We report the investigation
of a chalcopyrite leaching process
that implements millimeter-sized glass beads that are stirred in the
leach reactor to combine particle grinding, mechanical activation,
and surface removal of reaction products. The paper focuses on demonstrating
the impact of the so-called attrition-leaching phenomenon on the leaching
rate of a chalcopyrite concentrate and provides a first understanding
of the underlying mechanisms. For this purpose, we have compared the
copper leaching yield for different configurations under controlled
chemical conditions (1 kg of glass beads and 84 g of chalcopyrite
concentrate in 2.5 L of H2SO4-H2O
solution, pH = 1.3, E
h = 700 mV vs SHE,
and T = 42 °C). On top of elemental analysis
of the leach solution with time, we provide a full characterization
of the solid residue based on X-ray diffraction, elemental analysis,
and sulfur speciation. We demonstrate that glass beads led to a remarkable
enhancement of the leaching rate in conditions where particles were
already passivated by simple leaching and even when large amounts
of solid products (elemental sulfur and jarosite) were present. An
in-depth evaluation of particle size distribution showed that particle
breakage occurred during a rather short time (a few hours) at the
beginning of the runs, transforming the initial particles with d
4/3 = 30 μm to finer particles with d
4/3 = 15 μm. Then, particle breakage almost
stopped, while an attrition phenomenon was evidenced, inducing the
formation of very fine particles (<1 μm) and aggregates concomitantly
with copper leaching.