M.Tech. (Minerals Engineering) / This report deals with the feasibility study of a novel concept whereby a lead sulphide concentrate and a solid reductant are reacted with a manganese ore at a temperature of approximately lOOO=C. The manganese oxides are reduced to their lower oxides, which, having a higher affinity for sulphur than lead. scavenge the sulphur from the lead sulphide. A manganese sulphide mane is formed. and liquid lead metal is tapped off. The manganese sulphide mane is then leached with sulphuric acid. After a purification step to remove the base metals from solution, the electrolyte proceeds to an electrolytic manganese metal or manganese dioxide facility where the manganese is recovered. The benefits of this process are fourfold: firstly, lead ores may be beneficiated locally; secondly, the separate and often lengthy processes for the recovery of lead and manganese are combined into a simplified process, thereby reducing the capital expense: thirdly, the Leadman process can be applied to any scale of operation: and fourthly, no 502 is produced. Details of the investigation included the following: a literature survey. a laboratory scale study where the operating conditions were narrowed down, a smelting campaign on a rotary kiln, a mineralogical study, a brief leaching study, a leach liquor purification step and a techno-economic assessment. This study has shown the technical and economical feasibility of the Leadman process. The lead and manganese recoveries were both approximately 93%, with good accountability of all the other elements of interest. Depending on the operating conditions, between 80 and 100 per cent of silver, originally in the galena, was recovered with the lead bullion. The purity of the lead metal produced was good with a lead content of approximately 97 per cent, and low levels of contaminants. It was also shown that the manganese matte produced is suitable for use as feed to an existing manganese electrowinning operation. The techno-economic assessment showed a return of R 3 118/t of Pb, compared with R 939/t and R 240/t for the conventional manganese and lead blast processes, respectively.

The mineralogical basis for understanding biohydrometallurgical processing of low-grade sulphide ores and means by which microwave processing improves their microbial recovery is investigated using a Nigerian low-grade complex sulphide ore as a case study. The study is approached through an applied mineralogical study of the ore and its influence on developing an optimal route for the microbial leaching of the low-grade complex ore under varying process parameters, and an investigation on the interaction between mineralogy, microwave processing and bioleaching. Bioleaching behaviour, mechanisms of bioleaching, and the interplay of mineralogy and microwave irradiation and their influence on bioleaching process were carried out using mixed cultures of Thiobacillus ferrooxidans, Thiobacillus thiooxidans and Leptospirillium ferrooxidans in a mechanically stirred glass reactor at varying bioleaching process parameters and through electrochemical studies. Mineralogical analysis of the ore revealed the presence of siderite, sphalerite, galena, quartz, and traces of pyrite and chalcopyrite, with the ore exhibiting fine to coarse grain intergrowths of the constituent crystalline phases both at the interstitials and the boundaries. Complexity in the mineralogy of the ore affected mineralogical and elemental distribution amongst varying size fractions that led to variation in the galvanic behaviour within these size fractions and influenced microbe-mineral’s reactivity and the different dissolutions behaviours. Bioleaching at optimal bioleaching parameters revealed the highest dissolution at a particle size fraction of 75 μm, while electrochemical studies revealed the highest dissolution at particle size fraction of 106 μm. This discrepancy was consistent with and attributed both to the physical and mineralogical influences. The combined effects of mineralogical variation, precipitation phenomenon as well as the physico-chemical effect of particle size, controlled bioleaching behaviour, while galvanic interaction resulting from variations in mineralogical distribution controlled the electrochemical behaviour. Ore mineralogy and microwave heating both showed dual influences on heating characteristics, size reduction, and the effectiveness of microwave treatment in improving dissolution. The increase in the dissolution rate and the overall dissolution of the microwave treated samples is attributed to phase changes in the ore which promoted galvanic interaction within the system, decrease in the amounts of sulphur contents, and an increase in electrochemical and microbial growth sites resulting from an increase in the number of cracks induced by microwave heating.

A study has been made of two deposits of Fe-Cu-Zn sulphide ores, from Gr¢sli and Eiker, in the Proterozoic Kongsberg Series of South Norway. The ores are located at the junction of acid-intermediate supracrustals and amphibolitized gabbros. The supracrustals underwent Upper Amphibolite facies metamorphism of Svecofennian age (1600 to 1500 m.y.B.P.) and were then intruded by the gabbros which underwent subsequent Sveconorwegian (1200 to 1000 m.y.B.P.) metamorphism at ~lid-Amphiboli te facies grade. The ore bodies were originally part of the supracrustal sequence, which was deposited as a volcano-sedimentary succession (with some hydrothermally altc:ced equivalents), similar to the KuroKo-type c1r.'posits of Japan. The ores have thus undergone both phases of h5[;h grade regional metamorphism. At Gr¢sli, the ores were partially incorporated in the gabbros prior to the later (Sveconorwegian) metar.lorphism, during which extensive shearing occurred throughout the ores at Eiker. The cores of the gabbroic intrusions retained original igneous mineralogies and textures, with progressive amphibolitization towards the peripheries. A subsequent Epidote-Amphibolite and later Greenschist facies grade overprint produced varying retrograde assemblages in the silicate rocks. Under Greenschist facies conditions, rejuvenation of the Sveconorwegian shear (at Eiker) caused brittle faulting, while fluid activity (at both Gr¢sli and Eiker) caused the formation of chloriteact ino.li te-carbo!)a.te assemblages around some of the ore bodies. Renobilisation of ~he ore material itself was minimal. Studies of R00thermometry and geobarometry indicate that the ore deposits were re-equilibrated during the Epidote-Ampllj boli te facies overprinting.

A study was carried out to improve the flotation selectivity between galena and sphalerite during the flotation of a Cu-Pb-Zn sulphide composite ore from the Rosh Pinah Mine (Namibia). Xanthate collectors were found to be unselective for the flotation of the Rosh Pinah composite sample. It was observed that the recovery of sphalerite increased with both the recovery of galena and the concentrate mass pull. In addition, the recovery of sphalerite increased after activation with Cu(II) ions while that of galena decreased when the composite was dry ground in a mild steel mill with mild steel grinding media. However, the recovery of galena was not affected after wet milling in a stainless steel mill. The recovery of Cu(II)-activated sphalerite was independent of the milling environment (wet or dry) and grinding media. The activation of sphalerite by cuprous cyanide complexes, which are present in the recycled water, was clearly shown in this study. Both batch flotation tests and XPS analysis have confirmed that sphalerite was activated by copper(I) from the cuprous cyanide complexes. The recovery of copper(I)-activated sphalerite increased further when the composite was dry milled as compared to wet milling. Batch flotation tests have shown that the use of cyanide alone is not efficient for the depression of sphalerite due to the mineralogical texture of the Rosh Pinah ore. A large quantity of galena locked and/or attached to sphalerite was observed in the lead concentrate. Their prevalence increased with increasing particle size. The use of both cyanide and zinc sulphate improved the depression of sphalerite much better than cyanide alone. A flowsheet has been proposed to improve selectivity between galena and sphalerite in the lead flotation circuit. It includes the regrinding of the lead rougher concentrate prior to the cleaning stage due to poor liberation between galena and sphalerite. / Thesis (PhD (Metallurgical Engineering))--University of Pretoria, 2006. / Materials Science and Metallurgical Engineering / unrestricted