Novel collectors for the selective froth flotation of mineral sulfides

BACKGROUND OF THE INVENTION
This invention relates to novel collectors for the recovery of metal-containing sulfide minerals and sulfidized metal-containing oxide minerals from mineral ores by froth flotation.
Flotation is a process of treating a mixture of finely divided mineral solids, e.g., a pulverulent ore, suspended in a liquid whereby a portion of such solids is separated from other finely divided mineral solids, e.g., clays and other like materials present in the ore, by introducing a gas (or providing a gas in situ) in the liquid to produce a frothy mass containing certain of the solids on the top of the liquid, and leaving suspended (unfrothed) other solid components of the ore. Flotation is based on the principle that introducing a gas into a liquid containing solid particles of different materials suspended therein causes adherence of some gas to certain suspended solids and not to others and makes the particles having the gas thus adhered thereto lighter than the liquid. Accordingly, these particles rise to the top of the liquid to form a froth.
Various flotation agents have been admixed with the suspension to improve the frothing process. Such added agents are classed according to the function to be performed: collectors, for sulfide minerals including xanthates, thionocarbamates and the like; frothers which impart the property of forming a stable froth, e.g., natural oils such as pine oil and eucalyptus oil; modifiers such as activators to induce flotation in the presence of a collector, e.g., copper sulfate; depressants, e.g., sodium cyanide, which tend to prevent a collector from functioning as such on a mineral which it is desired to retain in the liquid, and thereby discourage a substance from being carried up and forming a part of the froth; pH regulators to produce optimum metallurgical results, e.g., lime, soda ash and the like.
The phenomena which makes flotation a particularly valuable industrial operation appear to be largely associated with selective affinity of the surface of particulate solids, suspended in a liquid containing entrapped gas, for the liquid on the one hand, the gas on the other.
The specific additives used in the flotation operation are selected according to the nature of the ore, the mineral sought to be recovered, and the other additives which are to be used in combination therewith.
Flotation is employed in a number of mineral separation processes among which is the selective separation of metal-containing sulfide minerals such as those containing copper, zinc, lead, tin, molybdenum and other metals from sulfide minerals containing primarily iron such as pyrite or pyrrhotite.
Once recovered, the metal-containing minerals are converted to the more useful pure metal state, often by a smelting process. Such smelting processes can result in the formation of volatile sulfur compounds. These volatile sulfur compounds are often released to the atmosphere through smokestacks, or are removed from such smokestacks by expensive and elaborate scrubbing equipment.
Among collectors commonly used for the recovery of metal-containing sulfide or sulfidized metal-containing oxide minerals are xanthates, dithiophosphates, and thionocarbamates. Unfortunately, the xanthates, thionocarbamates, and dithiophosphates are not particularly selective in the recovery of sulfide or sulfidized oxide minerals. For example, many nonferrous metal-containing sulfide minerals are found naturally in ore which also contains iron-containing sulfide minerals. When the iron-containing sulfide minerals are recovered in flotation processes along with the nonferrous metal-containing sulfide minerals or sulfidized metal-containing oxide minerals, there is excess sulfur present which is released in the smelting processes resulting in an undesirably high amount of sulfur present during the smelting operations. The xanthates, thionocarbamates and dithiophosphates do not selectively recover nonferrous metal-containing sulfide minerals in the presence of iron-containing sulfide minerals. On the contrary, such collectors collect and recover all metal-containing sulfide minerals.
Other materials commonly recognized as useful in the recovery of sulfide-containing metal or sulfidized metal oxide values include mercaptans. Unfortunately, the mercaptan collectors have an environmentally undesirable odor, are very slow kinetically in the flotation of metal sulfides and do not selectively recover nonferrous metal sulfides in the presence of ferrous sulfides. Therefore, the mercaptans are not generally used commercially.
It has also been proposed in U.S. Pat. No. 1,774,183 to use compounds of the formula R--S.sub.x --R' wherein R and R' stand for the same or different alkyl or aralkyl hydrocarbon radicals or groups such as CH.sub.3, C.sub.2 H.sub.5, C.sub.3 H.sub.7, C.sub.4 H.sub.9, C.sub.5 H.sub.11, C.sub.6 H.sub.5 CH.sub.2 or the like and x signifies the number 1 or a number greater than 1. Although the reference teaches that R and R' can be the same or different and that x can be 1, if x is 1, R and R' are the same in the only exemplified compounds. Moreover, of the described compounds, those of the formula R-S-S-R' are particularly preferred and are stated to effect a better separation than the monosulfides (see, specifically page 2, lines 87-88). The exemplified materials have not been found to be particularly selective in the recovery of metal-containing sulfide or oxidized metal-containing sulfide minerals, particularly those minerals which do not contain copper.
Similarly, U.S. Pat. No. 4,274,950 teaches using a compound of the formula R-S-R' wherein R and R' are the same or different and are a saturated or unsaturated organic radical. Although R and R' can be unsubstituted hydrocarbon radicals such as alkyl groups, the preferred compounds are substituted with either a hydroxy or carboxy group, e.g., are of the formulas R--S(CH.sub.2).sub.n OH or R--S(CH.sub.2).sub.n --COOR". All the specifically exemplified materials are substituted with a hydroxy or carboxy group except one compound wherein R is a C.sub.12-18 alkyl group and R' is a C.sub.1-6 alkyl group. Again, the exemplified materials have not been found to be particularly selective in the recovery of metal-containing sulfide or sulfidized metal-containing oxide minerals, particularly those minerals which do not contain copper.
In addition, the disulfides and higher sulfides are generally slow kinetically in the recovery of metal-containing sulfide minerals.
In view of the foregoing, a flotation collector which will selectively recover, at good rates and selectivity, metal-containing sulfide and sulfidized metal-containing oxide minerals, including the recovery of nonferrous metal-containing sulfide minerals or sulfidized metal-containing oxide minerals in the presence of sulfide or sulfidized oxide minerals containing primarily iron is desired.
SUMMARY OF THE INVENTION
Accordingly, this invention relates to a froth flotation process for selectively recovering metal-containing sulfide minerals or sulfidized metal-containing oxide minerals from mineral ores. More particularly, the method of the present invention comprises subjecting the mineral ore, in the form of an aqueous pulp, to a froth flotation process in the presence of a flotating amount of an organic compound of the formula:
R.sub.1 --S--R.sub.2 (I)
wherein R.sub.1 is a methyl, ethyl, epoxy (i.e., ##STR2## group or R.sub.3 --S--R.sub.4 wherein R.sub.3 is a hydrocarbyl or substituted hydrocarbyl group and R.sub.4 is a hydrocarbylene group or substituted hydrocarbylene group; and R.sub.2 is an aliphatic, cycloaliphatic, aromatic or combination thereof having from 5 to 11 carbon atoms, under conditions such that the metal-containing sulfide mineral or sulfidized metal-containing oxide mineral is recovered in the froth.
It has been found that the choice of the R.sub.1 and R.sub.2 groups are particularly critical to effectiveness of the organic compound as a collector in froth flotation processes and the foregoing designation of R.sub.1 and R.sub.2 results in excellent performance in recovery of a broad range of minerals. If R.sub.1 and R.sub.2 are the same or if one of R.sub.1 and R.sub.2 contains too many carbon atoms, their performance as collectors is generally poorer, especially on non-copper-containing minerals.
Using the method of the present invention, a nonferrous metal-containing sulfide mineral or sulfidized metal-containing oxide minerals can be recovered at relatively high recoveries. In addition, a relatively high selectivity toward nonferrous metal-containing sulfide minerals and sulfidized metal-containing oxide minerals is capable of being achieved when such metal-containing sulfide or sulfidized metal-containing oxide minerals are found in the presence of sulfide minerals containing primarily iron. The recoveries are particularly good in view of the recoveries of similar compounds in which R.sub.1 and R.sub.2 are the same (i.e., a symmetric monosulfide molecule) or one R.sub.1 or R.sub.2 contains 12 or more carbon atoms.
DETAILED DESCRIPTION OF THE INVENTION
The flotation collectors employed in the method of the present invention are organic compounds corresponding to the formula:
R.sub.1 --S--R.sub.2
wherein R.sub.1 is a methyl, ethyl, epoxy (i.e., ##STR3## group or R.sub.3 --S--R.sub.4 wherein R.sub.3 is a hydrocarbyl or substituted hydrocarbyl group and R.sub.4 is a hydrocarbylene or substituted hydrocarbylene group; and R.sub.2 is an aliphatic, cycloaliphatic, aromatic group or combination thereof having from 5 to 11 carbon atoms.
In the event the flotation collector is R.sub.3 --S--R.sub.4 --S--R.sub.1, the total number of carbon atoms in the collector is preferably at least 6, more preferably at least 8 and less than about 20, more preferably less than about 16 carbon atoms. R.sub.3 is preferably an alkyl or substituted alkyl group having from 1 to 4, preferably 1 or 2, carbon atoms, most preferably methyl or ethyl, and R.sub.4 is an alkylene group having from 3 to 10 carbon atoms or an aralkylene group having from 6 to 12 carbon atoms, more preferably ##STR4## wherein n is from 3 to 8. If substituted, R.sub.3 and R.sub.4 are preferably substituted with a hydroxy, cyano, ether or halo moiety.
Preferably, R.sub.1 is methyl, ethyl or epoxy, more preferably methyl or ethyl and R.sub.2 is an alkyl or aralkyl group having from 6 to 10 carbon atoms, more preferably an alkyl group having from 6 to 8 carbon atoms.
Examples of compounds within the scope of this invention include methylpentyl sulfide, methylhexyl sulfide, methylheptyl sulfide, methyloctyl sulfide, methylnonyl sulfide, methyldecyl sulfide, methylundecyl sulfide, methylcyclopentyl sulfide, methylcyclohexyl sulfide, methylcycloheptyl sulfide, methylcyclooctyl sulfide, ethylpentyl sulfide, ethylhexyl sulfide, ethylheptyl sulfide, ethyloctyl sulfide, ethylnonyl sulfide, ethyldecyl sulfide, ethylundecyl sulfide, ethylcyclopentyl sulfide, ethylcyclohexyl sulfide, ethylcycloheptyl sulfide, ethylcyclooctyl sulfide. More preferred sulfides include methylhexyl sulfide, methylheptyl sulfide, methyloctyl sulfide, methylnonyl sulfide, methyldecyl sulfide, ethylhexyl sulfide, ethylheptyl sulfide, ethyloctyl sulfide, ethylnonyl sulfide and ethyldecyl sulfide.
Aliphatic refers herein to straightand branched-chain, and saturated and unsaturated, hydrocarbon compounds, that is, alkanes, alkenes or alkynes. Cycloaliphatic refers herein to saturated and unsaturated cyclic hydrocarbons, that is, cycloalkenes and cycloalkanes.
Hydrocarbyl means herein a monovalent organic radical containing carbon and hydrogen atoms and hydrocarbylene means a bivalent organic radical containing carbon and hydrogen atoms. The term hydrocarbyl includes the following organic radicals: alkyl, alkenyl, alkynyl, cycloalkyl, cycloalkenyl, aryl, aliphatic and cycloaliphatic aralkyl and alkaryl. The term aryl refers herein to biaryl, biphenylyl, phenyl, naphthyl, phenanthrenyl, anthracenyl and two aryl groups bridged by an alkylene group. Alkaryl refers herein to an alkyl-, alkenyl- or alkynyl-substituted aryl substituent wherein aryl is as defined hereinbefore. Aralkyl means herein an alkyl group, wherein aryl is as defined hereinbefore.
The method of this invention is useful for the recovery by froth flotation of metal-containing sulfide and sulfidized metal-containing oxide minerals from ores. An ore refers herein to the metal as it is taken out of the ground and includes the metal-containing minerals in admixture with the gangue. Gangue refers herein to those materials which are of lesser or no value and are desirably separated from the metal-containing minerals.
Ores for which the method of this invention are useful include sulfide mineral ores containing copper, zinc, molybdenum, cobalt, nickel, lead, arsenic, silver, chromium, gold, platinum, uranium, and mixtures thereof. Examples of metal-containing sulfide minerals which may be concentrated by froth flotation using the method of the present invention include copper-bearing minerals such as covellite (CuS), chalcocite (Cu.sub.2 S), chalcopyrite (CuFeS.sub.2), valleriite (Cu.sub.2 Fe.sub.4 S.sub.7 or Cu.sub.3 Fe.sub.4 S.sub.7), bornite (Cu.sub.5 FeS.sub.4), cubanite (Cu.sub.2 SFe.sub.4 S.sub.5), enargite (Cu.sub.3 (As.sub.1 Sb)S.sub.4), tetrahedrite (Cu.sub.3 SbS.sub.2), tennantite (Cu.sub.12 As.sub.4 S.sub.13), brochantite (Cu.sub.4 (OH).sub.6 SO.sub.4), antlerite (Cu.sub.3 SO.sub.4 (OH).sub.4), famatinite (Cu.sub.3 (SbAs)S.sub.4), and bournonite (PbCuSbS.sub.3); lead-bearing minerals such as galena (PbS); antimony-bearing minerals such as stibnite (Sb.sub.2 S.sub.3); zinc-bearing minerals such as sphalerite (ZnS); silver-bearing minerals such as stephanite (Ag.sub.5 SbS.sub.4) and argentite (Ag.sub.2 S); chromium-bearing minerals such as daubreelite (FeSCrS.sub.3); nickel-bearing minerals such as pentlandite [(FeNi).sub.9 S.sub.8 ] ; molybdenum-bearing minerals such as molybdenite (MoS.sub.2); and platinum- and palladium-bearing minerals such as cooperite (Pt(AsS).sub.2). Preferred metal-containing sulfide minerals include molybdenite (MoS.sub.2), chalcopyrite (CuFeS.sub.2), galena (PbS), sphalerite (ZnS), bornite (Cu.sub.5 FeS.sub.4), and pentlandite [(FeNi).sub.9 S.sub.8 ].
Sulfidized metal-containing oxide minerals are minerals which are treated with a sulfidization chemical, so as to give such minerals sulfide mineral characteristics, so the minerals can be recovered in froth flotation using collectors which recover sulfide minerals. Sulfidization results in oxide minerals having sulfide characteristics. Oxide minerals are sulfidized by contact with compounds which react with the minerals to form a sulfur bond or affinity. Such methods are well-known in the art. Such compounds include sodium hydrosulfide, sulfuric acid and related salts such as sodium sulfide.
Sulfidized metal-containing oxide minerals and metal-containing oxide minerals for which this process is useful include oxide minerals containing copper, aluminum, iron, titanium, magnesium, chromium, tungsten, molybdenum, manganese, tin, uranium or mixtures thereof. Examples of metal-containing oxide minerals which may be concentrated by froth flotation using the process of this invention include copper-bearing minerals such as cuprite (Cu.sub.2 O), tenorite (CuO), malachite (Cu.sub.2 OH).sub.2 CO.sub.3), azurite (Cu.sub.3 (OH).sub.2 (CO.sub.3).sub.2), atacamite (Cu.sub.2 Cl(OH).sub.3), chrysocolla (CuSiO.sub.3); aluminum-bearing minerals such as corundum; zinc-containing minerals such as zincite (ZnO) and smithsonite (ZnCO.sub.3); tungsten-bearing minerals such as wolframite [(Fe, Mn)WO.sub.4 ]; nickel-bearing minerals such as bunsenite (NiO); molybdenum-bearing minerals such as wulfenite (PbMoO.sub.4) and powellite (CaMoO.sub.4); iron-containing minerals such as hematite and magnetite; chromium-containing minerals such as chromite (FeOCr.sub.2 O.sub.3 iron- and titanium-containing minerals such as ilmenite; magnesium- and aluminum-containing minerals such as spinel; titanium-containing minerals such as rutile; manganese-containing minerals such as pyrolusite; tin-containing minerals such as cassiterite; and uranium-containing minerals such as uraninite, gummite (UO.sub.3 nH.sub.2 O) and pitchblende (U.sub.2 O.sub.5 (U.sub.3 O.sub.8)).
In a preferred embodiment, metal-containing sulfide minerals are recovered. In a more preferred embodiment, the method of this invention is employed to recover sulfide minerals containing copper, nickel, lead, zinc, or molybdenum. In an even more preferred embodiment, sulfide minerals containing copper are recovered.
The collectors of this invention can be used in any concentration which gives the desired recovery of the desired mineral(s). The concentration at which the collector is most advantageously employed is dependent upon a variety of factors including the specific collector employed, the particular mineral(s) to be recovered, the grade of the ore to be subjected to the froth flotation process and the desired quality of the metal value to be recovered. Preferably, the collectors of this invention are used in concentrations of 0.001 kg to 1.0 kg per metric ton of ore, more preferably between about 0.010 kg and 0.2 kg of collector per metric ton of ore to be subjected to froth flotation.
During the froth flotation process of the present invention, frothers are preferably employed. Frothers are well-known in the art and reference is made thereto for the purposes of this invention. Any frother which results in the recovery of the desired metal value can be employed herein.
Frothers useful in this invention include any frothers known in the art which give the recovery of the desired mineral value. Examples of such frothers include C.sub.5-8 alcohols, pine oils, cresols, C.sub.1-4 alkyl ethers of polypropylene glycols, dihydroxylates of polypropylene glycols, glycols, fatty acids, soaps, alkylaryl sulfonates, and the like. Furthermore, blends of such frothers may also be used. All frothers which are suitable for beneficiation of mineral ores by froth flotation can be used in this invention.
In addition, in the method of this invention it is contemplated that collectors of this invention can be used in mixtures with other collectors well-known in the art. Collectors, known in the art, which may be used in admixture with the collectors of this invention are those which will give the desired recovery of the desired mineral value. Examples of collectors useful in this invention include alkyl monothiocarbonates, alkyl dithiocarbonates, alkyl trithiocarbonates, dialkyl dithiocarbamates, alkyl thionocarbamates, dialkyl thioureas, monoalkyl dithiophosphates, dialkyl and diaryl dithiophosphates, dialkyl monothiophosphates, thiophosphonyl chlorides, dialkyl and diaryl dithiophosphonates, alkyl mercaptans, xanthogen formates, xanthate esters, mercapto benzothiazoles, fatty acids and salts of fatty acids, alkyl sulfuric acids and salts thereof, alkyl and alkaryl sulfonic acids and salts thereof, alkyl phosphoric acids and salts thereof, alkyl and aryl phosphoric acids and salts thereof, sulfosuccinates, sulfosuccinamates, primary amines, secondary amines, tertiary amines, quaternary ammonium salts, alkyl pyridinium salts, guanidine, and alkyl propylene diamines.
Under preferred conditions, the recovery of the liberated iron sulfide in the froth is reduced by at least 10, more preferably at least 25, most preferably at least 40, percent when compared to mercaptan disulfide and polysulfide collectors.
The following examples are included for for purposes of illustration only and should not be construed to limit the scope of the invention or claims. Unless otherwise indicated, all parts and percentages are by weight.
In the following examples, the performance of the frothing processes described is shown by giving the rate constant of flotation and the amount of recovery at infinite time. These numbers are calculated by using the formula ##EQU1## wherein: r is the fractional amount of mineral recovered at time t, K is the rate constant for the rate of recovery and R is the calculated fractional amount of the mineral which would be recovered at infinite time. The amount recovered at various times is determined experimentally and the series of values are substituted into the equation to obtain the R and K. The above formula is explained in Klimpel, "Selection of Chemical Reagents for Flotation", Chapter 45, pp. 907-934, Mineral Processing Plant Design, 2nd Ed., 1980, AIME (Denver) (incorporated herein by reference).

EXAMPLE 1
Froth Flotation of Copper-Containing Sulfide Mineral
In this example, the method of the present invention is employed to run a series of trials using the various collectors as specified in Table I for flotation of copper-containing sulfide minerals. In each trial, a 500-g quantity of Western Canada copper ore, a relatively high grade chalcopyrite-containing ore with little pyrite, is placed in a rod mill having one-inch (2.5 cm) rods, with 257 g of deionized water and ground for 420 revolutions at a speed of 60 rpm to produce a size distribution of 25 percent less than 100 mesh. A quantity of lime is also added to the rod mill, based on the desired pH for the subsequent flotation. The ground slurry is transferred to a 1500 ml cell of an Agitair Flotation machine. The float cell is agitated at 1150 rpm and the pH is adjusted to 8.5 by the addition of further lime.
The specified collector is then added to the float cell (8 g/metric ton), followed by a conditioning time of one minute, at which time the frother, DOWFROTH.RTM. 250 (trademark of The Dow Chemical Company) is added (18 g/metric ton). After the additional one-minute conditioning time, the air to the float cell is turned on at a rate of 4.5 liters per minute and the automatic froth removal paddle is started. The froth samples were taken off at 0.5, 1.5, 3, 5 and 8 minutes. For purposes of comparison, samples of the copper-containing sulfide mineral ore are subjected to identical froth flotation conditions except using collectors not within the scope of the present invention.
The froth samples are dried overnight in an oven, along with the flotation tailings. The dried samples are weighed, divided into suitable samples for analysis, pulverized to insure suitable fineness, and dissolved in acid for analysis. The samples are analyzed using a DC Plasma Spectrograph. The results are compiled in Table I.
TABLE I__________________________________________________________________________ Cu Gangue Cu Gangue Selec-Collector K R K R R-8.sup.1 R-8.sup.1 tivity.sup.2__________________________________________________________________________potassium amyl xanthate.sup.3 2.16 0.694 1.88 0.143 0.654 0.135 4.8butyl mercaptan.sup.3 2.16 1.000 1.86 0.246 0.943 0.230 4.1hexyl mercaptan.sup.3 0.89 0.961 0.82 0.216 0.850 0.187 4.5octyl mercaptan.sup.3 0.56 0.765 0.52 0.160 0.571 0.118 4.8dodecyl mercaptan.sup.3 0.31 0.552 0.30 0.129 0.341 0.079 4.3dibenzyl tetrasulfide.sup.3 2.26 0.310 1.94 0.067 0.298 0.064 4.7N--(2-mercaptoethyl)- 2.77 0.413 2.43 0.093 0.393 0.089 4.4ethylamide.sup.3diphenyl sulfide.sup.3 2.40 0.365 1.77 0.081 0.348 0.078 4.5phenylmethyl sulfide.sup.3 2.96 0.397 2.20 0.095 0.381 0.093 4.1dipropyl disulfide.sup.3 9.53 0.872 6.84 0.190 0.859 0.192 4.5dihexyl disulfide.sup.3 3.21 0.569 2.34 0.113 0.543 0.109 5.0dioctyl disulfide.sup.3 2.19 0.331 1.81 0.072 0.315 0.069 4.6didecyl disulfide.sup.3 3.32 0.428 2.58 0.095 0.409 0.092 4.4dibutyl sulfide.sup.3 5.94 0.930 4.95 0.194 0.902 0.188 4.8dihexyl sulfide.sup.3 2.57 0.908 2.01 0.176 0.866 0.168 5.23-hydroxypropylhexyl 9.56 0.938 6.77 0.231 0.919 0.228 4.0sulfide.sup.3ethylbenzyl sulfide 5.15 0.877 4.29 0.179 0.850 0.175 4.9methylhexyl sulfide 4.29 0.898 3.84 0.182 0.853 0.175 4.9ethylhexyl sulfide 8.80 0.937 6.98 0.205 0.917 0.202 4.5ethyloctyl sulfide 4.56 0.920 3.52 0.184 0.891 0.180 5.0methyloctyl sulfide 6.68 0.802 4.29 0.158 0.803 0.159 5.11,6-(methyl thio)hexane 4.41 0.937 4.26 0.208 0.903 0.208 4.32,3-epoxypropyl- 5.65 0.865 4.03 0.171 0.853 0.171 5.0octyl sulfide__________________________________________________________________________ .sup.1 R8 is experimental recovery after 8 minutes .sup.2 Selectivity is calculated as the copper recovery at 8 minutes divided by the gangue at 8 minutes .sup.3 Not examples of the invention
The method of this invention using collectors of the formula R.sub.1 --S--R.sub.2 wherein R.sub.1 and R.sub.2 are as hereinbefore defined demonstrates relatively higher rates and equilibrium recovery than methods using mercaptan, polysulfide, or symmetrical monosulfide collectors.
EXAMPLE 2
Froth Flotation of Copper/Molybdenum Ore
Bags of homogeneous ore containing chalcopyrite and molybdenite minerals are prepared with each bag containing 1200 g. The rougher flotation procedure is to grind a 1200-g charge with 800 cc of tap water for 14 minutes in a ball mill having a mixed ball charge (to produce approximately a 13 percent plus 100 mesh grind). This pulp is transferred to an Agitair 1500 ml flotation cell outfitted with an automated paddle removal system. The slurry pH is adjusted to 10.2 using lime. No further pH adjustments are made during the test. The standard frother is methyl isobutyl carbinol (MIBC). A four-stage rougher flotation scheme is then followed.
______________________________________STAGE 1: Collector 0.0042 kg/ton MIBC 0.015 kg/ton condition - 1 minute float - collect concentrate for 1 minuteSTAGE 2: Collector 0.0021 kg/ton MIBC 0.005 kg/ton condition - 0.5 minute float - collect concentrate for 1.5 minutesSTAGE 3: Collector 0.0016 kg/ton MIBC 0.005 kg/ton condition - 0.5 minute float - collect concentrate for 2.0 minutesSTAGE 4: Collector 0.0033 kg/ton MIBC 0.005 kg/ton condition - 0.5 minute float - collect concentrate for 2.5 minutes______________________________________
TABLE II______________________________________Copper/Molybdenum Orefrom Western CanadaCol- Dosage Ave Ave Avelec- kg/metric Cu Molyb Cu Mo Fetor ton R-7.sup.1 R-7.sup.1 Grade.sup.2 Grade.sup.2 Grade.sup.2______________________________________.sup. A.sup.3 0.0112 0.776 0.725 0.056 0.00181 0.254B 0.0112 0.699 0.697 0.107 0.00386 0.164B 0.0224 0.723 0.723 0.112 0.00392 0.142______________________________________ A potassium amyl xanthate B hexylmethyl sulfide .sup.1 R7 is the experimental fractional recovery after 7 minutes .sup.2 Grade is the fractional content of the specified metal in total weight collected in the froth .sup.3 Not an example of this invention
The method of the present invention has a significant influence both on improving the overall concentrate grade (the fraction of desired metal sulfide in the final flotation product) as well as a significant lowering of pyrite in the concentrate as measured by the lowering of the Fe assay of the product. This is true regardless of the dosage being used. This means less mass being fed to smelters and less sulfur emissions per unit of metal being produced.
EXAMPLE 3
Froth Flotation of Copper/Nickel Ore from Eastern Canada Containing Very High Amounts of Iron Sulfide Mineral in the Form of Pyrrhotite
A series of samples are drawn from the feeders to plant rougher bank and placed in buckets to give approximately 1200 g of solid. The slurry contained chalcopyrite and pentlandite. The contents of each bucket are then used to perform a time-recovery profile on a Denver cell using an automated paddle and constant pulp level device with individual concentrates selected at 1.0, 3.0, 6.0 and 12.0 minutes. The chemicals are added once with a condition time of one minute before froth removal is started. The dosage of the collectors is 0.028 kg/ton of flotation feed. Individual concentrates are dried, weighed, ground and statistically representative samples prepared for assay. Time-related recoveries and overall head grades are calculated using standard mass balance equations.
TABLE III______________________________________Cu/Ni Ore from Eastern Canada Cu NiCollector R-12.sup.1 R-12.sup.1______________________________________C.sub.5 H.sub.11 OCS.sub.2 Na.sup.3 0.931 0.849(sodium amyl xanthate)C.sub.4 H.sub.9 SC.sub.4 H.sub.9.sup.3 0.928 0.630C.sub.6 H.sub.13 SC.sub.6 H.sub.13.sup.3 0.898 0.547CH.sub.3 SC.sub.6 H.sub.13 0.924 0.721C.sub.2 H.sub.5 SC.sub.6 H.sub.13 0.935 0.735C.sub.2 H.sub.5 SC.sub.8 H.sub.17 0.905 0.703______________________________________ .sup.1 R12 is experimental recovery after 12 minutes .sup.2 Selectivity is calculated as the nickel recovery at 12 minutes divided by the pyrrhotite recovery at 12 minutes .sup.3 Not an example of the present invention
As evidenced by the data set forth in Table III, the recovery of copper using the method of this invention is equivalent to copper recovery using C.sub.4 H.sub.9 SC.sub.4 H.sub.9 or C.sub.6 H.sub.13 SC.sub.6 H.sub.13. However, the recovery of nickel, a more difficult metal to recover, using the method of the present invention is significiant higher than either the method using C.sub.6 H.sub.13 SC.sub.6 H.sub.13 or C.sub.4 H.sub.9 SC.sub.4 H.sub.9 as the collector.
EXAMPLE 4
Froth Flotation of A complex Pb/Zn/Cu/Ag Ore from Central Canada
Uniform 1000-g samples of ore are prepared. The ore contains galena, sphalerite, chalcopyrite and argentite. For each flotation run, a sample is added to a rod mill along with 500 cc of tap water and 7.5 ml of SO.sub.2 solution. Six and one-half minutes of mill time are used to prepare a feed of 90 percent less than 200 mesh (75 microns). After grinding, contents are transferred to a cell fitted with an automated paddle for froth removal, and the cell attached to a standard Denver flotation mechanism.
A two-stage flotation is then performed. In Stage I a copper/lead/silver rougher, and in Stage II a zinc rougher. To start the Stage I flotation, 1.5 g/kg Na.sub.2 CO.sub.3 is added (pH of 9 to 9.5), followed by the addition of collector(s). The pulp is then conditioned for 5 minutes with air and agitation. This is followed by a 2-minute condition period with agitation only. MIBC frother is then added (standard dose of 0.015 ml/kg). Concentrate is collected for 5 minutes of flotation and labeled as copper/lead rougher concentrate.
The Stage II flotation consists of adding 0.5 kg/metric ton of CuSO.sub.4 to the cell remains of Stage I. The pH is than adjusted to 10.5 with lime addition. This is followed by a condition period of 5 minutes with agitation only. pH is then rechecked and adjusted back to 10.5 with lime. At this point, the collector(s) are added, followed by a 5-minute condition period with agitation only. MIBC frother is then added (standard dose of 0.020 ml/kg). Concentrate is collected for 5 minutes and labeled as zinc rougher concentrate.
Concentrate samples are dried, weighed, and appropriate samples prepared for assay using X-ray techniques. Using the assay data, recoveries and grades are calculated using standard mass balance formulae.
In addition to the above procedure, tests are also run at lower pH in Stage I (no Na.sub.2 CO.sub.3 is added, giving a pH of 8.5) and in Stage II only enough lime is added to give a pH of 9.5. Also with the lower pH, 0.3 kg/metric ton of CuSO.sub.4 is added.
TABLE IV__________________________________________________________________________Pb/Zn/Cu/Ag Ore from Central CanadaTest Stage Col- Dosage Ag Cu Pb Zn# (Rougher) lector (g/t) pH R-5 Grade R-5 Grade R-5 Grade R-5 Grade__________________________________________________________________________.sup. 1.sup.1 Cu/Pb A 5.0 9.5 0.868 0.267 0.935 0.109 0.787 0.052 0.208 -- B 7.5 Zn A 20.0 10.5 0.069 -- 0.038 -- 0.089 -- 0.774 0.474 C 15.02 Cu/Pb D 12.5 9.5 0.871 0.264 0.936 0.106 0.748 0.049 0.234 -- Zn D 35.0 10.5 0.067 -- 0.031 -- 0.114 -- 0.741 0.460.sup. 3.sup.1 Cu/Pb A 5.0 8.5 0.843 0.286 0.926 0.120 0.738 0.053 0.179 -- B 7.5 Zn A 20.0 9.5 0.109 -- 0.057 -- 0.155 -- 0.808 0.314 C 15.04 Cu/Pb D 12.5 8.5 0.748 0.382 0.860 0.159 0.567 0.060 0.104 -- Zn D 35.0 9.5 0.158 -- 0.105 -- 0.276 -- 0.873 0.451__________________________________________________________________________ .sup.1 Not an example of the invention A sodium ethyl xanthate B dithiophosphate (Aero .RTM. 241 sold by American Cyanamid) C thionocarbamate (Minerac .RTM. 2030 sold by Minerac Corp.) D octylmethyl sulfide R5 is the actual recovery after 5 minutes
The data in Table IV indicates that the method of this invention can be employed using a single collector of the formula R.sub.1 --S--R.sub.2 wherein R.sub.1 and R.sub.2 are as hereinbefore described to give equivalent or better performance than a method using 3 commercially optimized collectors at the normal pH and CuSO.sub.4 selected as optimal for the commercial collectors (test nos. 1 and 2). The corresponding test nos. 3 and 4, conducted at lower pH and CuSO.sub.4 levels also show similar results. The fact that this is true can represent significant savings in lime and CuSO.sub.4 costs to a plant operation, as the main reason pH is controlled to 10.5 in Stage I and 9.5 in Stage II is to improve selectivity and the main reason for adding CuSO.sub.4 is to improve Zn recovery while maintaining grade. Note that at the lower CuSO.sub.4 runs, (test no. 4) the method of this invention actually increases Zn recovery and maintains good grade.
EXAMPLE 5
A series of samples of ore containing galena, sphalerite, chalcopyrite and argentite are treated using the tehcniques of Example 4 using the various collectors and pH values specified in Table V. Each of the collected samples are evaluated as specified in Example 4. The results of the analysis are set forth in Table V.
TABLE V______________________________________ Stage Col- DosageTest (Rough- lec- (g/metric Ag Cu Pb ZnNo. er) tor t) pH R-5 R-5 R-5 R-5______________________________________1.sup.1 Cu/Pb A 5.0 9.5 0.886 0.941 0.794 0.220 B 7.5 Zn A 20.0 10.5 0.052 0.030 0.077 0.762 C 15.02.sup.1 Cu/Pb D 5.0 9.5 0.885 0.935 0.774 0.188 B 7.5 Zn D 35.0 10.5 0.013 0.008 0.014 0.1173.sup. Cu/Pb E 5.0 9.5 0.888 0.945 0.799 0.231 B 7.5 Zn E 35.0 10.5 0.061 0.032 0.088 0.744______________________________________ A sodium ethyl xanthate B dithiophosphate C thionocarbamate D C.sub.6 H.sub.13 SC.sub.6 H.sub.13 E C.sub.8 H.sub.17 SCH.sub.3 .sup.1 Not an example of this invention
As evidenced by the data in Table V, the method of the present invention using a collector of the formula R.sub.1 --S--R.sub.2 wherein R.sub.1 is methyl and R.sub.2 is octyl exhibited similar R-5 values in the recovery of silver and copper when compared to the results obtained in the comparative test runs (Test Nos. 1 and 2). More importantly, the method of the present invention exhibited superior R-5 values in the recovery of lead and much superior R-5 values in the recovery of zinc as compared to Test No. 2 wherein a compound of the same formula except that R.sub.1 and R.sub.2 are the same and are both hexyl (i.e., a less desirable symmetric configuration) was employed. This result is totally unexpected in view of the prior art. This is similar to the trend exhibited in Example 3 in the recovery of nickel.
EXAMPLE 6
Froth Flotation of a Copper/Molybdenum Ore
A 500-g quantity of a copper/molybdenum ore from South America is placed in a rod mill having one-inch (2.5 cm) rods along with 257 g of deionized water and a quantity of lime. The mixture is ground for 360 revolutions at a speed of 60 rpm to produce a size distribution of suitable fineness (about 25 percent less than 100 mesh). The ground slurry, containing various copper-containing sulfide minerals and molybdenite, is transferred to a 1500-ml cell of an Agitair Flotation machine. The float cell is agitated at 1150 rpm and the pH is adjusted to 8.5 by the addition of either lime or hydrochloric acid.
The collector is added to the float cell (45 g/metric ton), followed by a conditioning time of one minute, at which time the frother, DOWFROTH.RTM. 250, is added (36.4 g/metric ton). After an additional conditioning time of one minute, the air to the float cell is turned on at a rate of 4.5 liters per minute and the automatic froth removal paddle started. Samples of the froth are collected at 0.5, 1.5, 3, 5 and 8 minutes. The froth samples are dried overnight in an oven along with the flotation tailings. The dried samples are weighed, divided into suitable samples for analysis, pulverized to insure suitable fineness, and dissolved in acid for analysis on a DC Plasma Spectrograph. The results are compiled in Table VI.
TABLE VI______________________________________ Cu Mo FeCollector pH R-8.sup.1 R-8.sup.1 R-8.sup.1______________________________________Xanthate/thio- 10.5 0.891 0.742 0.398nocarbamate.sup.2Octyl ethyl sulfide 10.5 0.854 0.791 0.278Xanthate/thio- 8.0 0.912 0.780 0.422nocarbamate.sup.2Octyl ethyl sulfide 8.0 0.887 0.822 0.394______________________________________ .sup.1 R8 is experimental fractional recovery after 8 minutes .sup.2 Not an example of the invention (50/50 w/w mixture of sodium ethyl xanthate and isopropyl ethyl thionocarbamate)
The method of this invention shows a significant increase in molybdenum recovery over the standard recovery method; however, there is a decrease in the copper recovery. Also, a very significant desired decrease is shown in the recovery of iron-bearing sulfide minerals.
EXAMPLE 7
Froth Flotation of a Copper Ore
When the procedure of Example 1 is repeated using a relatively high grade chalcopyrite-containing ore with little pyrite from a different location in the same mine as Example 1, the results as compiled in Table VII are obtained.
TABLE VII__________________________________________________________________________ Cu Gangue Cu Gangue Selec-Collector K R K R R-8.sup.1 R-8.sup.1 tivity.sup.2__________________________________________________________________________sodium sulfide.sup.3 1.39 0.215 1.34 0.439 0.195 0.040 4.9ethylisopropyl 4.21 0.369 3.01 0.092 0.358 0.089 4.0sulfide.sup.3ethylbutyl sulfide.sup.3 9.52 0.765 6.46 0.174 0.750 0.172 4.4ethylpentyl sulfide 9.11 0.869 6.33 0.187 0.858 0.186 4.6ethylhexyl sulfide 10.2 0.899 6.91 0.200 0.893 0.200 4.5ethyloctyl sulfide 2.51 0.909 2.27 0.179 0.870 0.171 5.1ethyldecyl sulfide 3.66 0.709 2.68 0.160 0.694 0.156 4.4ethyldodecyl sulfide.sup.3 1.69 0.614 1.41 0.143 0.568 0.131 4.3methyldodecyl sulfide.sup.3 1.78 0.615 1.23 0.152 0.576 0.137 4.2__________________________________________________________________________ .sup.1 R8 is experimental fractional recovery after 8 minutes .sup.2 Selectivity is calculated as the copper recovery at 8 minutes divided by the gangue at 8 minutes .sup.3 Not an example of this invention
As evidenced by the data in Table VII, the effectiveness of the collectors of the formula R.sub.1 --S--R.sub.2 is very dependent on the number of carbon atoms and their distribution in the molecule. The desirability of having a non-symmetrical molecule has been shown in the previous examples. This example shows clearly that, for maximum performance, the number of carbon atoms in R.sub.2 should not be less than 5 or more than 12. This result is totally unexpected in view of the prior art.

Number	Name	Date
1774183	Moses et al.	Aug 1930
2027357	Moses et al.	Jan 1936
4274950	Larribau et al.	Jun 1981
4504384	Parlman et al.	Mar 1985
4526696	Delourme et al.	Jul 1985
4554137	Maurice et al.	Nov 1985

Novel collectors for the selective froth flotation of mineral sulfides

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