The electrolytic extraction of liquid copper at 1105 • C from a molten sulfide electrolyte composed of 57 wt% BaS and 43 wt% Cu 2 S was investigated. DC cyclic voltammetry, Fourier transformed AC voltammetry, and galvanostatic electrolysis revealed that the electrodeposition of copper is possible in the selected molten sulfide electrolyte. The half wave potential for the reaction on graphite was determined, and liquid copper of high purity was obtained by galvanostatic electrolysis. These preliminary results confirm that molten sulfides free of alkaline elements could be used as an electrolyte for faradaic applications, despite the semi-conducting nature of the melt. In addition to demonstrating the need for enhanced understanding of the transport properties of such electrolyte, the results show the critical impact of the cell design to improve the process faradaic efficiency. Sulfide-containing ores are the main raw material for copper extraction. The conventional chemical principle underlying metal extraction from such ore (smelting) is the selective oxidation of sulfide ions (S 2− ) by oxygen. The reaction 1 forms copper metal and sulfur dioxide (SO 2 ) as products, as written here for chalcocite (Cu 2 S):Such principle leads to a process characterized by large capital investments and significant environmental challenges. 1 This route requires handling SO 2 as a by-product, typically converted to sulfuric acid. To circumvent this issue, additional pyrometallurgical steps to convert SO x into elemental sulfur have been devised, using for example reduction or chlorination. Hydrometallurgy is an alternative to traditional smelting that does not involve SO 2 .3-5 It involves a succession of leaching, solvent extraction and finally electrowinning of Cu in an aqueous electrolyte. This route is also characterized by a relatively large footprint and capital cost. One of the limitations is inherited from the electrowinning/ refining steps, where the current density for copper electrodeposition is typically limited to 0.05 A.cm −2 .
6An alternative approach to avoid SO 2 formation is the direct decomposition of copper sulfide into copper and elemental sulfur, following reaction 2:At 1106• C, more than 20• C above copper melting point, reaction 2 is not spontaneous ( r G • = 90.5 kJ.mol −1 ) and would require a minimum amount of energy of 267 kJ.mol −1 (equivalent to 583 kWh.t Cu −1 ) a . 7 This reaction could therefore be driven by electricity, as practiced industrially for most metals, including copper and aluminum. In principle, electrolysis can also offer the selective recovery of multiple metals contained in the sulfides ores, for example elements more noble than copper, e.g. silver or molybdenum.The direct electrolysis of sulfides was proposed in concept by Townsend in a patent in 1906.2 Since then, the challenge remains in selecting a supporting electrolyte with an acceptable solubility for copper sulfide concentrates to guarantee large cathode current density, a requirement for tonnage production. Previous studi...