Thermogravimetry as a research tool for the development of an ammonium sulphate roasting process for selective metal extraction from minerals

Abstract

AbstractThe ammonium sulphate roasting process involves reacting mineral-bearing materials with ammonium sulphate via a solid–solid roasting process and subjecting the resulting roast residue to aqueous leaching. This process enables the simultaneous, non-selective co-extraction of strategic metals from the starting materials. However, effective separation of the extracted metals is often mandatory to produce quality products of high purity. In this study, the combined application of thermogravimetric analysis, X-ray powder diffraction and inductively coupled plasma optical emission spectrometry confirmed the non-selectivity of the process when applied to a South African diamond mine residue residue roasted with ammonium sulphate in a 1:2 mass ratio (m/m) at 450 °C for 2 h, with magnesium, iron and aluminium being co-extracted into water-soluble metal sulphates. Thermogravimetry was then applied to develop a multi-step, multi-temperature selective roasting process using mixtures of pure commercial metal sulphate salts. The first step of the modified process successfully separated iron and aluminium sulphates from magnesium-sulphates in the roast residues by thermally decomposing soluble iron and aluminium sulphates into insoluble oxides via calcination at 750 °C for 2 h. This temperature was lower than the one at which magnesium sulphates convert into magnesium oxide. In the second and final step, iron and aluminium were recovered from the oxide minerals via solid–solid re-roasting with ammonium sulphate at 450 °C for 1 h, causing the oxides to revert back to their water-soluble sulphate forms. The effectiveness of the modified process was subsequently verified using a diamond mine residue, showing that the soluble iron and aluminium contents in the magnesium-bearing leachate could be reduced by over 90%.