Journal of Environmental Chemical Engineering 1 (2013) 10851090

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Journal of Environmental Chemical Engineering

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Recovery of cobalt and copper through reprocessing of tailings from otation of

oxidised ores
Michel Shengo Lutandula a,*, Banza Maloba b
a
Chemistry Department, Faculty of the Sciences, University of Lubumbashi, Likasi road, P.O. Box 1825, City of Lubumbashi, Katanga Province, The Democratic Republic of Congo
b
Kakanda Concentrator Laboratory (KDC) Boss Mining, The CAMEC group, Kakanda, Katanga Province, The Democratic Republic of Congo

A R T I C L E I N F O A B S T R A C T

Article history: In the Katanga province of the Democratic Republic of Congo (DRC), efuents from otation of oxidised
Received 6 June 2013 ores of copper and cobalt are stored in settling ponds in view separation of tailings and the mill
Received in revised form 2 August 2013 wastewaters, which are sent in the rivers. Tailings consist of the gangue minerals accompanied by the
Accepted 17 August 2013
uncovered metals of interest. In some cases, tailings may contain copper and cobalt to concentrations
that can be economically recovered. The present research aims at recovering copper and cobalt through
Keywords: reprocessing of tailings from otation of oxidised ores of copper and cobalt achieved at the Kambove
Tailings reprocessing
Concentrator (DRC). It focuses on the determination of the reagents dosage that enables obtaining the
Flotation
highest recovery of copper (44.80%) and cobalt (88.30%) through otation of the studied tailings. Based
Metals recovery
Resources conservation on both the achievable recovery of the metals of interest and the concentrate grade (3.31% Cu and 2.22%
Environment safeguard Co), it was concluded that the reprocessing of tailings from the Kambove Concentrator through otation
appears to be an attractive practice because it could enable minimising the footprint of the mineral
processing industry on the environment. It could also contribute to the resources conservation through
the recovery of metals from the minerallurgical processes wastes.
2013 Elsevier Ltd. All rights reserved.

Introduction opportunities for by-products recovery [11]. This change in the

At present, residues from minerallurgical and metallurgical
processes are looked at as the potentially exploitable and cost-
saving raw materials since they consist of mined and comminuted
minerals where one nds the base metals of interest [15]. This
growing interest towards minerallurgical and metallurgical
wastes is due at rst instant to depletion of mineral resources
in the most industrialised countries along with the development
of up-to-date technologies enabling the beneciation of ores even
from the poorest deposits [19]. Additionally, one observes all
over the world the decreasing trend in the cut off grade in the
majority of the world-famous deposits as their mining progresses
[6]. Experts involved in the world trade of mineral resources and
metals argue that the reuse of metals along with the reprocessing
of residues from metallurgical and minerallurgical processes can
positively inuence the availability of metals and consequently,
stabilise their prices on the world market [5,8,10]. That is why
the American mining industry, which yearly was producing
7,000,000 tons of residues from processes, had already identied
* Corresponding author. Tel.: +243818422753/+243995084289/+32488860021.
E-mail addresses: shengolutandulamichel@yahoo.fr, Lutandulas@unilu.ac.cd,
M.ShengoLutandula@doct.ulg.ac.be (M.S. Lutandula).
attitude towards tailings and residues from metallurgical and
minerallurgical processes throughout the world is stimulated by
the adoption of stringent environmental regulations in the mining
sector by the majority of countries [3,7,12,13]. As the matter of
fact, when large tailings piles are improperly stored or abandoned,
they can undergo weathering and erosion through exposure to the
rainfall and winds. As a result, the surrounding areas will be
affected by the airborne particles and the release of contaminants
of water, soils, vegetation and wildlife. The abandoned tailings can
also endanger the human health with toxic metals such as lead
and cadmium [3]. Astonishingly, in the Katanga province of the
Democratic Republic of Congo until 2002, the approach was quite
different with regard to the management of wastes from
minerallurgical and metallurgical processes. As the matter of
fact, huge amounts of tailings and slags are improperly stored or
abandoned since many decades [1316]. One nds them in the
cities of Lubumbashi (8 Mt, 15% Zn), Kipushi (25 Mt, 2.73% Zn and
0.40% Cu), Kolwezi (112 Mt, 1.49% Cu and 0.32% Co), Kakanda
(18 Mt, 1.20% Cu and 0.14% Co), Kambove (36 Mt, 0.89% Cu and
0.19% Co), Shituru and Panda (13 Mt, 1.50% Cu and 0.23% Co). One
thinks that wastes from minerallurgical and metallurgical
processes are releasing pollutants that threaten the aquatic
ecosystems in the Katanga province. That is why, Kalenga et al.
[15] have focused on environmental issues related to the

2213-3437/$ see front matter 2013 Elsevier Ltd. All rights reserved.
http://dx.doi.org/10.1016/j.jece.2013.08.025
1086 M.S. Lutandula, B. Maloba / Journal of Environmental Chemical Engineering 1 (2013) 10851090

production, storage and disposal of solid wastes from the copper 2X MS ! MX2 S 2e (4)
industry in view improvement of practices in their management.
Kitobo [17] has suggested a method enabling deactivation of O2 2H2 O 4e 4OH (5)
tailings through the removal of sulphur and the recovery of copper 
As the matter of fact, xanthate ions (X ) liberated in solution
and zinc as economic by-products in view minimisation of their
by thiol collectors adsorb, via chimisorption or an electrochem-
environmental footprint. Moreover, according to the D.R. Congo
ical process, on the activated minerals surfaces in the form of
mining code published in 2002, residues from minerallurgical and
hydrophobic species (adsorbed xanthate Xads, dixanthogena X2
metallurgical processes along with wastes generated by mining
and the metal xanthate MX2). These species enable the
operations belong to a special category of mineral resources
attachment of the mineral particles to air bubbles within the
considering their contents in the economically recoverable base
agitated pulp submitted to otation [23,28]. At Kambove,
metals of interest namely copper, cobalt and zinc [16,18]. They are
potassium amylxanthate (KAX)-10%, which is a thiol, is used
assimilated to low-grade ores due to their huge amounts [6]. In the
as the primary collector (0.300.35 kg/t) to oat malachite and
Katanga province, the growing interest towards wastes from
heterogenite as the main bearing minerals of copper and cobalt
minerallurgical and metallurgical processes is noticeable through
in the ores. The otation circuit enables to produce a
the reuse of tailings from the Kulumaziba pond in view to produce
concentrate grading 1014% in copper. Built between 1963
copper and cobalt by means of the gravity separation process. The
and 1964, the Kambove Concentrator was designed to handle
change in attitude towards wastes from industrials processes is
and treat monthly 125,000 tons of oxidised ores of copper and
also materialised by the smelting of slag practiced since 2002 at
cobalt from the deposits of Kamfundwa, the South and central
the Big Hill Smelter in Lubumbashi with the aim to produce
Kamoya and Kamwale [16]. The run-of-mine ore undergoes the
copper and cobalt alloys [1921]. The present research work aims
primary and secondary crushing followed by a series of re-
at recovering copper and cobalt through otation of tailings from
crushing and screening stages to ensure that the desired degree
the beneciation of oxidised ores achieved at the Kambove
of fragmentation is attained in view liberation of the valuable
Concentrator. It is an attempt oriented towards the lowering of the
minerals from the gangue. The comminuted ore is conditioned
mineral processing industry footprint on the environment
with sodium silicate inside a rod mill working in closed circuit
through the reprocessing of tailings from the beneciation of
with hydrocyclones that deliver their overow to the talc
oxidised ores of copper and cobalt [17]. As the matter of fact, it is
removal section and afterward, to the primary roughing
expected that the reprocessing of tailings can enable minimising
otation circuit. The valuable minerals retained in tailings are
the release of pollutants to watercourses and soils. It can also give
recovered, as a low-grade copper concentrate, through repro-
a boost to the conservation of resources practices since it enables
cessing of tails from the rougher section using a otation circuit
the recovery of the metals of value from wastes generated by
comprising the secondary roughing and scavenging, cleaning
minerallurgical processes.
and re-cleaning. The obtained concentrate is returned back to
the primary rougher section. However, it is worth mentioning
Material and methods
that the Kambove Concentrator throughput is presently halved
due to aging of the facilities that require a refurbishment
Flotation process and the efuents management at the Kambove
[15,19]. Concerning the mill efuents, they were stored at the
Concentrator
Kabambakola sites before the collapse of the tailings ponds
wall, which occurred in 1992. One nds at Kabambakola about
The Kambove Concentrator uses a Hybrid otation process
36 Mt of tailings (0.89% Cu and 0.19% Co) from the Kambove
which is based on the particular reagents regime where the
Concentrator [14]. At present, efuents with low contents in
sulphidiser (3.03.5 g/t NaSH-36%) is partially replaced by a
solids (Fig. 1) liberated by the concentrate thickeners and the
mixture (0.15 kg/t) of gasoil (90%) and synthetic fatty acids
lter-press are temporarily stored in an open ditch named 617
(10%) named Rinkalore 10. This mixture plays the role of the
[16].
secondary collector and enables obtaining a concentrate
As for those loaded in solids discharged by the otation
assaying about 11% in copper. Flotation is a process to separate
machines and consisting of the pulps impoverished in minerals of
valuable minerals from the gangue based on differences in
interest, they are added to mine waters from the Musesa open pit
surface properties of the particles after milling of metallic ores
before being pumped to the mill spillway in view retention of
[22]. Oxidised minerals found in ores processed at Kambove are
tailings and clarication of the mill wastewaters that continue
hydrophilic and do not oat well using thiol collectors such as
their course until in the Kambakola River.
xanthates traditionally destined for sulphide minerals [2325].
That is why, they undergo sulphidisation by means of NaSH as
shown by the reaction (1): Tailings separation and chemical analysis
2
MOs S aq 2H aq MSs H2 O (1) Efuents of our interest were sampled at the Kambove
Sulphidisation of oxidised minerals of copper and cobalt is Concentrator discharge point (S1) as well as at two separated
achieved through the above chemical reaction that enables their points (S2 and S3) located far away along the area drain leading to
activation or the formation of a metal sulphide or elementary the mill process waters spillway (Fig. 2).
sulphur on their surfaces [23,26,27] for rendering them Tailings of our focus were recovered from efuents after their
amenable to otation using the collecting properties of thiol. settling in view to separate out the mill wastewaters. The chemical
Xanthates are made of heteropolar molecules analysis of tailings was achieved through dissolution (15 min) of a
ROCS
or X M ; where M is Na or K that re- representative sample (1 g) using a leaching liquor consisting of
2M
act with the activated minerals surfaces based on the chemical 10 mL of nitric acid (65% w/w) and 2 mL of hydrogen peroxide
reactions below: (100% w/w), dilution (1:10) and spectrophotometric measure-
ments of copper, cobalt, iron, cadmium, nickel and lead using an
X ! Sads e (2) Analytkjena AA300 device. The same analytical procedure has
enabled determining the contents in copper and cobalt in the
2X ! X2 2e (3) concentrate and the reprocessed tailings.
[(Fig._1)TD$IG] M.S. Lutandula, B. Maloba / Journal of Environmental Chemical Engineering 1 (2013) 10851090 1087

Fig. 1. Efuents management system at the Kambove Concentrator plant.

Particles size analysis
A sample (300 g) of the studied tailings was sieved using a
Retsch vibrating device (from 400 to +48 meshes). The sieved
matters were dewatered through heating at 105 8C in a Memmert
steam room, weighted using a Mettler Toledo SB 1600 analytic
balance and afterwards, spectrophotometrically assayed for
copper and cobalt.
Recovery of copper and cobalt through otation of tailings
The roughing otation of tailings was achieved at laboratory
(14 min) using a Denver D-12 mechanical machine with the
impeller speed kept at 1350 rpm (Fig. 3). The yields in copper and
cobalt were studied versus the reagents dosage. The reagents were
[(Fig._2)TD$IG]
introduced in the slurry to be oated while keeping constant (0.1)
the ratio of dosages. The individual dosages of the reagents were
varied between 0.6 and 0.7 kg/ton for the sulphidising reagent
(NaSH-36%) and 6 and 7 kg/ton for the primary collector
respectively (KAX-10%).
During the reprocessing of tailings, a mixture (0.15 kg/t)
consisting of gasoil (90%) and tall oil (10%) was utilised as the
secondary collector. The pulp to be oated (pH 8.49) was prepared
using 1 kg of tailings and tap water and the specic weight was
adjusted around 1300 g/L. The ore was conditioned with 0.25 kg/t
of sodium silicate (30%) and 0.05 kg/t of sodium carbonate (30%)
were introduced in the pulp respectively as the slimes depressor/
dispersant and pH modier. Tailings were oated using the
industrial-graded reagents as in the beneciation of oxidised ores
of copper achieved at the Kambove Concentrator.
Results and discussions

The results discussed in the present research work are related to

the chemical analysis of tailings and the size distribution of
particles. They are also related to the recovery of copper and cobalt
through froth otation of tailings.
[(Fig._3)TD$IG]
F

2 minutes
2 minutes 2 minutes 4 minutes 4 minutes
TR T
C1 C2 C3 C4

F - Feed consisting of 1,000 g of tailings

RC
T - Flotation tails (reprocessed tailings)
TR - talc removal
RC - Roughing concentrate
C1, C2, C3 and C4 - the roughing concentrate fractions

Fig. 2. Sampling of efuents from otation and recovery of tailings. Fig. 3. Flotation of tailings recovered from the Kambove Concentrators efuents.
1088 [(Fig._4)TD$IG]
M.S. Lutandula, B. Maloba / Journal of Environmental Chemical Engineering 1 (2013) 10851090

Table 1
Chemical composition of tailings from the Kambove Concentrator.

Element (%) S1 S2 S3 Average composition

Ca 1.31 1.40 1.17 1.29

Cd 0.01 0.01 0.01 0.01
Co 0.40 1.08 0.36 0.61
Cu 1.59 1.66 1.82 1.69
Fe 3.54 3.46 3.31 3.44
Mn 12.57 13.23 11.16 12.32
Ni 1.28 1.33 1.23 1.28
Pb 8.38 5.61 3.15 5.71

S1, tailings recovered from efuents sampled at the concentrator discharge point;
S2, tailings from efuents sampled in the area drain at 500 m far away; and S3,
tailings from efuents sampled in the area at 2000 m far away from. Italic variables
simply signify the contents in the metals of interest in the initial and the
reprocessed tailings.

Chemical composition of tailings submitted to otation

Fig. 4. Concentrate mass pull versus the reagents weights ratio.

The chemical composition of tailings to be reprocessed by froth

otation is given in Table 1.
It is obvious that tailings contain manganese (12.32%), lead
(5.71%) and iron (3.44%) to high concentrations. They also contain
copper (1.69%) and cobalt (0.61%), which are the metals of interest,
to concentrations comprised between 1.50% and 1.90% and 0.30%
and 1.10%, respectively. The content in cobalt enables considering
tailings as the potentially exploitable raw materials according to
the mining code of the Democratic Republic of Congo [18]. Indeed,
cobalt is present in tailings to concentrations comparable to those
found in a number of minerals deposits (0.21% Co) mined in the
Katanga province and the Zambian province of Copper belt [4].
interest (1.47% Cu and 0.85% Co). Copper (80%) and cobalt (76%) are
mainly distributed in ne solids of tailings. It is obvious that the
otation of the bearing particles of copper and cobalt will be
inuenced by their size distribution in the studied tailings. Nearly
35% tailings consist of particles with the size comprised between
400 and 68 meshes. Their contents in copper (0.60%) and cobalt
(0.47%) represent about 20% and 23% respectively of the total
amount contained in the studied tailings.
Recovery of copper and cobalt versus the reagents dosage

Particles size distribution in tailings
The size distribution of particles in the studied tailings is given
in Table 2.
As can be seen from Table 2, about 63% of particles consist of
slimes (400 meshes) with the highest contents in the metals of
Flotation of tailings was achieved while varying the reagents
dosage as show in Table 3.
The obtained results reveal that the recovery of copper and
cobalt depends on the reagents dosage (Fig. 4). Indeed, the increase
in the reagents dosage of 17% results in signicant drops in the
recovery of copper (18%) and cobalt (31%) during the roughing

Table 2
Size distribution of particles in tailings.

Size (mesh) W (g) Wp (%) CW (g) Copper Cobalt

% W (g) CW1 (g) % W (g) CW2 (g)

+48 1.76 0.59 1.76 1.24 0.02 0.02 0.71 0.01 0.01
+68 2.83 0.95 4.59 0.75 0.02 0.04 0.61 0.02 0.03
+100 5.59 1.87 10.18 0.60 0.03 0.07 0.53 0.03 0.06
+150 11.77 3.94 21.95 0.61 0.07 0.14 0.49 0.06 0.12
+200 25.74 8.62 47.69 0.54 0.14 0.28 0.44 0.11 0.23
+270 28.19 9.44 75.88 0.61 0.17 0.45 0.44 0.12 0.35
+325 14.20 4.75 90.08 0.64 0.09 0.54 0.44 0.06 0.41
+400 20.02 6.70 110.10 0.89 0.18 0.72 0.49 0.10 0.51
400 (slimes) 188.64 63.15 298.74 1.47 2.77 3.49 0.85 1.60 2.11
Total 298.74 100 1.17 3.49 0.71 2.11

W, weight in grams; Wp, proportion in percents; CW, cumulated weight in grams; CW1, cumulated weight in grams for copper; CW2, cumulated weight in grams for cobalt.

Table 3
Concentrates grades and recoveries in copper and in cobalt versus the reagents dosage.

KAX/NaSH = 0.60/6.0 KAX/NaSH = 0.65/6.5 KAX/NaSH = 0.70/7.0

Copper (%) Cobalt (%) Copper (%) Cobalt (%) Copper (%) Cobalt (%)

W G R G R W G R G R W G R G R

Tlc 45.5 1.8 4.8 0.6 4.1 51.7 1.2 3.7 0.6 4.8 42.1 1.2 2.9 0.4 2.8
C1 42.1 3.2 7.9 1.6 11.1 41.7 4.4 10.8 3.6 24.3 22.9 1.2 2.6 0.5 1.9
C2 41.4 2.7 6.5 1.5 10.2 26.2 5.2 8.1 4.3 18.5 22.3 13.5 17.6 8.3 30.4
C3 120.0 4.1 29.3 3.0 59.3 16.3 5.0 4.8 4.1 10.9 9.1 4.9 2.7 4.0 5.9
C4 25.1 0.8 1.1 0.7 2.8 14.7 3.3 2.4 2.7 6.5 22.3 2.3 3.0 3.8 13.9
RC 229.0 3.3 44 .8 2.2 83.3 98.9 4.6 26.7 3.7 60.1 76.6 5.5 24.9 4.2 52.1

W, weight in grams; G, grade of copper (cobalt) in the concentrate, R, recovery of copper (cobalt); Tlc, Talc; RC, roughing concentrate.
[(Fig._5)TD$IG] [(Fig._7)TD$IG]
M.S. Lutandula, B. Maloba / Journal of Environmental Chemical Engineering 1 (2013) 10851090 1089

240
80
Concentrate mass pull (g)

Recovery of cobalt (%)

200
60

160
40

120
20
KAX/NaSH : 0.60/6.0
80 KAX/NaSH : 0.65/6.5
KAX/NaSH : 0.70/7.0
0
0.61/6.0 0.65/6.5 0.70/7.0 0 2 4 6 8 10 12
KAX/NaSH weight's ratio Time (minutes)

Fig. 5. Selectivity of copper and cobalt versus the reagents dosage. Fig. 7. Recovery of cobalt versus time and the reagents dosage.

otation of tailings. Consequently, a concentrate grading 5.50% in Table 4

Chemical composition of the initial and the reprocessed tailings.
copper and 4.15% in cobalt is obtained.
Nearly 19% of cobalt and 61% copper are retained in tailings. The Element Initial tailings (%) Reprocessed tailings (%) Recovery (%)
drops in the recoveries of the valuable metals are related to their Ca 1.29 1.01 22.0
bearing particles size distribution in the studied matter where the Cd 0.01 0.01 0.0
majority of copper is located in slimes that do not suitably oat. As Co 0.61 0.08 87.0
the matter of fact, slimes consist in their majority of hydrophilic Cu 1.69 0.005 99.7
Fe 3.44 3.44 0.0
ultra-ne particles that are responsible for the valuable minerals
Mn 12.32 12.0 0.03
coating and the reagents overconsumption resulting in loss of the Ni 1.28 1.00 22.0
otation process performances [2,29]. However, it is worth Pb 8.38 8.04 4.0
mentioning that the highest recovery of the metals of interest
(45% Cu and 83% Co) was achieved at consumption of 0.6 kg/t KAX
and 6 kg/t NaSH. Additionally, one observes a decrease in the
concentrate mass pull as the reagent dosage augments (Fig. 5). depressing effect from the excess NaSH introduced in the pulp
Based on the reagents regime implemented at the Kambove on malachite and heterogenite, which are the bearing minerals of
Concentrator, it can be stated that the reprocessing of tailings copper and cobalt in the studied tailings [12,24,28,30].
through otation is a reagents-consuming operation. On a kinetics
standpoint, the best recovery of copper and cobalt is achieved Chemical composition of the reprocessed tailings
while using the lowest dosage of the reagents (Figs. 6 and 7)
because more copper (>40%) and cobalt (>80%) are recovered in The chemical compositions of both the starting material and the
concentrate within the rst 8 min of otation of the studied reprocessed tailings are shown in Table 4.
tailings. It is obvious that the initial tailings have been scavenged in the
Beneath or beyond the reagents dosage considered as optimum, metals of interest. As the matter of fact, about 100% of copper and
the highest recoveries of copper and cobalt do not surpass 65% and 88% cobalt were recovered in the concentrate during the roughing
30%, respectively. It is though that the loss in performances otation. Based on what precedes, it appears that the reprocessing
undergone by the otation process might result from the of tailings can be successfully done through otation because it has
[(Fig._6)TD$IG] enabled recovering the rejected values consisting of cobalt and
copper retained in tailings from otation of ores achieved at
50
Kambove Concentrator.

40 Conclusion
Recovery of copper (%)

30 Based on the obtained results, it appears that the reprocessing

of tailings of our focus can be successfully achieved through
otation. This practice can be suggested to the mining operator in
20 view the best management of tailings associated to the benecia-
tion of oxidised ores of copper and cobalt achieved at the Kambove
10 Concentrator. It could enable identifying new opportunities of
KAX/NaSH : 0.60/6.0 recovering economic by-products from otation efuents. As the
KAX/NaSH : 0.65/6.5
KAX/NaSH : 0.70/7.0
matter of fact, tailings from the dressing of copper ores achieved at
0 the Kambove are made of comminuted rocks that can be reused as
low-cost raw materials considering their contents in copper and
0 2 4 6 8 10 12 cobalt. Their reprocessing through otation can contribute to the
Time (minutes) resources conservation, to minimisation of wastes from miner-
allurgical processes and consequently, to the lowering of the
Fig. 6. Recovery of copper versus time and the reagents dosage. mineral processing industry footprint on the environment in the
1090 M.S. Lutandula, B. Maloba / Journal of Environmental Chemical Engineering 1 (2013) 10851090
areas where concentrators are operating. However, it is worth
mentioning that the reagents overconsumption related to the
particles size distribution in majority made of slimes remains
drawback of concern to the best implementation of this method on
the technical and economical standpoint. In the days to come, we
suggest to address this relevant issue. As for the secondary tailings,
they can be incorporated in building materials as cemented pastes
whereas the mill wastewaters generated by otation of tailings can
undergo reclamation and returned back to Kambove Concentrator
milling process.
Acknowledgements
We are gratefully thanking the leading staff of the Kambove
Concentrator for their collaboration to this research through their
outstanding support in the achievement of otation tests and the
assays of our samples. We are indebted to the Division of Metallurgy
at the Gecamines the city of Likasi for their technical support.
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