that 99.6% of the available Cu was extracted. Table 2: Chemical composition of insolubles

3. Approximately 400 ml filtrate (470g) was obtained after filtration. To this filtrate, 19.8 g iron powder was added while stirring. After 30 minutes, the resulting reduction reaction was completed.

4. The copper cement, resulting from the reduction, was washed, filtered and dried, and 27.4g Cu was recovered. It is noted that this copper can be pressed and melted or used to produce CuS0 ₄ .5H ₂ 0 crystals.

5. The remaining filtrate, approximately 350 ml (470g), was used as a scrubbing solution to scrub 84 g of HCI gas (originating from the decomposition step 8, below). During the scrubbing of the HCI gas, the temperature of the solution was kept at 30 - 35 °C.

6. 228g of FeCI _2. 4H ₂ 0 crystals were formed in step 5. These were filtered from the remaining HCI solution (326g).

7. These crystals were dried at 150°C to give approximately 166 g FeCI ₂ .H ₂ 0 (s). This dried product was milled in situ to -2mm.

8. The milled product was then heated in air at 400°C. At this temperature, all the FeCI _2. H ₂ 0 was oxidized into Fe ₂ 0 ₃ (s) and HCI(g).

9. 91 .5g of Fe ₂ 0 ₃ was recovered. 38.5g can be sold while 53 g is recycled with 326g HCI solution (step 6), 18 g new HCI (33 wt%) solution as a top reagent and 108 g water. To this 10Og of feed may be added to restart the next digestion run.

For more information, refer to Figure 2 as well.

Example 2 - Beneficiation of nickel sulphide concentrate

The ore concentrate beneficiated in this example, has a composition as set out in Table 3 below. Table 3: Chemical composition of feed

^* Note: If the S of the insoluble fraction is floated off, the PGM’s > 100 ppm

Table 4: Morphology of the feed

Note: These values are semi quantitative

1. To 100g concentrate (-45pm), 85g Fe ₂ 0 ₃ (recycled) was added. This feed was digested with 400 ml HCI(c), approximately 33%, via reflux at 105°C for 4 hours.

2. Directly after digestion, while the solution was still warm, the slurry (including insoluble) was pumped through a tank containing an excess of scrap Fe. This served to neutralize excess HCI, reduce excess FeC into FeCI ₂ and cement Cu. Approx 6g of Fe scrap was used in this step.

3. The slurry was then filtered and washed to produce 62g of insolubles plus 5g of Cu- cement and 370 ml filtrate.

4. The insolubles together with the copper cement was treated with a dilute solution of H ₂ S0 and HN0 ₃ to produce a CuS0 ₄ solution. After filtration and wash, the CuS0 can be crystallized into CuS0 ₄ .5H ₂ 0 while the insolubles contain the upgraded PGM’s.

5. The 370 ml filtrate was used to scrub approximately 100g HCI(g). The temperature was kept between 15 -20°C. The scrubbing of the HCI(g) displaced the ferrous, nickel and cobalt chlorides from the solution, forming solid hydrated crystals thereof. The resulting solution contained approximately 30-36% HCI.

6. After filtration of the crystals, the crystals were washed with a new filtrate solution to rid it from the HCI(c) background. Approximately 95% of the ferrous and 70% of the Ni/Co crystals were obtained this way. The balance was recycled with the HCI solution back to digestion and would build-up in further runs where more will crystallize as the concentrations increase.

7. The washed crystals were dried at 150°C while clean steam was produced.

8. The dried crystals were then decomposed at 400°C to produce Fe ₂ 0 ₃ , anhydrous Ni(Co)CI ₂ and HCI(g) to be recycled to step 5. 9. Cold water was added to the Fe ₂ 0 ₃ to dissolve the Ni(Co)CI ₂ . After filtration and wash, the excess Fe ₂ 0 ₃ can be sold while the Ni(Co)CI ₂ can beneficiated from solution.

For more information, refer to Figure 3 as well.