Copper sulfides agglomeration using a novel lab-scale granulator: Integrated evaluation of bonding, leaching and mechanical behavior

The ore agglomerations could ameliorate intra-particle pore network, homogenize flow paths, and improve leaching efficiency of heap leaching. This paper innovatively develops a novel ore granulator with adjustable inclined angle and rolling speed. To comprehensively evaluate granulation procedure, the effects of physical (crushed feeds particle size distribution, rolling speed, inclined angle), chemical (binder type, curing time) and biological factors (bacterial concentration) on bonding performance of crushed feeds are analyzed. The objective of this paper is to obtain the optimal granulation conditions by studying the influence of various factors on the bonding ability, strength, and stability of granulated ores, in order to improve the pore structure of the heap leaching system, and increase the leaching rate of the ore. The results show that well-shaped agglomeration (WAs) does improve minerals leaching efficiency, and the uniaxial compressive strength of WAs is positively related to curing time, binder concentration, inclined angle, and rolling speed. The excessive lower or higher rolling speed is not suitable to get a higher extraction rate due to undesirable disintegration or compaction. The higher concentration (0.5–10 %) sulfuric acid solution could obviously increase WAs strength from 32.6 KPa to 48.3 KPa. The organic binders such as polyacrylamide are benefit for powders bonding and increase the compressive strength, but does not good for the desirable leaching reaction rate. The bacterial pre-adding has no significant positive influence on bonding and leaching efficiency. Relied on the 3D response surface, the preferred preparing condition is: 78.9 rpm rolling speed, 30° inclined angle, 7-days curing time and 9.3 % H 2 SO 4 solution. Future studies should focus on exploring the intrinsic correlation between the various factors and evaluating the granulating and leaching effects from the perspective of chemical detection and leaching bacteria. • A novel lab-scale ore granulator with adjustable inclined angle (0–30°) and rolling speed (30–150 rpm) is firstly developed. • Influence of physical, chemical, biological issues of copper sulfides agglomeration is revealed; • Powder bonding, leaching and structural feature of well-shaped agglomeration (WAs) is evaluated. • Multi-factor 3D response features of WAs preparation is carefully discussed.