US20150053049A1 - Process for recovering metals by reduction and carbonylation - Google Patents
Process for recovering metals by reduction and carbonylation Download PDFInfo
- Publication number
- US20150053049A1 US20150053049A1 US14/531,942 US201414531942A US2015053049A1 US 20150053049 A1 US20150053049 A1 US 20150053049A1 US 201414531942 A US201414531942 A US 201414531942A US 2015053049 A1 US2015053049 A1 US 2015053049A1
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- United States
- Prior art keywords
- material composition
- metal material
- fraction
- target metal
- solid particulate
- Prior art date
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- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 44
- 238000005810 carbonylation reaction Methods 0.000 title claims description 257
- 229910052751 metal Inorganic materials 0.000 title claims description 187
- 239000002184 metal Substances 0.000 title claims description 185
- 230000006315 carbonylation Effects 0.000 title claims description 60
- 150000002739 metals Chemical class 0.000 title claims description 13
- 239000000463 material Substances 0.000 claims abstract description 860
- 239000000203 mixture Substances 0.000 claims abstract description 686
- 239000007787 solid Substances 0.000 claims abstract description 361
- 239000007769 metal material Substances 0.000 claims abstract description 329
- 239000010970 precious metal Substances 0.000 claims abstract description 266
- 229910052761 rare earth metal Inorganic materials 0.000 claims abstract description 234
- 150000002910 rare earth metals Chemical class 0.000 claims abstract description 231
- 239000007806 chemical reaction intermediate Substances 0.000 claims abstract description 91
- 230000000694 effects Effects 0.000 claims abstract description 50
- 239000003638 chemical reducing agent Substances 0.000 claims abstract description 33
- 238000004519 manufacturing process Methods 0.000 claims abstract description 24
- 239000011236 particulate material Substances 0.000 claims abstract description 19
- 238000000926 separation method Methods 0.000 claims description 474
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 claims description 97
- 239000003795 chemical substances by application Substances 0.000 claims description 59
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 claims description 54
- 229910052759 nickel Inorganic materials 0.000 claims description 53
- OKTJSMMVPCPJKN-UHFFFAOYSA-N Carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 claims description 34
- 229910052799 carbon Inorganic materials 0.000 claims description 34
- 229910052742 iron Inorganic materials 0.000 claims description 20
- UGFAIRIUMAVXCW-UHFFFAOYSA-N Carbon monoxide Chemical compound [O+]#[C-] UGFAIRIUMAVXCW-UHFFFAOYSA-N 0.000 claims description 16
- 229910002091 carbon monoxide Inorganic materials 0.000 claims description 16
- 239000002245 particle Substances 0.000 claims description 11
- 239000002131 composite material Substances 0.000 claims description 2
- 239000010949 copper Substances 0.000 description 30
- 238000000354 decomposition reaction Methods 0.000 description 26
- 229940087654 iron carbonyl Drugs 0.000 description 23
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 20
- 229910052802 copper Inorganic materials 0.000 description 20
- 229910017052 cobalt Inorganic materials 0.000 description 17
- 239000010941 cobalt Substances 0.000 description 17
- 239000011777 magnesium Substances 0.000 description 17
- 239000011651 chromium Substances 0.000 description 16
- 239000011572 manganese Substances 0.000 description 16
- GUTLYIVDDKVIGB-UHFFFAOYSA-N cobalt atom Chemical compound [Co] GUTLYIVDDKVIGB-UHFFFAOYSA-N 0.000 description 15
- 239000007800 oxidant agent Substances 0.000 description 11
- 239000002243 precursor Substances 0.000 description 11
- 229910052760 oxygen Inorganic materials 0.000 description 10
- 239000001301 oxygen Substances 0.000 description 10
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 9
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 8
- FYYHWMGAXLPEAU-UHFFFAOYSA-N Magnesium Chemical compound [Mg] FYYHWMGAXLPEAU-UHFFFAOYSA-N 0.000 description 8
- PWHULOQIROXLJO-UHFFFAOYSA-N Manganese Chemical compound [Mn] PWHULOQIROXLJO-UHFFFAOYSA-N 0.000 description 8
- KDLHZDBZIXYQEI-UHFFFAOYSA-N Palladium Chemical compound [Pd] KDLHZDBZIXYQEI-UHFFFAOYSA-N 0.000 description 8
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 8
- 239000004411 aluminium Substances 0.000 description 8
- 229910052782 aluminium Inorganic materials 0.000 description 8
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 8
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical group [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 8
- 229910052804 chromium Inorganic materials 0.000 description 8
- 229910052749 magnesium Inorganic materials 0.000 description 8
- 229910052748 manganese Inorganic materials 0.000 description 8
- 229910052710 silicon Inorganic materials 0.000 description 8
- 239000010703 silicon Substances 0.000 description 8
- 238000006243 chemical reaction Methods 0.000 description 7
- UCKMPCXJQFINFW-UHFFFAOYSA-N Sulphide Chemical compound [S-2] UCKMPCXJQFINFW-UHFFFAOYSA-N 0.000 description 6
- 125000002915 carbonyl group Chemical group [*:2]C([*:1])=O 0.000 description 5
- 239000010931 gold Substances 0.000 description 5
- 229910001710 laterite Inorganic materials 0.000 description 5
- 239000011504 laterite Substances 0.000 description 5
- RWSOTUBLDIXVET-UHFFFAOYSA-N Dihydrogen sulfide Chemical compound S RWSOTUBLDIXVET-UHFFFAOYSA-N 0.000 description 4
- 229910017147 Fe(CO)5 Inorganic materials 0.000 description 4
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 description 4
- UQSXHKLRYXJYBZ-UHFFFAOYSA-N Iron oxide Chemical compound [Fe]=O UQSXHKLRYXJYBZ-UHFFFAOYSA-N 0.000 description 4
- NINIDFKCEFEMDL-UHFFFAOYSA-N Sulfur Chemical compound [S] NINIDFKCEFEMDL-UHFFFAOYSA-N 0.000 description 4
- 239000005864 Sulphur Substances 0.000 description 4
- BWFPGXWASODCHM-UHFFFAOYSA-N copper monosulfide Chemical compound [Cu]=S BWFPGXWASODCHM-UHFFFAOYSA-N 0.000 description 4
- 238000004508 fractional distillation Methods 0.000 description 4
- 229910052739 hydrogen Inorganic materials 0.000 description 4
- 239000001257 hydrogen Substances 0.000 description 4
- 238000002386 leaching Methods 0.000 description 4
- 238000011084 recovery Methods 0.000 description 4
- 239000010948 rhodium Substances 0.000 description 4
- 238000005549 size reduction Methods 0.000 description 4
- 238000000605 extraction Methods 0.000 description 3
- PCHJSUWPFVWCPO-UHFFFAOYSA-N gold Chemical compound [Au] PCHJSUWPFVWCPO-UHFFFAOYSA-N 0.000 description 3
- 229910052737 gold Inorganic materials 0.000 description 3
- 229910052763 palladium Inorganic materials 0.000 description 3
- 229910052697 platinum Inorganic materials 0.000 description 3
- 230000004580 weight loss Effects 0.000 description 3
- 229910052684 Cerium Inorganic materials 0.000 description 2
- 229910052692 Dysprosium Inorganic materials 0.000 description 2
- 229910052691 Erbium Inorganic materials 0.000 description 2
- 229910052693 Europium Inorganic materials 0.000 description 2
- 229910052688 Gadolinium Inorganic materials 0.000 description 2
- 229910052689 Holmium Inorganic materials 0.000 description 2
- 229910052765 Lutetium Inorganic materials 0.000 description 2
- 229910052779 Neodymium Inorganic materials 0.000 description 2
- 229910052777 Praseodymium Inorganic materials 0.000 description 2
- 229910052773 Promethium Inorganic materials 0.000 description 2
- KJTLSVCANCCWHF-UHFFFAOYSA-N Ruthenium Chemical compound [Ru] KJTLSVCANCCWHF-UHFFFAOYSA-N 0.000 description 2
- 229910052772 Samarium Inorganic materials 0.000 description 2
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 2
- 229910052771 Terbium Inorganic materials 0.000 description 2
- 229910052775 Thulium Inorganic materials 0.000 description 2
- 229910052769 Ytterbium Inorganic materials 0.000 description 2
- QZPSXPBJTPJTSZ-UHFFFAOYSA-N aqua regia Chemical compound Cl.O[N+]([O-])=O QZPSXPBJTPJTSZ-UHFFFAOYSA-N 0.000 description 2
- GWXLDORMOJMVQZ-UHFFFAOYSA-N cerium Chemical compound [Ce] GWXLDORMOJMVQZ-UHFFFAOYSA-N 0.000 description 2
- KBQHZAAAGSGFKK-UHFFFAOYSA-N dysprosium atom Chemical compound [Dy] KBQHZAAAGSGFKK-UHFFFAOYSA-N 0.000 description 2
- UYAHIZSMUZPPFV-UHFFFAOYSA-N erbium Chemical compound [Er] UYAHIZSMUZPPFV-UHFFFAOYSA-N 0.000 description 2
- OGPBJKLSAFTDLK-UHFFFAOYSA-N europium atom Chemical compound [Eu] OGPBJKLSAFTDLK-UHFFFAOYSA-N 0.000 description 2
- 238000005188 flotation Methods 0.000 description 2
- UIWYJDYFSGRHKR-UHFFFAOYSA-N gadolinium atom Chemical compound [Gd] UIWYJDYFSGRHKR-UHFFFAOYSA-N 0.000 description 2
- 230000005484 gravity Effects 0.000 description 2
- KJZYNXUDTRRSPN-UHFFFAOYSA-N holmium atom Chemical compound [Ho] KJZYNXUDTRRSPN-UHFFFAOYSA-N 0.000 description 2
- 229910052741 iridium Inorganic materials 0.000 description 2
- GKOZUEZYRPOHIO-UHFFFAOYSA-N iridium atom Chemical compound [Ir] GKOZUEZYRPOHIO-UHFFFAOYSA-N 0.000 description 2
- JEIPFZHSYJVQDO-UHFFFAOYSA-N iron(III) oxide Inorganic materials O=[Fe]O[Fe]=O JEIPFZHSYJVQDO-UHFFFAOYSA-N 0.000 description 2
- 229910052746 lanthanum Inorganic materials 0.000 description 2
- FZLIPJUXYLNCLC-UHFFFAOYSA-N lanthanum atom Chemical compound [La] FZLIPJUXYLNCLC-UHFFFAOYSA-N 0.000 description 2
- OHSVLFRHMCKCQY-UHFFFAOYSA-N lutetium atom Chemical compound [Lu] OHSVLFRHMCKCQY-UHFFFAOYSA-N 0.000 description 2
- 238000007885 magnetic separation Methods 0.000 description 2
- 229910052976 metal sulfide Inorganic materials 0.000 description 2
- 238000003801 milling Methods 0.000 description 2
- QEFYFXOXNSNQGX-UHFFFAOYSA-N neodymium atom Chemical compound [Nd] QEFYFXOXNSNQGX-UHFFFAOYSA-N 0.000 description 2
- 229910000480 nickel oxide Inorganic materials 0.000 description 2
- 229910052762 osmium Inorganic materials 0.000 description 2
- SYQBFIAQOQZEGI-UHFFFAOYSA-N osmium atom Chemical compound [Os] SYQBFIAQOQZEGI-UHFFFAOYSA-N 0.000 description 2
- GNRSAWUEBMWBQH-UHFFFAOYSA-N oxonickel Chemical compound [Ni]=O GNRSAWUEBMWBQH-UHFFFAOYSA-N 0.000 description 2
- 125000004430 oxygen atom Chemical group O* 0.000 description 2
- PUDIUYLPXJFUGB-UHFFFAOYSA-N praseodymium atom Chemical compound [Pr] PUDIUYLPXJFUGB-UHFFFAOYSA-N 0.000 description 2
- VQMWBBYLQSCNPO-UHFFFAOYSA-N promethium atom Chemical compound [Pm] VQMWBBYLQSCNPO-UHFFFAOYSA-N 0.000 description 2
- 229910052702 rhenium Inorganic materials 0.000 description 2
- WUAPFZMCVAUBPE-UHFFFAOYSA-N rhenium atom Chemical compound [Re] WUAPFZMCVAUBPE-UHFFFAOYSA-N 0.000 description 2
- 229910052703 rhodium Inorganic materials 0.000 description 2
- MHOVAHRLVXNVSD-UHFFFAOYSA-N rhodium atom Chemical compound [Rh] MHOVAHRLVXNVSD-UHFFFAOYSA-N 0.000 description 2
- 229910052707 ruthenium Inorganic materials 0.000 description 2
- KZUNJOHGWZRPMI-UHFFFAOYSA-N samarium atom Chemical compound [Sm] KZUNJOHGWZRPMI-UHFFFAOYSA-N 0.000 description 2
- 229910052706 scandium Inorganic materials 0.000 description 2
- SIXSYDAISGFNSX-UHFFFAOYSA-N scandium atom Chemical compound [Sc] SIXSYDAISGFNSX-UHFFFAOYSA-N 0.000 description 2
- 229910052709 silver Inorganic materials 0.000 description 2
- 239000004332 silver Substances 0.000 description 2
- 239000011343 solid material Substances 0.000 description 2
- GZCRRIHWUXGPOV-UHFFFAOYSA-N terbium atom Chemical compound [Tb] GZCRRIHWUXGPOV-UHFFFAOYSA-N 0.000 description 2
- FRNOGLGSGLTDKL-UHFFFAOYSA-N thulium atom Chemical compound [Tm] FRNOGLGSGLTDKL-UHFFFAOYSA-N 0.000 description 2
- 238000010977 unit operation Methods 0.000 description 2
- NAWDYIZEMPQZHO-UHFFFAOYSA-N ytterbium Chemical compound [Yb] NAWDYIZEMPQZHO-UHFFFAOYSA-N 0.000 description 2
- 229910052727 yttrium Inorganic materials 0.000 description 2
- VWQVUPCCIRVNHF-UHFFFAOYSA-N yttrium atom Chemical compound [Y] VWQVUPCCIRVNHF-UHFFFAOYSA-N 0.000 description 2
- FQYUMYWMJTYZTK-UHFFFAOYSA-N Phenyl glycidyl ether Chemical compound C1OC1COC1=CC=CC=C1 FQYUMYWMJTYZTK-UHFFFAOYSA-N 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- -1 rare earth rare earth metals Chemical class 0.000 description 1
- 239000007858 starting material Substances 0.000 description 1
Images
Classifications
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B11/00—Obtaining noble metals
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B13/00—Making spongy iron or liquid steel, by direct processes
- C21B13/006—Starting from ores containing non ferrous metallic oxides
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21B—MANUFACTURE OF IRON OR STEEL
- C21B15/00—Other processes for the manufacture of iron from iron compounds
- C21B15/04—Other processes for the manufacture of iron from iron compounds from iron carbonyl
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B1/00—Preliminary treatment of ores or scrap
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B23/00—Obtaining nickel or cobalt
- C22B23/06—Refining
- C22B23/065—Refining carbonyl methods
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B3/00—Extraction of metal compounds from ores or concentrates by wet processes
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B5/00—General methods of reducing to metals
- C22B5/02—Dry methods smelting of sulfides or formation of mattes
- C22B5/20—Dry methods smelting of sulfides or formation of mattes from metal carbonyls
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B59/00—Obtaining rare earth metals
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22B—PRODUCTION AND REFINING OF METALS; PRETREATMENT OF RAW MATERIALS
- C22B7/00—Working up raw materials other than ores, e.g. scrap, to produce non-ferrous metals and compounds thereof; Methods of a general interest or applied to the winning of more than two metals
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P10/00—Technologies related to metal processing
- Y02P10/10—Reduction of greenhouse gas [GHG] emissions
- Y02P10/134—Reduction of greenhouse gas [GHG] emissions by avoiding CO2, e.g. using hydrogen
Definitions
- the subject matter relates to processes for recovering precious metals or rare earth metals, or both.
- Precious metals and rare earth metals are, currently, difficult to recover from materials, such as ore deposits, when present in low mass concentrations.
- a process for treating a feed material composition includes contacting the feed material composition with a reducing agent in a reducing agent zone to effect production of a reaction intermediate material composition, wherein the feed material composition is configured to be separated into a target metal material-rich feed material composition separation fraction and one or more target metal material-lean feed material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich feed material composition separation fraction would become separated from the one or more target metal material-lean feed composition separation fractions, and such that one or more separations would be effected and each one of the one or more separations would be defined by the separation of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions would be
- the reaction intermediate material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a post-carbonylation material composition, wherein the post-carbonylation material composition is configured to be separated into a target metal material-rich post-carbonylation material composition separation fraction and one or more target metal material-lean post-carbonylation material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich post-carbonylation material composition separation fraction would become separated from the one or more target metal material-lean post-carbonylation material composition separation fractions, and such that one or more separations would become effected and each one of the one or more separations would be defined by the separation of the target metal material-rich post-carbonylation material composition separation fraction from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich post-carbonylation material composition separation fraction from a one
- a process for treating a feed material composition including a solid particulate precious metal material-rich feed material composition fraction and a solid particulate rare earth metal material-rich feed material composition fraction, wherein the solid particulate precious metal material-rich feed material composition fraction includes one or more precious metals, and wherein the solid particulate rare earth metal material-rich feed material composition fraction includes one or more rare earth metals.
- the process includes contacting the solid particulate feed material composition with a reducing agent within a reducing agent contacting zone to effect production of a reaction intermediate solid particulate material composition.
- the reaction intermediate solid particulate material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a solid particulate post-carbonylation material composition.
- a process for treating a solid particulate feed material composition includes contacting the solid particulate feed material composition with a reducing agent in a reducing agent contacting zone to effect production of a reaction intermediate solid particulate feed material composition, wherein the solid particulate feed material composition is derived from laterite ore.
- the reaction intermediate solid particulate feed material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a solid particulate post-carbonylation material composition.
- a process for treating material derived from a sulphide ore includes contacting a sulphide ore-derived pre-cursor material with an oxidizing agent to effect production of a sulphide ore-derived solid particulate feed material composition.
- the sulphide ore-derived solid particulate feed material composition is contacted with a reducing agent in a reducing agent contacting zone to effect production of a reaction intermediate solid particulate feed material composition.
- the reaction intermediate solid particulate feed material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a solid particulate post-carbonylation material composition.
- FIG. 1 is a flowsheet illustrating an embodiment of the process
- FIG. 2 is another flowsheet illustrating another embodiment of the process.
- a process for treating a feed material composition 22 is provided so as to facilitate separation of target metal material from the feed material composition 22 .
- the target metal material is defined by either one of (i) one or more precious metals, or (ii) one or more rare earth metals.
- the feed material composition is a solid material composition.
- the precious metal is any one of platinum(Pt), palladium(Pd), iridium(Ir), rhodium(Rh), ruthenium(Ru), osmium (Os), gold (Au), rhenium (Re), and silver (Ag).
- the rare earth metal is any one of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), and lutetium (Lu).
- Sc scandium
- Y yttrium
- La lanthanum
- Ce cerium
- Pr praseodymium
- Nd neodymium
- Pm promethium
- Sm samarium
- Eu europium
- Gd gadolinium
- Tb terbium
- Dy dysprosium
- Ho holmium
- Er erbium
- Tm
- the feed material composition 22 is contacted with a reducing agent within a reducing agent contacting zone 20 to effect production of a reaction intermediate material composition 30 .
- suitable reducing agents include gaseous diatomic hydrogen and carbon monoxide.
- the reducing agent contacting zone 20 is disposed at a temperature of between 550 degrees Celsius and 850 degrees Celsius, and at a pressure of between one (1) and 12 bars. In some of these embodiments, for example, the reducing agent contacting zone 20 is disposed at a temperature of about 650 degrees Celsius.
- the feed material composition 22 is configured to be separated into a target metal material-rich feed material composition separation fraction and one or more target metal material-lean feed material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich feed material composition separation fraction would become separated from the one or more target metal material-lean feed composition separation fractions, and such that one or more separations would be effected and each one of the one or more separations would be defined by the separation of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions would be, at least partially, based on a difference between a value of a separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material
- the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of the target metal material of the target metal material-rich feed material composition separation fraction. Also for each one of the one or more feed material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction would be less than a maximum operative difference.
- the value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction would be greater than the value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction would be less than the value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction.
- the separation agent is any material input, any energy input, or any combination thereof.
- the separation agent is an energy input effected by a gravitational force.
- the separation agent is an energy input effected by a magnetic force.
- the separation agent-responsive characteristic is a characteristic or quality of a material.
- a separation agent is said to be associated with a separation agent-responsive characteristic when application of the separation agent to the material, having material fractions with distinct separation agent-responsive characteristic, effects a response, whereby the material fractions respond differently to the energy input such that separation of the material fractions, from one another, is effected.
- the separation agent is an energy input effected by gravitational force
- the separation agent-responsive characteristic is density
- the separation agent is an energy input effected by magnetic force
- the separation agent-responsive characteristic is magnetic field
- the contacting with the reducing agent effects reduction of iron and nickel of the feed material composition 22 .
- the contacting with the reducing agent effects reduction of iron of an iron oxide of the feed material composition 22 .
- the contacting with the reducing agent effects reduction of nickel of a nickel oxide of the feed material composition 22 .
- the feed material composition 22 is derived from an ore.
- the ore is laterite 16 .
- the ore is dried and subjected to size reduction (for example, by milling) prior to being subjected to the contacting with the reducing agent.
- the reaction intermediate material composition 30 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the reaction intermediate material composition 30 to copper sulphide. Excessive copper within the carbonylation supply material composition 104 to the carbonylation zone 112 may, in some embodiments, interfere with carbonylation.
- a sulphur comprising-material such as gaseous hydrogen sulphide
- the feed material composition 22 includes treated pre-cursor solid metal sulphide-comprising material 14 produced by contacting of a pre-cursor solid metal sulphide-comprising material 12 , such as a size-reduced sulphide ore, with an oxidizing agent within an oxidizing agent contacting zone 10 .
- a pre-cursor solid metal sulphide-comprising material 12 such as a size-reduced sulphide ore
- the process further includes contacting of a pre-cursor solid metal sulphide-comprising material 12 with an oxidizing agent within an oxidizing agent contacting zone 10 to effect production of a treated pre-cursor solid metal sulphide-comprising material 14 , wherein the solid particulate feed material composition 22 includes the treated pre-cursor solid metal sulphide material 14 .
- the oxidizing agent contacting zone 10 is disposed at a temperature of between 850 degrees Celsius and 1400 degrees Celsius (such as between 1000 degrees Celsius and 1100 degrees Celsius) and at a pressure of between one (1) and two (2) bars (such as atmospheric pressure).
- the process 100 , 102 further includes contacting the carbonylation supply material composition 104 with carbon monoxide in a carbonylation zone 110 so as to effect production of a post-carbonylation material composition 112 .
- the carbonylation supply material composition 104 is in the form of a solid particulate, and at least 90 weight % of the solid particulate carbonylation material composition has a particle size of less than one (1) millimetre measured using a Fisher Sub-Sieve Sizer (FSSS).
- FSSS Fisher Sub-Sieve Sizer
- the solid particulate carbonylation material composition has a particle size of about 50 microns measured using a Fisher Sub-Sieve Sizer (FSSS).
- the post-carbonylation material composition 112 is configured to be separated into a target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ) and one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122 ), in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ) would become separated from the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122 ), and such that one or more separations would become effected and each one of the one or more separations would be defined by the separation of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ) from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122 ), wherein each one of the one or more separations of the target metal material-rich post-carbony
- the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction 124 would be less than the mass concentration of the target metal material of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ).
- the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122 ) and a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ) would be greater than or equal to the maximum operative difference.
- the value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122 ) would be greater than the value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ).
- the value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122 ) would be less than the value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ).
- the carbonylation zone is disposed at a pressure of between 5 bar and 60 bar, and at a temperature of between 80 degrees Celsius and 120 degrees Celsius.
- Exemplary reactions within the carbonylation zone include the following:
- the contacting of the carbonylation supply material composition 104 with the carbon monoxide effects liberation of carbon monoxide-reactive metal material from the carbonylation supply material composition 104 .
- the carbon monoxide-reactive metal material is defined by one or more carbon monoxide-reactive metals.
- the carbon monoxide-reactive metal material is at least one of nickel, iron, and cobalt.
- the contacting with the carbon monoxide further effects production of a metal-comprising gaseous material including carbon monoxide-reactive metal material whose liberation from the carbonylation supply material composition is effected by the contacting.
- the metal-comprising gaseous material includes at least one metal carbonyl.
- the metal-comprising gaseous material includes any one of, or any combination of nickel carbonyl, iron carbonyl, and cobalt carbonyl.
- the metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 132 and a nickel carbonyl-rich fraction 134 from the metal-comprising gaseous material, such that the iron carbonyl-rich fraction 132 and the nickel carbonyl-rich fraction 134 become separated.
- each one of the iron carbonyl-rich fraction 132 and the nickel carbonyl-rich fraction 142 is supplied to a respective decomposition zone 140 , 142 so as to effect its respective decomposition into a substantially pure form of the respective metal (ie.
- each of the decomposition zones is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions.
- Exemplary reactions within the decomposition zones 140 , 142 include the following:
- the target metal material, of the target metal material-rich post-carbonylation material composition separation fraction is one or more precious metals, such that the target metal material-rich post-carbonylation material composition separation fraction would be a precious metal material-rich post-carbonylation material composition separation fraction 122 including the one or more precious metals.
- the mass concentration of the one or more precious metals of the target metal material-lean post-carbonylation material composition separation fraction 124 would be less than the mass concentration of the one or more precious metals of the precious metal material-rich post-carbonylation material composition separation fraction 122 .
- the one or more target metal material-lean post-carbonylation material composition separation fractions 124 is a rare earth metal material-rich post-carbonylation material composition separation fraction 124 including one or more rare earth metals.
- the mass concentration of the one or more rare earth rare earth metals of the rare earth metal material-rich post-carbonylation material composition separation fraction 124 would be greater than the mass concentration of the one or more rare earth metals of the precious metal material-rich post-carbonylation material composition separation fraction 122 .
- the target metal material, of the target metal material-rich post-carbonylation material composition separation fraction is one or more rare earth metals, such that the target metal material-rich post-carbonylation material composition separation fraction would be a rare earth metal material-rich post-carbonylation material composition separation fraction 124 including the one or more rare earth metals.
- the mass concentration of the one or more rare earth metals of the target metal material-lean post-carbonylation material composition separation fraction 122 would be less than the mass concentration of the one or more rare earth metals of the target metal material-rich post-carbonylation material composition separation fraction 124 .
- the one or more target metal material-lean post-carbonylation material composition separation fractions 122 is a precious metal material-rich post-carbonylation material composition separation fraction 122 including one or more precious metals.
- the mass concentration of the one or more precious metals of the precious metal material-rich post-carbonylation material composition separation fraction 122 would be greater than the mass concentration of the one or more precious metals of the rare earth metal material-rich post-carbonylation material composition separation fraction 124 .
- the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction by at least 25%. In some embodiments, for example, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction by at least 50%.
- the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction by at least 75%.
- the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich feed material composition separation fraction by at least 25%. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich feed material composition separation fraction by at least 50%.
- the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich feed material composition separation fraction by at least 75%.
- the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122 ), from which the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124 ) is separable define the remainder of the post-carbonylation material composition 112 .
- the one or more target metal-lean feed material composition separation fractions, from which the target metal-rich feed material composition separation fraction becomes separated upon separation of the target metal-rich feed material composition separation fraction from the feed material composition 22 define the remainder of the feed material composition 22 .
- the feed material composition 22 is defined by solid particulate material, such that the feed material composition 22 is a solid particulate feed material composition 22 , and such that the target metal material-rich feed material composition separation fraction, which is separable from the solid particulate feed material composition 22 , is defined by solid particulate material, such that the target metal material-rich feed material composition separation fraction is a solid particulate target metal material-rich feed material composition separation fraction.
- each one of the one or more target metal material-lean feed material composition separation fractions is defined by solid particulate material, such that each one of the one or more target metal material-lean feed material composition separation fractions is a solid particulate target metal material-lean feed material composition separation fraction.
- the mass concentration of target metal material of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the solid particulate target metal material-rich feed material composition separation fraction.
- the solid particulate target metal material-rich feed material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either the same or less
- the one or more solid particulate target metal material-lean feed material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration, of the target metal material, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be greater than the maximum mass concentration, of the target metal material, of the maximum mass concentration-
- At least 90 weight % of the solid particulate feed material composition material 104 has a particle size of less than one (1) millimetre measured using a Fisher Sub-Sieve Sizer (FSSS).
- FSSS Fisher Sub-Sieve Sizer
- the solid particulate feed material composition has a particle size of about 50 microns measured using a Fisher Sub-Sieve Sizer (FSSS).
- the post-carbonylation material composition 120 is defined by solid particulate material, such that the post-carbonylation material composition 120 is a solid particulate post-carbonylation material composition 120 , and such that the target metal material-rich post-carbonylation material composition separation fraction, which is separable from the solid particulate post-carbonylation material composition 22 , is defined by solid particulate material, such that the target metal material-rich post-carbonylation material composition separation fraction is a solid particulate target metal material-rich post-carbonylation material composition separation fraction.
- each one of the one or more target metal material-lean post-carbonylation material composition separation fractions is defined by solid particulate material, such that each one of the one or more target metal material-lean feed material composition separation fractions is a solid particulate target metal material-lean post-carbonylation material composition separation fraction.
- the mass concentration of target metal material of the solid particulate target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the solid particulate target metal material-rich post-carbonylation material composition separation fraction.
- the solid particulate target metal material-rich post-carbonylation material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the solid particulate target metal material-rich post-carbonylation material composition separation fraction, would be either the same or less
- the one or more solid particulate target metal material-lean post-carbonylation material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the one or more solid particulate target metal material-lean post-carbonylation material composition separation fractions, would be either greater or the same, and, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mimimum mass concentration, of the target metal material, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich post-carbony
- At least 90 weight % of the solid particulate post-carbonylation material composition 120 has a particle size of less than one (1) millimetre, measured using a Fisher Sub-Sieve Sizer (FSSS).
- FSSS Fisher Sub-Sieve Sizer
- the solid particulate post-carbonylation material composition 120 has a particle size of about 50 microns, measured using a Fisher Sub-Sieve Sizer (FSSS).
- the target metal material is defined by one or more precious metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction.
- the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate target metal material-rich feed material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either the same or less
- the one or more solid particulate target metal material-lean feed material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be greater than the maximum
- the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction.
- the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fractions, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- each one of the one or more target metal material-lean feed material composition separation fractions is a rare earth metal material-rich feed material composition separation fraction including one or more rare earth metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction.
- the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the one or more solid particulate target metal material-lean feed material composition separation fractions would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same
- the solid particulate target metal material-rich feed material composition separation fraction would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation
- the target metal material is defined by one or more rare earth metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction.
- the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate target metal material-rich feed material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either the same or less
- the one or more solid particulate target metal material-lean feed material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either greater or the same,
- the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction.
- the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fractions, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- each one of the one or more target metal material-lean feed material composition separation fractions would be a precious metal material-rich feed material composition separation fraction including one or more precious metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction.
- the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the one or more solid particulate target metal material-lean feed material composition separation fractions would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same
- the solid particulate target metal material-rich feed material composition separation fraction would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration of the one or more precious metals, of the minimum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, is greater
- one of: (i) a solid particulate target metal material-rich feed material composition fraction of the solid particulate feed material composition 22 , and (ii) a solid particulate target metal material-lean feed material composition fraction of the solid particulate feed material composition 22 , is defined by a solid particulate rare earth metal material-rich feed material composition fraction including one or more rare earth metals, and the other one of (i) the solid particulate target metal material-rich feed material composition fraction, and (ii) the solid particulate target metal material-lean feed material composition fraction is defined by a solid particulate precious metal material-rich feed material composition fraction including one or more precious metals.
- the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich feed material composition fraction.
- the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%.
- the solid particulate precious metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich feed material composition fraction, is either the same or less
- the solid particulate rare earth material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich feed material composition fraction is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition
- the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich feed material composition fraction.
- the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more rare earth metals, within the solid particulate precious metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%.
- the solid particulate rare earth metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either the same or less
- the solid particulate precious metal material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich feed material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid part
- the mass concentration of an operative metal material fraction of the solid particulate precious metal-rich feed material composition fraction is greater than the mass concentration of the operative metal material fraction of the solid particulate rare earth metal-rich feed material composition fraction.
- the operative metal material fraction is defined by copper (Cu), cobalt (Co), nickel (Ni), iron (Fe) and precious metals.
- the mass concentration, of the operative metal material fraction, of the solid particulate precious metal-rich feed material composition fraction is greater than the mass concentration, of the operative metal material fraction, of the solid particulate rare earth metal-rich feed material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate precious metal-rich feed material composition fraction includes: (i) at least 1 ⁇ 10 ⁇ 6 weight % of one or more precious metals, based on the total weight of the precious metal-rich feed material composition fraction, (ii) at least 50 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the precious metal-rich feed material composition fraction, (iii) less than weight 1 ⁇ 10 ⁇ 6 % of one or more rare earth metals, based on the total weight of the precious metal-rich feed material composition fraction, (iv) less than 40 weight % of one or more operative oxides, based on the total weight of the precious metal-rich feed material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn
- the reaction intermediate material composition 30 is defined by a solid particulate precious metal material-rich reaction intermediate material composition fraction and a solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction, is either the same or less
- the solid particulate rare earth material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material
- the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction.
- the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more rare earth metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either the same or less
- the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich reaction intermediate material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining
- the mass concentration of non-oxygen bonded metal material of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of non-oxygen bonded metal material of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- Non-oxygen bonded metal material is defined by any metal that is not chemically bonded to an oxygen atom.
- the mass concentration of oxygen of the solid particulate precious metal material-rich reaction intermediate material composition fraction is less than the mass concentration of oxygen of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- the solid particulate precious metal material-rich reaction intermediate material composition fraction includes: (i) at least 1 ⁇ 10 ⁇ 6 weight % of one or more precious metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (ii) at least 15 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iii) less than 1 ⁇ 10 ⁇ 6 weight % of one or more rare earth metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iv) less than 15 weight % of one or more operative oxides, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon
- the process further includes separating the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions.
- the separation agent-responsive characteristic is density
- the separating of the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions is effected by gravity separation.
- the separation agent-responsive characteristic is magnetic field, and the separating of the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions, is effected by magnetic separation.
- the separation agent-responsive characteristic is density
- the separating of the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions is effected by flotation.
- one of (i) a solid particulate target metal material-rich post-carbonylation material separation fraction, and (ii) a solid particulate target metal material-lean post-carbonylation material separation fraction is defined by a rare earth metal material-rich material composition 124 including one or more rare earth metals
- the other one of (i) the solid particulate target metal material-rich post-carbonylation material separation fraction, and (ii) the solid particulate target metal material-lean post-carbonylation material separation fraction is defined by a precious metal material-rich material composition 122 including one or more precious metals.
- the mass concentration of the one or more precious metals of the precious metal material-rich material composition 122 is greater than the mass concentration of the one or more precious metals of the rare earth metal-rich material composition 124 . In some embodiments, the mass concentration, of the one or more precious metals, of the precious metal material-rich material composition 122 is greater than the mass concentration, of the one or more precious metals, of the rare earth metal material-rich material composition 124 , by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the precious metal material-rich material composition 122 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the precious metal material-rich material composition 122 , is either the same or less
- the rare earth material-rich material composition 124 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the rare earth metal material-rich material composition 124 , is either greater or the same
- the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the precious metal material-rich material composition 122 is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the rare earth metal material-rich material composition 124 .
- the mass concentration of the one or more rare earth metals of the rare earth metal material-rich material composition 124 is greater than the mass concentration of the one or more rare earth metals of the precious metal material-rich material composition 122 . In some embodiments, the mass concentration, of the one or more rare earth metals, of the rare earth metal material-rich material composition 124 is greater than the mass concentration, of the one or more rare earth metals, of the precious metal material-rich material composition 122 , by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the rare earth metal material-rich material composition 124 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the rare earth metal material-rich material composition 124 , is either the same or less
- the precious metal material-rich material composition 122 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the precious metal material-rich material composition 122 , is either greater or the same
- the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the rare earth metal material-rich material composition fraction 124 is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the precious metal material-rich material composition 122 .
- the rare earth material-rich material composition 124 is extracted and subjected to a leaching process within a leaching zone 130 to effect recovery of the rare earth metals.
- the target metal material may not necessarily be the only metal, or combination of metals, which are intended to be recovered from the feed material composition 22 .
- the precious metal material-rich material composition 122 is subjected to further treatment to effect production of a precious metal concentrated product.
- the mass concentration of the one or more precious metals of the precious metal concentrated product is greater than the mass concentration of the one or more precious metals of the precious metal material-rich material composition 122 .
- the precious metal material-rich material composition 122 is supplied to a secondary carbonylation zone 150 and contacted with carbon monoxide within the secondary carbonylation zone so as to effect production of a post-secondary carbonylation product material including: (i) a post-secondary carbonylation metal-comprising gaseous material, and (ii) a metal-depleted post-carbonylation precious metal-rich fraction 152 .
- At least one metal of the post-secondary carbonylation metal-comprising gaseous material is a carbon monoxide-reactive metal that is liberated from the precious metal material-rich material composition 122 during the contacting.
- the mass concentration of precious metal material, defined by one or more precious metals, of the metal-depleted post-carbonylation precious metal-rich fraction 152 is greater than the mass concentration of precious metal material, defined by one or more precious metals, of the precious metal material-rich material composition 122 .
- the precious metal material-rich material composition 122 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the material 122 to copper sulphide. Excessive copper within the composition 122 may, in some embodiments, interfere with carbonylation.
- the metal-depleted post-carbonylation precious metal-rich fraction 152 is subjected to further treatment in unit operation 160 (for example, by contacting with aqua regia) to effect recovery of the precious metals.
- the carbon monoxide-reactive metal which is a metal of the post-secondary carbonylation metal-comprising gaseous material, is a metal selected from the group consisting of nickel and iron.
- the post-secondary carbonylation metal-comprising gaseous material includes at least one metal carbonyl.
- the post-secondary carbonylation metal-comprising gaseous material includes nickel carbonyl, or iron carbonyl, or both of nickel carbonyl and iron carbonyl.
- the post-secondary carbonylation metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 172 and a nickel carbonyl-rich fraction 174 from the metal-comprising gaseous material.
- each one of the iron carbonyl-rich fraction and the nickel carbonyl-rich fraction is supplied to a respective decomposition zone 140 , 142 , so as to effect its respective decomposition into a substantially pure form of the respective metal, as described above (ie.
- each of the decomposition zones 140 , 142 is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions.
- the solid particulate feed material composition 22 includes a solid particulate precious metal material-rich feed material composition fraction and a solid particulate rare earth metal material-rich feed material composition fraction.
- at least 90 weight % of the solid particulate feed material composition 22 has a particle size of less than one (1) millimetre, measured using a Fisher Sub-Sieve Sizer (FSSS).
- FSSS Fisher Sub-Sieve Sizer
- the solid particulate feed material composition has a particle size of about 50 microns, measured using a Fisher Sub-Sieve Sizer (FSSS).
- the solid particulate precious metal material-rich feed material composition fraction includes one or more precious metals, and the solid particulate rare earth metal material-rich feed material composition fraction includes one or more rare earth metals.
- the precious metal is any one of platinum(Pt), palladium(Pd), iridium(Ir), rhodium(Rh), ruthenium(Ru), osmium (Os), gold (Au), rhenium (Re), and silver (Ag).
- the rare earth metal is any one of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), and lutetium (Lu).
- Sc scandium
- Y yttrium
- La lanthanum
- Ce cerium
- Pr praseodymium
- Nd neodymium
- Pm promethium
- Sm samarium
- Eu europium
- Gd gadolinium
- Tb terbium
- Dy dysprosium
- Ho holmium
- Er erbium
- Tm
- the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich feed material composition fraction.
- the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%.
- the solid particulate precious metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich feed material composition fraction, is either the same or less
- the solid particulate rare earth material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich feed material composition fraction is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition
- the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich feed material composition fraction.
- the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more rare earth metals, within the solid particulate precious metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%.
- the solid particulate rare earth metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either the same or less
- the solid particulate precious metal material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich feed material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid part
- the mass concentration of an operative metal material fraction of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration of the operative metal material fraction of the solid particulate rare earth metal material-rich feed material composition fraction.
- the operative metal material fraction is defined by copper (Cu), cobalt (Co), nickel (Ni), iron (Fe) and one or more precious metals.
- the mass concentration, of the operative metal material fraction, of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration, of the operative metal material fraction, of the solid particulate rare earth metal material-rich feed material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate precious metal material-rich feed material composition fraction includes: (i) at least 1 ⁇ 10 ⁇ 6 weight % of one or more precious metals, based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, (ii) at least 50 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, (iii) less than weight 1 ⁇ 10 ⁇ 6 % of one or more rare earth metals, based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, (iv) less than 40 weight % of one or more operative oxides, based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si
- the solid particulate feed material composition 22 is derived from an ore.
- the ore is laterite 16 .
- the ore is dried and subjected to size reduction (for example, by milling) prior to being subjected to the contacting with the reducing agent.
- the solid particulate feed material composition 22 includes treated pre-cursor solid metal sulphide-comprising material 14 produced by contacting of a pre-cursor solid metal sulphide-comprising material 12 , such as a size-reduced sulphide ore, with an oxidizing agent within an oxidizing agent contacting zone 10 .
- a pre-cursor solid metal sulphide-comprising material 12 such as a size-reduced sulphide ore
- the process further includes contacting of a pre-cursor solid metal sulphide-comprising material 12 with an oxidizing agent within an oxidizing agent contacting zone 10 to effect production of a treated pre-cursor solid metal sulphide-comprising material 14 , such that the solid particulate feed material composition 22 includes the treated pre-cursor solid metal sulphide material 14 .
- the oxidizing agent contacting zone 10 is disposed at a temperature of between 850 degrees Celsius and 1400 degrees Celsius (such as between 1000 degrees Celsius and 1100 degrees Celsius) and at a pressure of between one (1) and two (2) bars (such as atmospheric pressure).
- the solid particulate feed material composition 22 is contacted with a reducing agent within a reducing agent contacting zone 20 to effect production of a reaction inteimmediate solid particulate material composition 30 .
- suitable reducing agents include gaseous diatomic hydrogen and carbon monoxide.
- the reducing agent contacting zone 20 is disposed at a temperature of between 550 degrees Celsius and 850 degrees Celsius, and at a pressure of between one (1) and 12 bars. In some of these embodiments, for example, the reducing agent contacting zone 20 is disposed at a temperature of about 650 degrees Celsius.
- the contacting with the reducing agent effects reduction of iron and nickel of the solid particulate feed material composition 22 .
- the contacting with the reducing agent effects reduction of iron of an iron oxide of the solid particulate feed material composition 22 .
- the contacting with the reducing agent effects reduction of nickel of a nickel oxide of the solid particulate feed material composition 22 .
- the reaction intermediate solid particulate material composition 30 includes a solid particulate precious metal material-rich reaction intermediate material composition fraction and a solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction, is either the same or less
- the solid particulate rare earth material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material
- the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction.
- the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more rare earth metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either the same or less
- the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich reaction intermediate material composition fraction, is either greater or the same
- the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining
- the mass concentration of non-oxygen bonded metal material of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of non-oxygen bonded metal material of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- Non-oxygen bonded metal material is defined by at least one operative metallic element, wherein each one of the at least one operative metallic element is not chemically bonded to an oxygen atom.
- the mass concentration of oxygen of the solid particulate precious metal material-rich reaction intermediate material composition fraction is less than the mass concentration of oxygen of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.
- the solid particulate precious metal material-rich reaction intermediate material composition fraction includes: (i) at least 1 ⁇ 10 ⁇ 6 weight % of one or more precious metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (ii) at least 15 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iii) less than 1 ⁇ 10 ⁇ 6 weight % of one or more rare earth metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iv) less than 15 weight % of one or more operative oxides, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (M
- the solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes: (i) at least 3 ⁇ 10 ⁇ 6 weight % of one or more rare earth metals, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, (ii) at least 70 weight % of one or more operative oxides, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), (iii) less than 1 ⁇ 10 ⁇ 7 weight % of one or more precious metals, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, and (iv) less than 15 weight % of one or more operative metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (
- the reaction intermediate material composition 30 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the reaction intermediate material composition 30 to copper sulphide. Excessive copper within the carbonylation supply material composition 104 to the carbonylation zone 112 may, in some embodiments, interfere with carbonylation.
- a sulphur comprising-material such as gaseous hydrogen sulphide
- the process 100 , 102 further includes contacting the carbonylation supply material composition 104 with carbon monoxide in a carbonylation zone 110 so as to effect production of a post-carbonylation material composition 112 .
- at least 90 weight % of the solid particulate post-carbonylation material composition 112 has a particle size of less than one (1) millimetre, measured using a Fisher Sub-Sieve Sizer (FSSS).
- FSSS Fisher Sub-Sieve Sizer
- the solid particulate post-carbonylation material composition 112 has a particle size of about 50 microns, measured using a Fisher Sub-Sieve Sizer (FSSS).
- the carbonylation zone 112 is disposed at a pressure of between 5 bar and 60 bar, and at a temperature of between 80 degrees Celsius and 120 degrees Celsius.
- Exemplary reactions within the carbonylation zone 112 include the following:
- the contacting of the solid particulate carbonylation supply material composition 104 with the carbon monoxide effects liberation of carbon monoxide-reactive metal material from the solid particulate carbonylation supply material composition 104 .
- the carbon monoxide-reactive metal material is defined by one or more carbon monoxide-reactive metals.
- the carbon monoxide-reactive metal material is at least one of nickel, iron, and cobalt.
- the contacting with the carbon monoxide further effects production of a metal-comprising gaseous material including carbon monoxide-reactive metal material whose liberation from the feed material composition is effected by the contacting.
- the metal-comprising gaseous material includes at least one metal carbonyl.
- the metal-comprising gaseous material includes any one, or any combination of nickel carbonyl, iron carbonyl, and cobalt carbonyl.
- the metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 132 and a nickel carbonyl-rich fraction 134 from the metal-comprising gaseous material.
- each one of the iron carbonyl-rich fraction 132 and the nickel carbonyl-rich fraction 142 is supplied to a respective decomposition zone 140 , 142 so as to effect its respective decomposition into a substantially pure form of the respective metal (ie.
- each of the decomposition zones is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions.
- Exemplary reactions within the decomposition zones 140 , 142 include the following:
- a solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 and a solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 are separated from the post-carbonylation material composition, such that the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 becomes separated from the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 .
- the separation is effected by any one, or any combination of: gravity separation, magnetic separation, and flotation.
- the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 .
- the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 , by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 , is either the same or less
- the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 , is either greater or the same
- the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is
- the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 . In some embodiments, the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.
- the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 , is either the same or less
- the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 , is either greater or the same
- the solid particulate rare earth metal material-rich feed material composition separation fraction 124 is extracted and subjected to a leaching process within a leaching zone 130 to effect recovery of the rare earth metals.
- the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is subjected to further treatment to effect production of a precious metal concentrated product.
- the mass concentration of the one or more precious metals of the precious metal concentrated product is greater than the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 .
- the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is supplied to a secondary carbonylation zone 150 and contacted with carbon monoxide within the secondary carbonylation zone so as to effect production of a post-secondary carbonylation product material including: (i) a post-secondary carbonylation metal-comprising gaseous material, and (ii) a metal-depleted post-carbonylation precious metal-rich fraction 152 .
- At least one metal of the post-secondary carbonylation metal-comprising gaseous material is a carbon monoxide-reactive metal that is liberated from the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 during the contacting.
- the mass concentration of precious metal material, defined by one or more precious metals, of the metal-depleted post-carbonylation precious metal-rich fraction 152 is greater than the mass concentration of precious metal material, defined by one or more precious metals, of the solid particulate precious metal-rich post-carbonylation material composition separation fraction 122 .
- the composition 122 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the solid material 122 to copper sulphide. Excessive copper within the composition 122 may, in some embodiments, interfere with carbonylation.
- the metal-depleted post-carbonylation precious metal-rich fraction 152 is subjected to further treatment in unit operation 160 (for example, by contacting with aqua regia) to effect recovery of the precious metals.
- the carbon monoxide-reactive metal which is a metal of the post-secondary carbonylation metal-comprising gaseous material, is at least one metal selected from the group consisting of nickel and iron.
- the post-secondary carbonylation metal-comprising gaseous material includes at least one metal carbonyl.
- the post-secondary carbonylation metal-comprising gaseous material includes nickel carbonyl, or iron carbonyl, or both of nickel carbonyl and iron carbonyl.
- the post-secondary carbonylation metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 172 and a nickel carbonyl-rich fraction 174 from the metal-comprising gaseous material.
- each of the iron carbonyl-rich fraction and the nickel carbonyl-rich fraction is supplied to a respective decomposition zone 140 , 142 , so as to effect its respective decomposition into a substantially pure form of the respective metal, as described above (ie.
- each of the decomposition zones 140 , 142 is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions.
- the residue from this run was magnetically separated using Davis Magnetic tube. 77 g of the magnetic fraction was separated from the carbonyl residue, with a yield of 95 weight %. The magnetic fraction had 2.3 weight % nickel, 95 weight % iron, 2.86 weight % cobalt and 10 weight % copper, all of which are based on the total weight of the magnetic fraction. Also, 98 weight % of the total platinum group elements (“PGE”—for purposes of the examples set out herein, the samples were analyzed for only the following PGEs: gold, platinum and palladium), from the feed material (i.e. 2.0 ppm), was in the magnetic portion, and the concentration of PGE in the magnetic portion was 46.3 ppm (grams per tonne of the magnetic portion) in total.
- PGE platinum group elements
- the reactor was opened and the residue was analyzed for nickel, iron, cobalt and PGE.
- the residue had 0.1 weight % nickel, 26.58 weight % cobalt, 60 weight % copper and 4.8 weight % of iron (all of which are based on the total weight of the residue) and 475 ppm (or grams per tonne of the residue) of PGE. This accounts for 98% of the PGE in the starting material.
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| US14/531,942 US20150053049A1 (en) | 2011-08-02 | 2014-11-03 | Process for recovering metals by reduction and carbonylation |
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| PCT/CA2012/000734 WO2013016813A1 (fr) | 2011-08-02 | 2012-08-02 | Procédé pour la récupération de métaux par réduction et carbonylation |
| US14/531,942 US20150053049A1 (en) | 2011-08-02 | 2014-11-03 | Process for recovering metals by reduction and carbonylation |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB250726A (en) * | 1925-03-06 | 1926-04-22 | Louis Dudley Hooper | Process for the separation and purification of platinum and other platinum metals from platiniferous ores and substances |
| US3785802A (en) * | 1970-01-19 | 1974-01-15 | Centro Speriment Metallurg | Method for extracting and separating iron and non-ferrous metals,from ferrous materials |
Family Cites Families (10)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US2757077A (en) * | 1953-06-12 | 1956-07-31 | Crucible Steel Co America | Method of recovering metallic values from ores containing iron and nickel |
| GB769099A (en) * | 1954-04-06 | 1957-02-27 | Mond Nickel Co Ltd | Improvements relating to the reduction of nickel oxide and the production of nickel carbonyl |
| US2793106A (en) * | 1954-06-15 | 1957-05-21 | Barium Steel Corp | Method for refining titanium, zirconium, cerium, hafnium and thorium |
| GB856425A (en) * | 1955-12-28 | 1960-12-14 | Int Nickel Canada | Improvements relating to the recovery of nickel from sulphide ores |
| CA898530A (en) * | 1969-03-28 | 1972-04-25 | E. O'neill Charles | Nickel recovery from lateritic ores |
| CN100999785A (zh) * | 2006-12-29 | 2007-07-18 | 金川集团有限公司 | 一种富集铁精矿中贵金属的方法 |
| CN100999786A (zh) * | 2006-12-29 | 2007-07-18 | 金川集团有限公司 | 一种从硫化铜镍矿中富集贵金属的方法 |
| CA2585541C (fr) * | 2007-04-20 | 2016-08-02 | Chemical Vapour Metal Refining Inc. | Appareil et procede de fabrication de nickel de grande purete |
| US7776129B2 (en) * | 2007-04-24 | 2010-08-17 | Chemical Vapour Metal Refining Inc. | Apparatus and process for making high purity nickel |
| GB2449280B (en) * | 2007-05-17 | 2012-12-19 | Cvmr Corp | Apparatus and process for making high purity nickel |
-
2012
- 2012-08-02 CA CA2843760A patent/CA2843760A1/fr active Pending
- 2012-08-02 WO PCT/CA2012/000734 patent/WO2013016813A1/fr not_active Ceased
- 2012-08-02 EP EP20120819996 patent/EP2739759A4/fr not_active Withdrawn
-
2014
- 2014-11-03 US US14/531,942 patent/US20150053049A1/en not_active Abandoned
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| GB250726A (en) * | 1925-03-06 | 1926-04-22 | Louis Dudley Hooper | Process for the separation and purification of platinum and other platinum metals from platiniferous ores and substances |
| US3785802A (en) * | 1970-01-19 | 1974-01-15 | Centro Speriment Metallurg | Method for extracting and separating iron and non-ferrous metals,from ferrous materials |
Also Published As
| Publication number | Publication date |
|---|---|
| CA2843760A1 (fr) | 2013-02-07 |
| WO2013016813A1 (fr) | 2013-02-07 |
| EP2739759A4 (fr) | 2015-04-08 |
| EP2739759A1 (fr) | 2014-06-11 |
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