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By Montaser S. EL Salmawy, Takahide Wakamatsu, Eishi Kusaka

"The effect of ethoxylation of long chain alcohols on the quartz and feldspar flotation behaviors was investigated for surfactants of the octylphenol polyoxyethylene family. The tests were carried out with an average of 7.5 (Triton X 114), 9.5 (Triton X 100), 30 (Triton X305), 40 (Triton X 405) and 70 (TritonX 705) oxyethylene units. Electrokinetic and flotation studies on quartz have shown that at low pH values, quartz could be floated with polyoxyethylene octytlphenols. The possible mode of adsorption of these nonionic surfactants may be suggested to be due to hydrogen bonding between the oxygen of ether and hydrogen in the free hydroxyl groups on quartz surface. It was anticipated that the selectivity between quartz and microcline would decrease as oxyethylenic chain length increases.Electrokinetic methods were used to elucidate the mechanism of surfactants adsorption and to correlate these findings with the optimum flotation conditions. The polymeric surfactants would reduce the negative values of zeta potential of quartz while the reverse is true for feldspar. After treatment of microcline with HCl, its electrokinetic behavior in the presence of Tritons X surfactants became similar to that of quartz.The obtained results would suggest that separation of quartz from feldspar using nonionic surfactants of octylphenoletoxylated alcohols having shorter oxyethylenic chain length at low pH could be achieved"

Jan 1, 2003

By Heribert F. Broicher, Arne Volland

The application of remote sensing techniques combined with fluorescence spectroscopy is realised in analytical devices called LIF Analysers. The analysis of laser-induced fluorescence facilitates non-destructive, non-contact, on-line and real-time rock identification and quality control of bulk solids in transport. LKAB of Sweden was the first company to test LIF Analysers in the Kiruna Mine for bulk sorting of run-of-mine ores depending on the phosphorus content. Other applications tested in Germany so far are quality control of limestone (iron and/or dolomite content) and rock identification in lignite mining. Of special interest also is rock identification in diamond mines for dilution control. The paper summarises the present state of the application of LIF Analysers.

Jan 1, 2003

By Lev O. Filippov, Inna V. Filippova

"Flotation of metal-organic precipitate in column is sensible to the hydrodynamic conditions determined by the diameter and the dispersion of rising bubbles. Thus, the dissipation energy in the system resulting of ratio between superficial fluid velocities (gas and feed) in the column is the main parameter for precipitate flotation in pilot or industrial scales. The suggested limiting factor is the aggregate stability under the turbulence created by the rising bubbles. The stability of precipitate is related to the structural organisation of aggregates, which determines the size distribution of particles during precipitation and flotation stages.Structural evolution of Mo precipitate and the destruction phenomenon were described by using of the various fractal dimensions. The fractal studies allow the detection of a structural scaled organisation of the precipitate flocs. The fractal dimension of the particle mass distribution Dm=1.94+/-0.15 suggests, for the floc structure, a cluster-cluster aggregation process either with restructuring or breakage phases.The destruction process, which occurs for the lowest values of the dissipation energy E (0.02 . 0.05 W/kg) was characterised by a fractal dimension Dg of size distribution. Besides, the destruction of floc produces very fine particles, and thus induces the difficulties of bubble-particle collision during the precipitate flotation in column."

Jan 1, 2003

By Dezhou Wei, Cong Han, Shuling Gao, Wengang Liu, Yanbai Shen

The recycling schemes of copper mineral to a copper raw ore produced in China is investigated in this paper, of which is aimed at copper concentrate‘s grade is over 26.00% and recovery is over 90.00%. The primary copper mineral the raw ore is chalcopyrite and the main gangue minerals are quartz, orthoclase, albite, clinochlore and phlogopite. There are four useful metal elements contained in the copper raw ore, which are Cu, Pb, Zn, Au and Ag, and the grade of each is 3.75%, 0.01%, 0.11%, 0.31 and 483.5 g/t. Two floating recycling schemes and its corresponding flotation reagent system were determined. The results show that calcium oxide, sodium carbonate and sodium sulphide were used as regulators, sodium n-butylxanthate was used as collector and terpenic oil was used as frother in two floating recycling schemes are effective. The open-circuit test’s results show that the copper mineral contained in raw ore can be effective collected, and both concentrates gotten through two schemes are up to grade.

Jan 1, 2014

By O. Martinsson

The Kiruna area is an important mining province in northern Sweden, which is dominated by Fe- and Cu-Au deposits. Economically most important for the region, are the apatite iron ores with an annual production of c. 43 M ton of crude Fe-ore and a total production of more than 2000 M ton of ore the last 100 years. The apatite iron ores in the Kiruna area are dominated by either Magnetite or Haematite and contain varying amounts of apatite giving them a content of Fe and P, which varies between 30-70 % and 0.05-5 %, respectively. A typical geochemical feature of the ores is the strong enrichment of REE that is caused by a high content of REE in apatite and the occurrence of Allanite and Monazite containing 22.4 and 69.8 wt% REO, respectively. At Kiirunavaara, the content of REE in apatite varies between 0.07 to 1.57 wt% REO with a dominance for the light rare earths. The variation in REE-content of apatite depending on textural and paragenetic aspects is not known but apatite grains may display a strong LREE-depletion due to hydrothermal alteration. Monazite occurs as rod-shaped or tabular inclusions in apatite and is suggested, to have formed in response to hydrothermal alteration of apatite after the emplacement of the ore. Inclusions are mainly found in the central part of apatite grains occurring in veins and schliren, while they are rare in apatite occurring disseminated in the ore. Monazite also occurs as larger grains outside apatite and together with Allanite is found in texturally and paragenetically different settings within the ore. These occurrences of REE-minerals may largely be a product of LREE mobilized by alteration of apatite after the emplacement of the ore. However, REE-minerals including Allanite and Monazite might also have formed directly from late magmatic fluids. Keywords: apatite, monazite, allanite, ree, kiirunavaara, iron ore of kiruna type, mineral chemistry

Sep 1, 2012

By Ali Dehghani Ahmad Abady

In Sarcheshmeh Copper Complex, a molybdenite floatation concentrate was produced by selective removal of copper impurities with 7 stages of cleaner floatation banks, that contains around 1% copper and 54.5% molybdenum. Mineralogical studies, physical and chemical characterizations showed that the sample contained 91% molybdenite (MoS2), 2.6% chalcopyrite (CuFeS2), 0.2%Covellite (CuS), 1.6% pyrite (FeS2) and 4.6% other nonmetallic impurities. In the present study, the removal of the copper sulfide was investigated by ferric chloride leaching for achieving a molybdenite concentrate with copper content less than 0.3%. Therefore, the application of response surface methodology (RSM) for modeling and optimization of the influence of three control parameters including ferric chloride (FeCl3) dosage, reaction temperature and reaction time, each varying in five levels, were considered, and the mathematical model for prediction of %Cu removal from molybdenite concentrate was derived. This study showed that RSM could effectively be applied for the modeling of ferric chloride leaching, and finding an economical optimum condition to achieve maximum de-coppering efficiency while consuming minimum leaching reagents. The optimum dissolution conditions to maximize Cu extraction were 200 kg/t for ferric chloride dosage, 120 min for reaction time and 80 °C for reaction temperature with a prediction of 83.20% Cu dissolution. Keywords: molybdenite concentrate, ferric chloride, leaching, response surface methodology (RSM)

Sep 1, 2012

By P. S. Rao

In 1951, Tata Steel became the pioneer in Asia by setting up its first ever washery in West Bokaro Colliery. The first beneficiation plant used to produce clean coal of 19% ash with chance cone. Feed size of chance washers were -75 mm to +6 mm. The fine coal (-6 mm) were used directly. With change in technology,in 1986,chance cones were replaced by DM cyclones and coal was washed in two circuits. In the coarse circuit -13 mm to +0.5 mm coal was washed in two stages while the fine coal of -0.5 mm was treated in froth floatation cell. With further improvement in the process the higher ash raw coal was feed to produce clean coal of 13% ash. In 1998, DSM cyclones were replaced by scrolled Evolute design cyclone which has Ep of 0.020 to 0.025 ranges resulting in increase efficiency of separation. With the increase in demand of clean coal, lower seam proportion has increased in raw coal production. The washability studies of individual seams indicated large difference in the seam characteristics in terms of washability and specific gravity cut points of the individual seams. So washing all seams together had resulted in frequent change in the character of coal and warrants frequent changes in the operating parameters of the plant in which the separating efficiency comes down and ultimately resulted in yield loss initially. With increase in knowledge and experience in coal washing the solution to this problem was achieved by adopting, seam-wise washing which is enabling process engineers by keeping set point for longer periods there by to enhance the separation efficiency. Keywords: coal processing, froth floatation, steam washing

Sep 1, 2012

By Gabriela Pino, Maurício Torem, Lorgio V. Gonzales

It has been long known that many microorganisms are able to interact with mineral particles to obtain a concentrate; thus, one possible technique is flotation and its related process. Biological process have been attracting attention in mineral processing due to lower operating cost and their possible applications to process low-grade and fine ores. The adhesion of microorganism to surface of mineral particles can alter the hydrophobicity of mineral markedly. Such surface modifications modify its hydrophobicity or hydrophilicity will be used to flotation of cassiterite fines. The major difficult to float fine particles is attributed to the low probability of bubble-particle collision, one characteristic of electroflotation process is the ability to create very tiny bubbles, which is known, improve the collision efficiency and flotation performance of fine particles. In this study, the electroflotation of fine particles using Rhodococcus opacus strain as bioreagent was investigated. Electroflotation experiments were carried out using particles of cassiterite around 8µm of mean diameter the adsorption of R. Opacus onto cassiterite particles was confirmed by Fourier transform infrared spectroscopy (FTIR), electrokinetic and contact angle analyses. The measurement of bubble size by laser diffraction showed a mean bubble size of around 26 µm, current density and bacteria concentration appear to be the main parameters affecting the mean diameter of bubbles, electroflotation tests reported recovery around of 64.5 % at pH 5, concentration of 2,87 x10¹² cells/ml (50 mg/L) and current density of 51,4 mA/cm2.

Jan 1, 2014

By Kari Niiranen

LKAB (Luossavaara-Kiirunavaara AB) is operating iron ore mines, concentration plants and pelletizing plants in Northern Sweden. The largest of the apatite magnetite deposits and the mines are Kiirunavaara with annual production rate of approximately 27 Mt crude ore underground. LKAB produces two varieties of pellets: blast furnace pellets and direct reduction pellets (LKAB DR Oxide Pellets). Meanwhile the concentration process in a sequence of the low intensity magnetic separation (LIMS) and flotation at the concentration plant. In spring 2007 there were noticed great fluctuations of SiO2 grade in the crude ore. The high SiO2 grade is particularly problematic in the case of direct reduction pellets. In consequence, a project was started (called Silica in the Mine) to define exactly the problem related with silica and to find out, if possible, the reason for the great fluctuation of SiO2 grade in the crude ore going to the processing plant. A further target of this project was to develop a simplified method at the laboratory scale, to predict SiO2 grade in the magnetite concentrate in the future, but also predict the physical properties of the ore with respect to mineral processing. The essential stage of systematic characterization of the ore body for mineral processing properties is the estimation and simulation of different parameters from the laboratory scale to the large scale at the concentration plants using empirical data collected at the mineral processing by LKAB in Kiruna. Further a target was also to find useful physical parameters for mineral processing and implant those parameters into the existing geological 3D-model of the deposit. This information will be used for making prognosis of the future mining and the quality of the crude ore. It will also give better control and improve the production planning in the mine and the performance at the concentration plant in Kiruna concerning the decrease of the SiO2 grade of the magnetite concentrate.

Sep 1, 2012

By M. Karamoozian

Modelling and optimisation of the power draw of large SAG mills are important due to the large power draw which modern mills require (5~10 MW). The cost of grinding is the single biggest cost within the entire process of mineral processing. Traditionally, modelling of the mill power draw has been done using empirical models. Although these models are reliable, they cannot model mills and operating conditions, which are not within the model database boundaries. Also, due to their static nature, the impact of the changing conditions on the power draw, within the mill, cannot be deter-mined using such models. Despite advances in computing power, on-line modelling of large plant scale mills could be a time consuming task. On the other hand, using on-line parameters for model-ling, result in more reliable control of SAG mill without performing any more costly tests. In this paper, SAG mill power draw is modelled using neural network approach. Six inputs, namely: solid percent, two bearing pressures, noise, recycle and feed rate were used to model the power draw. The produced model shows an acceptable correlation coefficient, R2 =0.9623.

Jan 1, 2014

By Vasile Murariu, William Pate, John Herbst, Dilek Alkac

"Multiphysics models are essentially first principles models capable of providing very accurate micro scale predictions. The computational requirements for Multiphysics Models are extensive, precluding their direct use for flowsheet simulations. Population balance models get their form from theory but the model parameters have to be provided from experiments. The prediction errors for the population balance models are typically significantly higher than those for the Multiphysics Models but the computational effort for Population Balance Models is typically much less than that for the Multiphysics models. The hybrid model described here takes advantage of the strengths of each of the two primary model types and minimizing the weaknesses of each. The Multiphysics Model is used to perform high accuracy "experiments" that are difficult or impossible to conduct in laboratories or plants. The results of these experiments are combined with standard laboratory or plant data to parameterize and further enhance the Population Balance portion of the hybrid model. The creation of a useful Hybrid Model is demonstrated for a MP1000 secondary crusher. The validation of the hybrid crusher model is also presented. Finally the use of the Hybrid Model is illustrated in a full comminution flowsheet simulator."

Jan 1, 2014

By J. C. van Dyk

In a previous study by Van Dyk, et al., (2006) and Van Dyk et al. (2006), a FactSage model was developed to understand the chemistry and interpret mineral matter transformation during a fixed bed counter-current gasification process. It was concluded that the FactSage model developed, compared with HT-XRD experimental results and that the FactSage thermodynamic modeling sup-plies insight into specific mineral reactions and slag formation. The specific value for Sasol in using FactSage, in combination with HT-XRD is that it can be used to analyze equilibrium conditions for reactions occurring between inorganic and organic materials together, as well as to provide insight into mineral transformation and slag formation. The purpose of the present study was to improve the current FactSage modeling approach, by combining specific zones in the gasification process. This can improve and speed-up the interpretation of mineral matter transformations and flow properties of reacted mineral matter in coal and assist in identifying and quantifying slag formation in the gasifier operation at temperatures not reflected by normal AFT analyses. The updated and improved FactSage model compared favorably with the original model as well as with HT-XRD results and thus will be able to supply results in a faster and more convenient manner. In the new FactSage model, supported by HT-XRD experimental findings, it is indicated that feldspar formation (including anorthite) correlated with slag formation at temperatures around 1000°C and no slag formation in the base case coal was observed in the drying and devolitilization zone, as was to be expected. Feldspar is one is the mineral species which has the lowest AFT causing the most slag-liquid formation and forms probably as a product between the SiO2, Al2O3 and Ca-containing species. In the gasification zone it was clear that slag-liquid formed at a temperature of 1000°C, with a decrease in the feldspar content. Mullite formation was also observed in the base case sample in the temperature range 1000°C and 1100°C. The decrease in the amount of SiO2 at 1100°C is related to the formation of mullite, but also that the slag-liquid phase also contains an amount of SiO2 in the molten form.

Jan 1, 2014

By J. A. Sweet

The issues facing graduate training in the mineral processing industry are not too different today from those that prompted the initiation of the Anglo American Platinum Graduate Development Programme (AGDP) in 2002. Graduate metallurgists in South Africa enter the industry from different undergraduate programmes at various tertiary institutions, and so the knowledge and skills of the young graduates varies. Further, the geographical expansion of the industry combined with the downsizing of business units means that there are fewer opportunities for young graduates to be mentored through their first few years on site. Anglo American Platinum chose to address these issues by implementing an intensive, structured graduate training programme for all their new metallurgical graduates, known as the AGDP. The first two years of experience of the AGDP, from the viewpoints of both graduates and lecturers, were presented to the mineral processing community at the IMPC in Turkey in 2006 (Sweet et al, 2006). From the beginning, the programme was structured in a modular fashion to include a basic technical ?toolbox? including statistics, the scientific method and sampling protocols, while the mineral processing content comprised advanced learning in comminution, classification and flotation (later extended to include hydrometallurgy). Technical communication ? both written and verbal ? was included from the start. The programme was focussed very strongly on site work (?learning by doing?), with a major integrated site campaign conducted and analysed by each cohort. In 2012 the AGDP will accept its ninth cohort into the programme. This paper describes how Anglo American Platinum and the University of Cape Town have developed and adapted the programme over the last few years, in response to the challenges of the global recession, skills retention, and the changing operational needs of the company. The programme, which was drawn up to accommodate around 15 concentrator-only graduates, now accommodates 35-40 concentrator, smelter and refinery graduates annually. The programme has also been modified to facilitate new graduates spending most of their first year on the operations. The benefits of the programme for Anglo American Platinum have been tangible, and will be discussed in the paper. Keywords: graduate training, technology transfer

Sep 1, 2012

By Heinrich Hutchison, Thomas von Moltke, Roelof F. Sandenbergh, Katarina P. Cerovic

In the leaching of gold in aqueous cyanide solutions the rate of gold leaching may be decreased by the passivation of the gold, that may however be prevented or reversed in the presence of lead species in solution. In the present study potentiostatic, potentiodyanamic and XPS (X-ray photoelectron spectroscopy) analysis were used to further clarify the action of lead ions on the anodic activity of gold in alkaline cyanide solutions. It was found that lead increased the gold dissolution rate as it deposited on the gold surface at potentials more positive than its reversible Nernst potential for bulk metal deposition, i.e. by underpotential deposition mechanism, but that it decreased gold activity if present as bulk plated lead on the gold.

Jan 1, 2003

By C. Carrasco

"Over the last 30 years the average grade of mined ore bodies has significantly decreased while the proportion of waste removal has in many cases more than doubled. This has been identified as prime reason of a major increase in energy consumption and decrease in productivity across mining operation. Metal coarse preconcentration of ROM feed grades by size rejects low grade gangue/waste material in the size range of 10-100 mm prior to grinding, typically before primary crushing. This relies on propensity of metal to preferentially deport in the fine size fractions after breakage. Metal preconcentration by size has the potential to increase energy efficiency and therefore improve mining productivity on unit of metal basis. Results of an extensive belt cut sampling campaign conducted at a major Australian Au-Cu mine operation show that for some samples between 90% of Au and 80% of Cu is in 40% of the mass at -50 mm fraction. This indicates that low grade coarse material can be removed from the circuit, doubling feed grade at half of the tonnage and therefore improve energy efficiency per unit metal produced. This response, however presents significant variability in the same order as other processing attributes such as impact hardness and flotation recovery. This has led to development of geometallurgical laboratory tests using blast hole chips and drill core facilitating mapping and population of coarse metal preconcentration signatures in long term resources and short term production models. Preferential Cu deportment by size at drilling scale can be recognised, however scales up factors are required to transform laboratory results to production responses. At 50 % of mass the drilling products underestimate the belt cut responses by 20-30 %. Bulk sampling campaign with blast hole and drill core samples spatially related was also conducted to investigate in more detail the difference between production scale and drilling scale preconcentration responses."

Jan 1, 2014

By F. Q. Cheng

As the important potash, the product yield of KCl in winter is low and the resources waste is serious according to the deficiency of collectors, which can be used in this condition currently. This paper studied on the change of contact angle, turbidity, and flotation recovery of KCl particles when different chain lengths, ratios of amines were used as collectors in KCl flotation process to get a new mixed collector. The contact angle values of KCl crystal in its brine solution added different amine collectors were first measured by captive bubble method. The turbidity of brine solutions were then measured by the laboratory turbidimeter at room temperature when different amine collectors were contained. In the end micro-flotation experiment using mixed amine with fixed ratios and ODA as collectors respectively at 5 °C, 23 °C were performed. The results show when the ratio of the mixed amine is DDA- 20%, ODA-60%, C20-20%, the contact angle at KCl surface is the maximum and the hydrophobic state is best. Meanwhile the result of turbidity measurement indicates that the dispersion of mixed amine colloids is better than the ODA collector due to the addition of DDA, which plays the role of frother. The flotation results also prove that the mixed amine is not only fit for the KCl flotation at room temperature but also fit for its flotation at low temperature. This study provides strong technical support to extend the production time of potash business in Chaerhan areas in China.

Sep 1, 2012

By O. Jerez, A. Novoselov, L. Gutiérrez, J. Morales, U. Kelm

"In Chile, the evaluation to reprocess tailings for elements other than the traditional Cu, Mo, Au, and Ag, as well as projects to implement long-term monitoring of mining residue sites are key elements of the government’s roadmap laid out for the mining industry for the next two decades. Characterization routines for tailings and mining residues in general have to be adapted from traditional ore and gangue mineral and micro-chemical studies. This contribution summarizes key aspects for the regional mining industry for a basic characterization of tailings with emphasis on small- to medium-size operations with limited in-house facilities and funds to carry out extensive characterization programs. The oldest tailings in Chile were deposited almost a century ago; this fact gives importance to the recovery of past ore /gangue feed information, process circuits and changes (e.g. acid to alkaline flotation), process water provenance and recovery, meteorological registers, and routines of filling a tailings impoundment. Basic characterization should include X-ray fluorescence spectrometry combined with laser diffraction (LD) granulometry followed by X-ray diffraction (XRD), optical microscopy (OM) and automated mineral analysis (AMA) on a reduced set of samples identified by hierarchical cluster analysis. For this detailed stage, only coarse tailings are recommended for direct a study by microscopy and automated mineralogy (P80 >100 µm); for fine tailings (P80 ~30 µm) a combination of XRD and deposit type adapted sequential extraction are more informative options. In particular, for XRD of clay phases, losses of crystallinity may result in deviation of spectra from standard reference phases due to prolonged storage. To monitor surface alteration, scanning electron microscopy can be complemented by Raman spectroscopy to detect residual reagents on mineral surfaces. For reactivity modeling BET measurements are essential."

Jan 1, 2018

By K. S. McClure, S. B. Chitralekha, R. B. Gopaluni, Chmylek. T., S. L. Shah

This is a tutorial paper on industrially successful approaches for nonlinear process monitoring. Online process monitoring is essential to continuous operation of plants at high efficiency. The problem of process monitoring is one where an impending but undesirable process condition has to be identified and used to alert process engineers. This problem has traditionally been solved by practicing engineers using statistical techniques that detect a change in the underlying correlation structure of process variables. For linear correlation structures, algorithms such as principal components analysis, independent component analysis and partial least squares have been proposed. However, many industrial processes exhibit nonlinear correlation structure between the process variables. In this tutorial we describe various nonlinear monitoring techniques and elaborate on two recently developed methods, namely Support Vector Machine and Local Linear Embedding. The two methods are evaluated by application on two experimental case studies, a SAG mill and a polymer extruder.

Jan 1, 2014

By S. Castro, L. Gutierrez

"Mining operations are often located in remote arid environments with limited access to fresh water. Shortage of fresh water in such cases makes it necessary to use seawater in mineral processing plants. Such plants treating Cu- Mo sulfide ores in seawater have been fully operational in Chile (e.g. Las Luces, Centinela). In many cases process waters used in commercial flotation plants (e.g. Mt Keith in Western Australia) are even more concentrated electrolyte solutions than seawater. This paper is an attempt at classification of the flotation operations carried out in process waters that are concentrated electrolyte solutions.INTRODUCTIONAccording to Gleick (1966), of the total Earth’ water resources 97.5% is in the oceans and ice caps, and thus only about 2.5% is fresh water. Shortage of fresh water in many parts of the world makes it necessary to use seawater in mineral processing operations. The existing commercial operations using seawater as well as recent research projects that deal not only with sulfide ores but also with apatite ores provide a lot of information that can now be generalized. The progress that has been made in this area is reviewed and based on this information an attempt is being made at classifying the flotation operations carried out in highly concentrated electrolyte process waters.SALT FLOTATIONFlotation in highly concentrated electrolyte solutions was studied by Klassen (Klassen, 1963). He reported that hydrophobic, bituminous coals, could float in salt solutions without addition of any other flotation agents. The process is referred to as salt flotation. Other inherently hyhrophobic minerals (e.g. talc, graphite, sulfur, etc.) were shown to behave similarly (Klassen and Mokrousov, 1963)As Figure 1 shows, some coals float quite well in solutions of Na2SO4, NaCl and NaNO3 (Klassen, 1963). While there are differences between the tested salts (explained by different foamabilities of these solutions) all the tests indicate that only bituminous coals float well in concentrated electrolyte solutions. 0.3 M solutions are quite sufficient to initiate a good and very fast flotation. If wettability of various coals is compared it becomes obvious that these well floating coals are very hydrophobic bituminous coals (Figure 2)."

Jan 1, 2018

By S. Swaroopa

Copper-chromium mixed oxides are widely used as catalyst for organic chemicals industry, NOx and CO oxidation, solid propellant etc. In the present investigation, one such spent Cu-Cr catalyst has been tested for recovering copper and chromium values through hydrometallurgical route. The spent catalyst used in this study contains about 42% Cu and 36% Cr. Phase analysis through XRD indicates that major phases are copper chromium oxide (CuCrO2) and copper chromate (CuCr2O4) while minor phase is copper oxide (Cu64O). SEM images show that high energy ball milling changes surface morphology significantly ? more regular shaped grains in unmilled samples changed to fine agglomerates. Surface area also changes significantly due to milling. Preliminary leaching experiments with NH3 and H2SO4 media using unmilled samples indicate that both the media are suitable for selective extraction of copper. About 55% copper recovery is achieved in 2 h using 1.2 M NH3 + 0.2M (NH4)2SO4 solution at 100°C. Increasing NH3 concentration or temperature does not improve the recovery significantly. Under the above conditions chromium, dissolution is insignificant (max. 2.24%). XRD analysis of the residue indicates that copper chromate fraction (CuCr2O4), which is a spinel structure, remains mostly intact. In sulphuric acid media at ambient temperature, 47% copper recovery is achieved with 7.5% (v/v) H2SO4 and maximum of 57% with the increase in acid concentration to 20%. However, 67% recovery is achieved by increasing the leaching temperature to 150°C. High energy ball milled samples show improved leaching efficiency. Under the leaching conditions of 7% H2SO4 (v/v), 2% pulp density, 80°C an unmilled sample yields 47% Cu recovery whereas 3h and 5h milled samples yield 65% and 90% Cu recovery respectively in 2h leaching time. Influence of temperature is also more pronounced in milled sample leaching in comparison to unmilled sample. Water leaching of alkali (NaOH) roasted milled sample carried out at 750°C for 2 h with 100% NaOH (w/w) resulted in 80% Cr recovery as compared to 37% Cr recovery using unmilled sample under the same conditions. Keywords: spent catalyst, copper, chromium, leaching, mechanical activation, roasting

Sep 1, 2012