The sulfide ore looping oxidation process: An alternative to current roasting and smelting practice

This novel method utilizes the reactions of metal sulfides and metal oxides. It is applicable to single-metal systems such as Mo, Cu, Co, Ni, Fe, and Zn individual sulfides and to mixed sulfides such as chalcopyrite and Mo/Fe. In addition to primary ores, waste stream products such as spent catalysts can be effectively processed. The benchmark work done on MoS2/MoO3 resulted in an MoO2 product with less than 0.095 wt.% sulfur. Other sulfide concentrate materials showed similar results. In the first stage of the looping process, a highly concentrated SO2 off-gas stream is produced that could be directed to an acid plant or converted to liquid. The products from the first process step can be directed down line for further processing or can be used as is. In the second step of looping oxidation, the product is oxidized back to its fully oxidized state and is mainly looped back to drive the oxidation process in the first reaction. There are also several opportunities for energy recovery and conversion, making looping oxidation an energy-efficient process.