METHODS FOR RAPIDLY LEACHING CHALCOPYRITE

Abstract

A method of improving leach kinetics and recovery during atmospheric or above-atmospheric leaching of a metal sulfide is disclosed. A system for practicing the aforementioned method is also disclosed. Apparatus for practicing the aforementioned method is also disclosed. A new composition of matter which is formed by the aforementioned method, and which may be utilized in the system and apparatus is further disclosed. The new composition of matter may exhibit improved leach kinetics, and may have some utility in the semi-conductor arts, including uses within photovoltaic materials.

Claims

1. A method of improving leach kinetics or metal recovery from a metal sulfide comprising an activation step wherein iron in the metal sulfide is exchanged for copper according to the equation:
Cu.sub.aFe.sub.bS.sub.c+xCu.sup.2+.fwdarw.Cu.sub.a+xFe.sub.b−(x+w)S.sub.c−w+(x+w)Fe.sup.2+ wherein “a” is substantially equal to one, “b” is substantially equal to one, “c” is substantially equal to two, and “x” is substantially equal to or less than 0.10.

2. The method according to claim 1, further comprising forming an activated metal sulfide product from the metal sulfide during the activation step.

3. The method according to claim 2, wherein the extent of conversion of the metal sulfide to the activated metal sulfide product is calculated by the ratio (x/a).

4. The method according to any one of claims 1-3, wherein the metal sulfide comprises chalcopyrite, and wherein “c” is substantially equal to two times “a” (2a) and “c” is substantially equal to two times “b” (2b).

5. The method according to any one of claims 1-4, wherein the activation step comprises a metathesis reaction wherein the molar ratio of iron released per mole of copper adsorbed is equal to or greater than one.

6. The method according to any one of claims 1-5, wherein the metal sulfide comprises chalcopyrite and the molar amount of iron released from the chalcopyrite during exchange exceeds the molar amount of copper absorbed by the chalcopyrite.

7. The method according to any one of claims 1-6, wherein the activation step comprises maintaining charge neutrality by producing an anion to balance the (“w”), amount of released iron, wherein the anion is produced by oxidizing sulfide atoms within a lattice of the metal sulfide.

8. The method according to any one of claims 1-7, wherein the activated metal sulfide product is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite.

9. The method according to any one of claims 2-8, wherein the activated product comprises an intermediate phase which is transitionary between chalcopyrite and covellite.

10. The method according to any one of claims 2-9, further comprising oxidatively leaching the activated metal sulfide product at atmospheric pressure.

11. The method according to any one of claims 2-10, further comprising oxidatively leaching the activated metal sulfide product at a pressure above atmospheric pressure.

12. A method of activating a material containing chalcopyrite, comprising the step of treating the material with copper sulfate under reducing conditions, the step of treating the material with copper sulfate under reducing conditions being operable for at least partially converting a portion of the material to a non-stoichiometric, iron-depleted copper sulfide specie according to the following reaction stoichiometry:
(CuFeS.sub.2).sub.n•3{Cu.sup.+Fe.sup.3+(S.sup.2−).sub.2}+3Cu.sup.2+=3Fe.sup.2++(CuFeS.sub.2).sub.n•2{(Cu.sup.+).sub.3(S.sub.2.sup.2−)(S.sup.•−)} wherein “n+3” is the total number of unit cells within a chalcopyrite particle, and wherein “.sup.•” denotes an electron hole.

13. The method according to claim 12, wherein treating the material with copper sulfate under reducing conditions is performed in the presence of chloride.

14. The method according to claim 12, wherein treating the material with copper sulfate under reducing conditions is performed in the absence of chloride.

15. The method according to any one of claims 12-14, wherein treating the material with copper sulfate under reducing conditions comprises a diffusion-controlled, solid-state reaction process.

16. A composition of matter formed via the method according to any of claims 1-15, comprising a non-stoichiometric, iron-depleted copper sulfide material which exhibits higher electrochemical reactivity than chalcopyrite.

17. An activated chalcopyrite product prepared by a method comprising contacting a surface of a chalcopyrite-containing particle with a cupric solution having a pH greater than about 1.8, under (a) reducing conditions, (b) temperature and (c) time, all of which are sufficient to convert at least a portion of chalcopyrite present at the surface to another copper-containing mineral phase.

18. The activated chalcopyrite product of claim 17, wherein said another copper-containing mineral phase comprises a hybrid covellite-chalcopyrite material comprising point defects and lattice strain within its crystal lattice structure.

19. The activated chalcopyrite product of claim 17 or 18, wherein said other copper-containing mineral phase comprises a non-stoichiometric, iron-depleted copper sulfide material.

20. The activated chalcopyrite product according to any one of claims 17-19, wherein said other copper-containing mineral phase is metastable.

21. The activated chalcopyrite product according to any one of claims 17-20, wherein said another copper-containing mineral phase is transitory.

22. The activated chalcopyrite product according to any one of claims 17-21, wherein said other copper-containing mineral phase is intermediate phase which is transitionary between chalcopyrite and covellite.

23. The activated chalcopyrite product according to any one of claims 17-22, wherein less than about 10.0 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase.

24. The activated chalcopyrite product of claim 23, wherein less than about 5.0 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase.

25. The activated chalcopyrite product of claim 24, wherein less than about 3.0 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase.

26. The activated chalcopyrite product of claim 25, wherein less than about 2.0 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase.

27. The activated chalcopyrite product of claim 26, wherein less than about 1.0 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said another copper-containing mineral phase.

28. The activated chalcopyrite product of claim 27, wherein less than about 0.5 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase.

29. The activated chalcopyrite product of claim 28, wherein less than about 0.1 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase.

30. The activated chalcopyrite product according to any one of claims 17-29, wherein the portion of the chalcopyrite-containing particle converted to said other copper-containing mineral phase comprises an outer nano-scale layer portion.

31. A method of activating a material containing chalcopyrite comprising the step of: treating a chalcopyrite-containing material under reducing conditions to at least partially convert a portion of the chalcopyrite-containing material to a new material according to the following reaction:
(CuFeS.sub.2).sub.n•3{Cu.sup.+Fe.sup.3+(S.sup.2−).sub.2}+3Cu.sup.2+=3Fe.sup.2++(CuFeS.sub.2).sub.n•2{(Cu.sup.+).sub.3(S.sub.2.sup.2−)(S.sup.•−)} wherein “n+3” is the total number of unit cells within a chalcopyrite particle, and wherein “.sup.•” denotes an electron hole.

32. The method of claim 31, further comprising the step of oxidatively leaching the treated chalcopyrite-containing material.

33. The method according to claim 31 or 32, wherein the treated chalcopyrite-containing material comprises a non-stoichiometric, iron-depleted copper sulfide material.

34. The method according to any one of claims 31-33, wherein the new material comprises a non-stoichiometric, iron-depleted copper sulfide material.

35. The method according to any one of claims 31-34, wherein the new material is metastable.

36. The method according to any one of claims 31-35, wherein the new material is transitory.

37. The method according to any one of claims 31-36, wherein the new material is an intermediate phase that is transitionary between chalcopyrite and covellite.

38. A metal sulfide leaching circuit comprising: (a) an activation stage configured to support a metathesis reaction wherein iron in the metal sulfide is exchanged for copper to form an activated metal sulfide material; (b) a first oxidative leach stage preceding the activation stage configured to produce heat needed for the metathesis reaction and the copper used to drive the metathesis reaction; and, (c) a second oxidative leach stage, following the activation stage, for oxidative dissolution of the activated metal sulfide material.

39. The metal sulfide leaching circuit according to claim 38, wherein the metal sulfide comprises chalcopyrite.

40. The metal sulfide leaching circuit according to claim 38 or 39, wherein a portion of the metal sulfide comprises a secondary copper bearing mineral selected from one or more of the group consisting of: covellite, chalcocite, bornite, a copper oxide, a copper carbonate, and a copper silicate.

41. The metal sulfide leaching circuit according to any one of claims 38-40, wherein less than 10 mol % of the activated metal sulfide material comprises a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite.

42. The metal sulfide leaching circuit according to claim 41, wherein less than 5 mol % of the activated metal sulfide material comprises a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite.

43. The metal sulfide leaching circuit according to claim 42, wherein less than 1 mol % of the activated metal sulfide material comprises a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite.

44. The metal sulfide leaching circuit according to claim 43, wherein less than 0.5 mol % of the activated metal sulfide material comprises a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] To complement the description which is being made, and for the purpose of aiding to better understand the features of the invention, a set of drawings illustrating a non-limiting preferred embodiment of a new composition of matter is attached to the present specification as an integral part thereof, in which the following has been depicted with an illustrative and non-limiting character.

[0012] FIG. 1 shows a TEM image of a new nano-composite composition containing species of chalcopyrite and a non-stoichiometric, iron-depleted copper sulfide. The new nano-composite composition may be formed through the reductive pretreatment of particles containing chalcopyrite. The new nano-composite composition may be leached (e.g., under oxidative conditions) or may have further applicability within the semi-conductor arts.

[0013] FIG. 2 shows the evolution of dissolved copper and iron over time during the activation of chalcopyrite. While the copper uptake is very fast, the iron release from the solids continues even after all the copper has been absorbed. Contrary to prior art teachings (wherein the exchange of iron by copper during the Cu metathesis of chalcopyrite occurs at a 1:1 molar ratio), the amount of iron released in the present invention is greater than the amount of copper absorbed. This indicates that a non-stoichiometric, iron-depleted, copper rich phase forms. Furthermore, the continued release of iron is an indication of lattice rearrangement within an activated energy state.

[0014] FIG. 3 shows a process flow diagram illustrating an aspect of the invention in which the copper for the activation reaction is generated by a first oxidative leach stage. By allowing the pH to rise above a pH of approximately 1.8, the system becomes preg-robbing with respect to dissolved Cu.sup.2+ thereby enabling the activation of any unleached CuFeS.sub.2 particles to take place during the solid/liquid separation operation. The activated CuFeS.sub.2 particles are then oxidatively leached to completion in a subsequent leach stage.

[0015] FIG. 4 is a schematic drawing illustrating the effect of particle size on the activation of chalcopyrite via Cu metathesis, wherein the x-axis represents the distance with the particle center at 0. As shown, the diffusion front may introduce lattice strain and/or point defects.

[0016] In the following, the invention will be described in more detail with reference to drawings in conjunction with exemplary embodiments.

SUMMARY OF THE INVENTION

[0017] A method of improving leach kinetics or metal recovery from a metal sulfide is disclosed. In some embodiments, the method comprises an activation step wherein iron in the metal sulfide is exchanged for copper according to the equation:

Cu.sub.aFe.sub.bS.sub.c+xCu.sup.2+.fwdarw.Cu.sub.a+xFe.sub.b−(x+w)S.sub.c−w+(x+w)Fe.sup.2+

wherein “a” is substantially equal to one, “b” is substantially equal to one, “c” is substantially equal to two, and “x” is substantially equal to or less than 0.10.

[0018] An activated metal sulfide product may be formed from the metal sulfide during the activation step. An extent of conversion of the metal sulfide to the activated metal sulfide product may be calculated by the ratio (x/a). According to some preferred embodiment, the metal sulfide comprises chalcopyrite, wherein “c” is substantially equal to two times “a” (2a) and “c” is substantially equal to two times “b” (2b). The activation step may comprise a metathesis reaction wherein the molar ratio of iron released per mole of copper adsorbed is equal to or greater than one (i.e., is not unity). In instances where the metal sulfide comprises chalcopyrite, the molar amount of iron released from the chalcopyrite (during the exchange of copper for iron) may exceed the molar amount of copper absorbed by the chalcopyrite. The activation step may comprise maintaining charge neutrality by producing an anion to balance the (“w”) amount of released iron, wherein the anion is produced by oxidizing sulfide atoms within a lattice of the metal sulfide. The activated metal sulfide product may be deficient in sulfide as well as iron, and may differ in unit cell structure from chalcopyrite and covellite. For example, the activated product may comprise an intermediate phase which is transitionary between chalcopyrite and covellite.

[0019] In some embodiments, the method may comprise oxidatively leaching the activated metal sulfide product (i.e., the activated product formed from the metal sulfide during the activation step) at atmospheric pressure. In some embodiments, oxidative leaching of the activated product may occur at a pressure above atmospheric pressure, without limitation.

[0020] Also disclosed, is a method of activating a material containing chalcopyrite, comprising the step of treating the material with copper sulfate (e.g., under reducing conditions). Preferably, the step of treating the material with copper sulfate is operable for at least partially converting a portion of the material to a non-stoichiometric, iron-depleted copper sulfide specie (i.e., a non-stoichiometric, iron-depleted copper sulfide “material”) according to the following reaction stoichiometry:

(CuFeS.sub.2).sub.n•3{Cu.sup.+Fe.sup.3+(S.sup.2−).sub.2}+3Cu.sup.2+=3Fe.sup.2++(CuFeS.sub.2).sub.n•2{(Cu.sup.+).sub.3(S.sub.2.sup.2−)(S.sup.•−)}

wherein “n+3” is the total number of unit cells within a chalcopyrite particle, and wherein “.sup.•” denotes an electron hole.

[0021] The step of treating the material containing chalcopyrite with copper sulfate (e.g., under reducing conditions) may be performed in the presence of chloride, or it may be performed in the absence of chloride, without limitation. The step of treating the material containing chalcopyrite with copper sulfate (e.g., under reducing conditions) may comprise a diffusion-controlled, solid-state reaction process.

[0022] A new composition of matter may be formed according to any of the method s described herein, including those aforementioned methods. The composition of matter may comprise a non-stoichiometric, iron-depleted copper sulfide material which exhibits higher electrochemical reactivity than chalcopyrite. An activated chalcopyrite product may be prepared by one of the methods described herein. For example, an activated chalcopyrite product may be prepared by contacting a surface of a chalcopyrite-containing particle with a cupric solution having a pH greater than about 1.8, under (a) reducing conditions, (b) temperature, and (c) time, all of which are sufficient to convert at least a portion of chalcopyrite present at the surface to another copper-containing mineral phase. For example, the pH may be greater than about 1.9, or may be greater than about 2.0, without limitation.

[0023] The other copper-containing mineral phase may comprise a hybrid covellite-chalcopyrite material comprising point defects and lattice strain within its crystal lattice structure. In some embodiments, the other copper-containing mineral phase may comprise a non-stoichiometric, iron-depleted copper sulfide material. In some embodiments, the other copper-containing mineral phase may be metastable. In some embodiments, the other copper-containing mineral phase may be transitory. In some embodiments, the other copper-containing mineral phase may be an intermediate phase which is transitionary between chalcopyrite and covellite.

[0024] Preferably, less than about 10.0 mol % of the chalcopyrite in the chalcopyrite-containing particle is converted to said other copper-containing mineral phase. For example, less than about 5.0 mol % of the chalcopyrite in the chalcopyrite-containing particle may be converted to said other copper-containing mineral phase. Alternatively, less than about 3.0 mol % of the chalcopyrite in the chalcopyrite-containing particle may be converted to said other copper-containing mineral phase. Alternatively, less than about 2.0 mol % of the chalcopyrite in the chalcopyrite-containing particle may be converted to said other copper-containing mineral phase. Alternatively, less than about 1.0 mol % of the chalcopyrite in the chalcopyrite-containing particle may be converted to said another copper-containing mineral phase. Alternatively, less than about 0.5 mol % of the chalcopyrite in the chalcopyrite-containing particle may be converted to said other copper-containing mineral phase. Alternatively, less than about 0.1 mol % of the chalcopyrite in the chalcopyrite-containing particle may be converted to said other copper-containing mineral phase. In some non-limiting embodiments, the portion of the chalcopyrite-containing particle converted to said other copper-containing mineral phase may comprise an outer nano-scale layer portion.

[0025] According to some embodiments, a method of activating a material containing chalcopyrite may comprise the step of treating a chalcopyrite-containing material under reducing conditions to at least partially convert a portion of the chalcopyrite-containing material to a new material according to the following reaction:

(CuFeS.sub.2).sub.n•3{Cu.sup.+Fe.sup.3+(S.sup.2−).sub.2}+3Cu.sup.2+=3Fe.sup.2++(CuFeS.sub.2).sub.n•2{(Cu.sup.+).sub.3(S.sub.2.sup.2)(S.sup.•−)}

wherein “n+3” is the total number of unit cells within a chalcopyrite particle, and wherein “.sup.•” denotes an electron hole. The method may further comprise the step of oxidatively leaching the treated chalcopyrite-containing material (i.e., oxidatively leaching the new material). The treated chalcopyrite-containing material may comprise a non-stoichiometric, iron-depleted copper sulfide material. For example, the new material may comprise a non-stoichiometric, iron-depleted copper sulfide material.

[0026] In some embodiments, the new material may be metastable. In some embodiments, the new material may be transitory. In some embodiments, the new material may comprise an intermediate phase that is transitionary between chalcopyrite and covellite, without limitation.

[0027] A metal sulfide leaching circuit according to the teachings disclosed herein may comprise: (a) an activation stage configured to support a metathesis reaction wherein iron in the metal sulfide is exchanged for copper to form an activated metal sulfide material; (b) a first oxidative leach stage preceding the activation stage which is configured to produce (i) the heat needed for the metathesis reaction and (ii) the copper used to drive the metathesis reaction; and, (c) a second oxidative leach stage, following the activation stage, for oxidative dissolution of the activated metal sulfide material. The metal sulfide may comprise chalcopyrite. A portion of the metal sulfide may also comprise a secondary copper bearing mineral, for example, a secondary copper bearing mineral such as covellite, chalcocite, bornite, a copper oxide, a copper carbonate, a copper silicate, or a combination thereof, without limitation.

[0028] In some preferred embodiments, less than about 10 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and may differ in unit cell structure from chalcopyrite and covellite (e.g., may differ in atomic arrangement and/or bond lengths from chalcopyrite and covellite). For example, less than 5 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite. Alternatively, less than 4 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite. Alternatively, less than 3 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite. Alternatively, less than 2 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite. Alternatively, less than 1 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite. Alternatively, less than 0.5 mol % of the activated metal sulfide material may comprise a product phase which is deficient in sulfide as well as iron, and differs in unit cell structure from chalcopyrite and covellite.

DETAILED DESCRIPTION OF THE INVENTION

[0029] The following description of the non-limiting embodiments shown in the drawings is merely exemplary in nature and is in no way intended to limit the inventions disclosed herein, their applications, or uses.

[0030] According to some embodiments, a new leach process (e.g., FLSmidth® Rapid Oxidation Leach (ROL) Process) may comprise a first aspect. The first aspect may comprise a new method for treating chalcopyrite and chalcopyrite-containing materials. Accordingly, a first aspect of the FLSmidth® Rapid Oxidation Leach (ROL) Process is discussed below.

[0031] The atmospheric leaching of chalcopyrite concentrates using acidic ferric sulfate lixiviants is well known to suffer from slow leach kinetics and poor copper recoveries. A number of alternative approaches have been proposed for improving leach kinetics and recoveries. Many of these, while effective, suffer from either high CAPEX or OPEX. As many mine sites begin transitioning from heap leaching of copper oxides to processing of primary sulfides, new cost-efficient leach processes that are compatible with existing SX/EW processes will be needed to maintain existing cathode production. One approach that appears to be highly effective at increasing copper recoveries takes advantage of the enhanced reactivity of transitory, crystal defect structures generated during particle fracture. Significant process efficiencies are gained by matching the rate of grinding to the rate of electrochemical leaching.

[0032] The FLSmidth® ROL process uses a Stirred Media Reactor (SMRt reactor) with a specific energy of approximately 20-30 kW m.sup.−3 to achieve copper recoveries of 97+% in 6 hours or less. This approach overcomes many of the surface passivation problems that have hindered other atmospheric leach processes.

[0033] According to some embodiments, a new leach process (e.g., FLSmidth® Rapid Oxidation Leach (ROL) Process) may comprise a second aspect. The second aspect may comprise a new chemical activation process. Accordingly, a second aspect of the FLSmidth® Rapid Oxidation Leach (ROL) Process is discussed below.

[0034] The majority of efforts to improve primary copper sulfide leaching have focused on solution chemistry, temperature, O.sub.2 pressure, use of catalysts, etc. Historically, very few studies have focused on the solid/solution interface. A new approach to catalyzed, sulfide leaching enables manipulation of the 2-D and 3-D semi-conductor properties of chalcopyrite. Additionally, the generation of point defects within the activated chalcopyrite particles further enhances the electrochemical dissolution rate and recovery of copper from chalcopyrite. Copper dissolution rates are still further accelerated by incorporating a Stirred Media Reactor (SMRt) into the process. By using minute amounts of Cu.sup.2+ to “pre-activate” chalcopyrite, leach times have been reduced from >20 hours with incomplete Cu dissolution to <2 hours with 98+% Cu dissolution at 75-80° C. Instead of the more typical slow and parabolic leach kinetics for chalcopyrite, pseudo-zero order leach kinetics have been observed in acidic ferric sulfate lixivants as a result of pre-activation.

[0035] The activation process takes approximately 15 to 120 minutes to complete at temperatures of 80° C. and is compatible with existing SX/EW processes. The activation time approximately doubles as the temperature is lowered from 80° C. to 70° C. The activation reaction rates are virtually non-existent at temperatures of approximately 50-60° C. and lower.

[0036] A method of improving leach kinetics and recovery during atmospheric and/or above-atmospheric leaching of a metal sulfide is disclosed. A system for improving leach kinetics and recovery during atmospheric and/or above-atmospheric leaching of a metal sulfide is also disclosed. New compositions of matter, including nano-composite compositions with enhanced electrochemical reactivity are disclosed. The new compositions may be formed via a reductive pretreatment method disclosed herein and in the aforementioned co-pending applications. The new compositions of matter may be used in systems and/or apparatus disclosed herein and in the aforementioned co-pending applications. The new compositions of matter may exhibit improved electrochemical reactivity, such as improved leach kinetics and/or improved semiconductor/electronic conductor properties, as substantially disclosed and described herein and in the aforementioned co-pending applications.

[0037] An activated chalcopyrite product is also disclosed. According to some non-limiting embodiments, the activated chalcopyrite product may be prepared by a method comprising: a metathesis reaction involving contacting a chalcopyrite-containing surface of a chalcopyrite-containing particle with a cupric solution having a pH not less than about 1.8 and not greater than about 7, under reducing conditions, at a temperature and for a period of time sufficient to convert at least a portion of chalcopyrite present at the surface to a non-stoichiometric, metastable, binary copper sulfide phase which is intermediate in composition between chalcopyrite and covellite. According to some non-limiting embodiments, the novel metathesis systems and methods disclosed herein, much less than full conversion is required, and as little as less than 5% conversion of chalcopyrite to a metastable, non-stoichiometric binary copper sulfide phase is required for favorable copper recovery during oxidative dissolution.

[0038] According to some non-limiting embodiments, the primary metal sulfide (e.g., chalcopyrite) is treated reductively to only partially convert a small amount of chalcopyrite to an activated, non-stoichiometric metal bisulfide product that is intermediate between chalcopyrite and covellite, wherein iron is exchanged by copper as illustrated by the equation:

Cu.sub.aFe.sub.bS.sub.c+xCu.sup.2+.fwdarw.Cu.sub.a+xFe.sub.b−(x+w)S.sub.c−w+(x+w)Fe.sup.2+

[0039] For chalcopyrite, c is equal to 2a and 2b. The fractional extent of conversion to the activated product is calculated as (x/a). Experimental data indicate that the molar ratio of copper sulfate to iron released is not restricted to unity, as in prior art metathesis processes. Instead, the moles of iron released from chalcopyrite can exceed the moles of copper absorbed. While not wishing to be held to any particular theory, the inventors realize that maintaining charge neutrality would require production of an anion to balance the additional iron (“w” in the equation above). This may be accomplished through oxidation of the sulfide atoms within the chalcopyrite lattice. The product phase would then be deficient in sulfide as well as iron, and would differ in both atomic arrangement and bond lengths from chalcopyrite and covellite. TEM analysis by electron diffraction measurements of the product phase, indeed, indicates the phase is intermediate between chalcopyrite and covellite.

[0040] According to some non-limiting embodiments, not more than about 4% of the chalcopyrite in the chalcopyrite-containing particle may be converted to said another mineral phase to form the activated chalcopyrite product. According to some non-limiting embodiments, not more than about 2% of the chalcopyrite in the chalcopyrite-containing particle may be converted to said another mineral phase to form the activated chalcopyrite product. According to some non-limiting embodiments, not more than about 1% of the chalcopyrite in the chalcopyrite-containing particle may be converted to said another mineral phase to form the activated chalcopyrite product. In some embodiments, the portion of the chalcopyrite-containing particle converted to an activated mineral phase may comprise an outer, nano-scale layer portion comprising a specie that is a metastable, non-stoichiometric binary copper sulfide.

[0041] According to some non-limiting embodiments, the source of the copper sulfate for carrying out the activation may be recycled raffinate, or obtained by dissolving reject copper cathodes or a combination thereof. Rejected copper cathodes that fail to meet quality specifications may be leached using sulfuric acid to produce solid copper sulfate.

[0042] According to some non-limiting embodiments, the activated chalcopyrite product, once formed, may be placed in a continuous stirred tank reactor and leached under oxidative conditions. According to some non-limiting embodiments, the activated chalcopyrite product, once formed, may be placed in a continuous stirred tank reactor coupled to with a stirred media reactor.

[0043] A method of activating a material containing chalcopyrite through a diffusion-controlled, solid-state reaction process, so as to create a new composition having greater electrochemical reactivity, is further disclosed. The method may comprise the step of: in a first stage, treating a chalcopyrite-containing material with copper sulfate under reducing conditions, either in the presence or absence of chloride to at least partially convert a portion of the chalcopyrite-containing material to a non-stoichiometric, iron depleted copper sulfide specie according to the following reaction stoichiometry:

(CuFeS.sub.2).sub.n•3{Cu.sup.+Fe.sup.3+(S.sup.2−).sub.2}+3Cu.sup.2+=3Fe.sup.2++(CuFeS.sub.2).sub.n•2{(Cu.sup.+).sub.3(S.sub.2.sup.2−)(S.sup.•−)}

[0044] The copper sulfate used in the activation of chalcopyrite may be recycled raffinate, dissolved copper derived from reject copper cathodes or a combination thereof. According to some non-limiting embodiments, the method may further comprise the step of oxidatively leaching the new composition, for example, in a second stage. Alternatively, the copper for the activation may be produced in situ during a first oxidative leach stage, which is followed by an activation stage (in which a metathesis reaction takes place), and then ultimately followed by a second final oxidative leach stage after the activation stage. This approach has the advantage of using the heat generated during the oxidative leaching in the first oxidative leach stage to drive the following activation stage, prior to the second final oxidative leach stage. This approach is enabled by controlling the pH and Eh of the intermediate slurry as illustrated in FIG. 3. Some non-limiting, non-exhaustive advantages of the embodiment shown in FIG. 3 may include: (1) a minimal need for separately heating components involved in the activation step, (2) copper required for activation may be provided directly from the leach, (3) leaching may be performed with lower initial acid, thereby reducing acid costs, and/or (4) means for transferring ferric ion to a second stage leach by precipitation on the solids is provided. According to some non-limiting embodiments, the new composition made by the aforementioned method and stoichiometry may exhibit impressive leach kinetics and may have utility within the semi-conductor arts, for example, within photovoltaic materials.

[0045] It should be known that the particular features, processes, and benefits which are shown and described herein in detail are purely exemplary in nature and should not limit the scope of the invention. For example, the specific gravity of grinding media may vary, and the rate of attrition grinding within a stirred media reactor device according to certain embodiments of the invention disclosed may be controlled, so as to match chemical reaction rates and control redox potentials to obtain pseudo zero-order leach kinetics.

[0046] Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. Accordingly, it is to be understood that the descriptions herein are proffered by way of example to facilitate comprehension of the invention and should not be construed to limit the scope thereof.