Processing of Economic Mineral Resources

Processing of Economic Mineral Resources
Several methods, both physical and chemical, are involved in the processing of economic mineral
resources.
Crushing, grinding, washing and separation (Au/Ag)
Gold and silver are extracted from fine ore in a number of ways depending on the nature of ore;
 Free milling ore

 Refractory ore
Free milling ore – ores that can be separated only by physical means, does not need to undergo chemical
treatment
Refractory ore – contained Au is bounded up with other minerals such as pyrite, most difficult ores to
process
1. Refractory ore
The first process involves the crushing and grinding of the bulk samples that are collected from the mine
pits. This usually done by large crushers before being taken to the mill. The bulk samples consist of ores
and wastes (rock fragments and other materials of no economic importance). The main reason for this
physical process of crushing and grinding is to increase the surface area of the materials before being
separated by chemical means.
The refractory ores are then treated by a process known as pressure oxidation. The pyrites and other
sulphides are oxidized and the gold is released. Pressure oxidation is carried out in autoclaves, which are
very large drums operated at high temperatures and pressures.
The process of separation begins when these fine ores are mixed with water (process known as
washing, or cyanide leaching) and sodium cyanide. Greater amount of gold dissolved by the cyanide
solutions. The solution is shaken up in large tanks containing carbon pellets. Compounds of gold-cyanide
attach themselves to the carbon pellets that are later removed by screening. Gold-cyanide is then
stripped from carbon by using hot cyanide solution. The carbon retrieved can be reused.
After the dissolving, the solution is transferred to an electrolysis tank where the steel wool cathode
becomes coated with gold in response to electric current. Gold is then smelted (heated at high
temperatures) in melting pots allowing impurities, or slag to float to the surface. The contents in the
melting pots are poured into moulds and left to harden. Glassy slag is then easily separated from melt
bars of gold and silver.
This system is currently being used at Porgera and Lihir gold mines.
2. Free milling ore
These ores do not need any chemical treatment as they contain minerals such as gold in free form and
not in chemical combination. When crushed and milled they can be separated by mechanical means.
Smelting is usually done to remove impurities which later poured into metal bars, e.g. gold form alluvial
mining.
Pyro-metallurgic process/smelting (Cu)
Smelting is one of the most important pyro-metallurgic process (fire-refined) by which metals are
recovered and concentrated to produce semi-refined metals. It is a high temperature process where
gangue (minerals of no economic minerals) are chemically altered or changed. They are reduced to form
low density molten slag which is separated from one or more heavier liquid metals or metallic
compounds. Before smelting the ores are prepared, dried and roast purposely to remove moisture.
Because of the high energy input required, only high grade ores or concentrates can be economically
smelted.
Fire-refined copper is known as blister. It contains traces of silver, gold and other metals. It is removed
as anode residue and as slime at the bottom of the electrolysis tanks. Copper which is precipitated on
the cathode is 99.9% pure.
Ore processing of Copper
i. Crushing of ore
ii. Milling of ore
iii. Concentration of ore
iv. Smelting of ore
v. Moulding of ore
vi. Electrolytic conversion of ores to finished products
Gold refining
Refining of gold involves the following processes;
 Ore to crushers
 Milling
 Leach Tanks
 Gold Recovery
 Melt Bars
The main methods of refining gold are:
 Miller Process – bubbling of chlorine gas through molten metal. Most base metals are released
as chlorine gas while silver and some copper forms a liquid chloride layer which is skimmed off
the surface.
 Aqua Regia – dissolving the impure metal in a mixture of nitric and hydrochloric acids (aqua
regia). Silver is turned into insoluble silver chloride which settles down at the bottom while pure
gold is precipitated from the solution by sulphur dioxide. The remaining solution has all silver
and gold removed and only contains traces of base metals
 Electro-refining – passing of electric current through a solution containing gold in an electrolytic
cell. Pure gold is deposited on the cathode of the cell, leaving impurities in solution or at the
bottom of the cell.

Processing of Economic Mineral Resources

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Processing of Economic Mineral Resources

Crushing, grinding, washing and separation (Au/Ag)

 Free milling ore

2. Free milling ore

Pyro-metallurgic process/smelting (Cu)

Ore processing of Copper

Refining of gold involves the following processes;

The main methods of refining gold are:

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