In the production of base metals by smelting of sulphide ore concentrates, large amounts of iron are rejected with iron silicate slags. These slags contain Ni, Cu and Co in concentrations up to several percent units. Extraction of the entrapped base metals using high pressure oxidative acid leaching (HPOXAL) was investigated in this work. Crystalline slags containing fayalite (Fe2SiO4), magnetite (Fe3O4), silica (SiO2) and matte (MeSn<1) were found to be highly amenable to leaching at 250°C, 90 psi (6.2 bar) O2 partial pressure and 70 g/L initial H2SO4. Extractions of Ni, Co and Cu exceeded 90% within 15-20 min and arrived at 95-97% after 45 min. The residues of leaching were identified as aggregates of crystalline hematite (Fe2O3) and amorphous silica. Dissolution of fayalite and magnetite was shown to be acid driven. Since HPOXAL operates with substoichiometric additions of sulphuric acid (10-20% of the stoichiometric requirement), acid regeneration facilitated by iron oxidation and hydrolysis is crucial to high rates of leaching. Low acidities (<10 g/L) were shown to cause precipitation of ferrous sulphate, slowing acid regeneration and slag dissolution. Elevated acidities (>70 g/L) result in excessive concentrations of Fe(III) in the leach solution, complicating downstream processing. The use of pyrrhotite tailings, an environmentally hazardous waste, as a substitute of sulphuric acid in slag leaching was investigated. Oxidative co-leaching of pyrrhotite tailings with naturally cooled converter slag at 250°C, 90 psi (6.2 bar) O2, 68 g/L equivalent H2SO4 was shown to have kinetics comparable to adding sulphuric acid with final extractions reaching 95-97% in 45 min. Granulation of slag melt can produce an amorphous solid solution of SiO2 and metal oxides. Amorphous slag is not amenable to HPOXAL due to the formation of a passive layer of silica. Leaching of amorphous slag at low temperatures was shown to proceed nearly to completion. The difference in the leachability of amorphous slag at high and low temperatures is explained in terms of the rate of silicic acid re-polymerization leading to closure of pores in the leached layer.

In the production of base metals by smelting of sulphide ore concentrates, large amounts of iron are rejected with iron silicate slags. These slags contain Ni, Cu and Co in concentrations up to several percent units. Extraction of the entrapped base metals using high pressure oxidative acid leaching (HPOXAL) was investigated in this work. Crystalline slags containing fayalite (Fe2SiO4), magnetite (Fe3O4), silica (SiO2) and matte (MeSn<1) were found to be highly amenable to leaching at 250°C, 90 psi (6.2 bar) O2 partial pressure and 70 g/L initial H2SO4. Extractions of Ni, Co and Cu exceeded 90% within 15-20 min and arrived at 95-97% after 45 min. The residues of leaching were identified as aggregates of crystalline hematite (Fe2O3) and amorphous silica. Dissolution of fayalite and magnetite was shown to be acid driven. Since HPOXAL operates with substoichiometric additions of sulphuric acid (10-20% of the stoichiometric requirement), acid regeneration facilitated by iron oxidation and hydrolysis is crucial to high rates of leaching. Low acidities (<10 g/L) were shown to cause precipitation of ferrous sulphate, slowing acid regeneration and slag dissolution. Elevated acidities (>70 g/L) result in excessive concentrations of Fe(III) in the leach solution, complicating downstream processing. The use of pyrrhotite tailings, an environmentally hazardous waste, as a substitute of sulphuric acid in slag leaching was investigated. Oxidative co-leaching of pyrrhotite tailings with naturally cooled converter slag at 250°C, 90 psi (6.2 bar) O2, 68 g/L equivalent H2SO4 was shown to have kinetics comparable to adding sulphuric acid with final extractions reaching 95-97% in 45 min. Granulation of slag melt can produce an amorphous solid solution of SiO2 and metal oxides. Amorphous slag is not amenable to HPOXAL due to the formation of a passive layer of silica. Leaching of amorphous slag at low temperatures was shown to proceed nearly to completion. The difference in the leachability of amorphous slag at high and low temperatures is explained in terms of the rate of silicic acid re-polymerization leading to closure of pores in the leached layer.