PROCESS FOR RECOVERING METALS BY REDUCTION AND CARBONYLATION

- CVMR CORPORATION

A process for treating a feed material composition includes a solid particulate precious metal material-rich feed material composition fraction and a solid particulate rare earth metal material-rich feed material composition fraction, in which the solid particulate precious metal material-rich feed material composition fraction includes one or more precious metals, and in which the solid particulate rare earth metal material-rich feed material composition fraction includes one or more rare earth metals. The process includes contacting the solid particulate feed material composition with a reducing agent within a reducing agent contacting zone to effect production of a reaction intermediate solid particulate material composition.

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Description
RELATED APPLICATIONS

This application claims priority to U.S. Provisional Patent Application Ser. No. 61/514,286 filed on Aug. 2, 2011.

FIELD

The subject matter relates to processes for recovering precious metals or rare earth metals, or both.

BACKGROUND

Precious metals and rare earth metals are, currently, difficult to recover from materials, such as ore deposits, when present in low mass concentrations.

SUMMARY

In one aspect, there is provided a process for treating a feed material composition. The process includes contacting the feed material composition with a reducing agent in a reducing agent zone to effect production of a reaction intermediate material composition, wherein the feed material composition is configured to be separated into a target metal material-rich feed material composition separation fraction and one or more target metal material-lean feed material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich feed material composition separation fraction would become separated from the one or more target metal material-lean feed composition separation fractions, and such that one or more separations would be effected and each one of the one or more separations would be defined by the separation of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions would be, at least partially, based on a difference between a value of a separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction, and such that one or more feed material composition separation fraction pairs would be defined, wherein, for each one of the one or more feed material composition separation fraction pairs, a one of the pair would be defined by the target metal material-rich feed material composition separation fraction and the other one of the pair would be defined by a one of the one or more target metal material-lean feed material composition separation fractions, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of the target metal material of the target metal material-rich feed material composition separation fraction, and, also, for each one of the one or more feed material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction would be less than a maximum operative difference. The reaction intermediate material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a post-carbonylation material composition, wherein the post-carbonylation material composition is configured to be separated into a target metal material-rich post-carbonylation material composition separation fraction and one or more target metal material-lean post-carbonylation material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich post-carbonylation material composition separation fraction would become separated from the one or more target metal material-lean post-carbonylation material composition separation fractions, and such that one or more separations would become effected and each one of the one or more separations would be defined by the separation of the target metal material-rich post-carbonylation material composition separation fraction from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich post-carbonylation material composition separation fraction from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions would be, at least partially, based on a difference between a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction and a value of the separation agent-responsive characteristic of target metal material-lean post-carbonylation material composition separation fraction, and such that one or more post-carbonylation material composition separation fraction pairs would be defined, wherein, for each one of the one or more post-carbonylation material composition separation fraction pairs, a one of the pair would be defined by the target metal material-rich post-carbonylation material composition separation fraction and the other one of the pair would be defined by a one of the one or more target metal material-lean post-carbonylation material composition separation fractions, and, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction, and, also, for each one of the one or more post-carbonylation material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction would be greater than or equal to the maximum operative difference. The target metal material is defined by either one of: (i) one or more precious metals, or (ii) one or more rare earth metals.

In another aspect, there is provided another process for treating a feed material composition including a solid particulate precious metal material-rich feed material composition fraction and a solid particulate rare earth metal material-rich feed material composition fraction, wherein the solid particulate precious metal material-rich feed material composition fraction includes one or more precious metals, and wherein the solid particulate rare earth metal material-rich feed material composition fraction includes one or more rare earth metals. The process includes contacting the solid particulate feed material composition with a reducing agent within a reducing agent contacting zone to effect production of a reaction intermediate solid particulate material composition. The reaction intermediate solid particulate material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a solid particulate post-carbonylation material composition.

In another aspect, there is provided a process for treating a solid particulate feed material composition. The process includes contacting the solid particulate feed material composition with a reducing agent in a reducing agent contacting zone to effect production of a reaction intermediate solid particulate feed material composition, wherein the solid particulate feed material composition is derived from laterite ore. The reaction intermediate solid particulate feed material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a solid particulate post-carbonylation material composition.

In yet another aspect, there is provided a process for treating material derived from a sulphide ore. The process includes contacting a sulphide ore-derived pre-cursor material with an oxidizing agent to effect production of a sulphide ore-derived solid particulate feed material composition. The sulphide ore-derived solid particulate feed material composition is contacted with a reducing agent in a reducing agent contacting zone to effect production of a reaction intermediate solid particulate feed material composition. The reaction intermediate solid particulate feed material composition is contacted with carbon monoxide within a carbonylation zone so as to effect production of a solid particulate post-carbonylation material composition.

BRIEF DESCRIPTION OF DRAWINGS

The preferred embodiments of the process will now be described with reference to the following accompanying drawings, in which:

FIG. 1 is a flowsheet illustrating an embodiment of the process; and

FIG. 2 is another flowsheet illustrating another embodiment of the process.

 DETAILED DESCRIPTION

A process for treating a feed material composition 22 is provided so as to facilitate separation of target metal material from the feed material composition 22. The target metal material is defined by either one of (i) one or more precious metals, or (ii) one or more rare earth metals. The feed material composition is a solid material composition.

In some embodiments, for example, the precious metal is any one of platinum(Pt), palladium(Pd), iridium(Ir), rhodium(Rh), ruthenium(Ru), osmium (Os), gold (Au), rhenium (Re), and silver (Ag).

In some embodiments, for example, the rare earth metal is any one of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), and lutetium (Lu).

First Aspect

Referring to FIGS. 1 and 2, the feed material composition 22 is contacted with a reducing agent within a reducing agent contacting zone 20 to effect production of a reaction intermediate material composition 30. In some embodiments, for example, suitable reducing agents include gaseous diatomic hydrogen and carbon monoxide. In some embodiments, for example, the reducing agent contacting zone 20 is disposed at a temperature of between 550 degrees Celsius and 850 degrees Celsius, and at a pressure of between one (1) and 12 bars. In some of these embodiments, for example, the reducing agent contacting zone 20 is disposed at a temperature of about 650 degrees Celsius.

The feed material composition 22 is configured to be separated into a target metal material-rich feed material composition separation fraction and one or more target metal material-lean feed material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich feed material composition separation fraction would become separated from the one or more target metal material-lean feed composition separation fractions, and such that one or more separations would be effected and each one of the one or more separations would be defined by the separation of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions would be, at least partially, based on a difference between a value of a separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction, and such that one or more feed material composition separation fraction pairs would be defined, wherein, for each one of the one or more feed material composition separation fraction pairs, a one of the pair would be defined by the target metal material-rich feed material composition separation fraction and the other one of the pair would be defined by a one of the one or more target metal material-lean feed material composition separation fractions. For each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of the target metal material of the target metal material-rich feed material composition separation fraction. Also for each one of the one or more feed material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction would be less than a maximum operative difference. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction would be greater than the value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction would be less than the value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction.

The separation agent is any material input, any energy input, or any combination thereof. In some embodiments, for example, the separation agent is an energy input effected by a gravitational force. In some embodiments, for example, the separation agent is an energy input effected by a magnetic force.

The separation agent-responsive characteristic is a characteristic or quality of a material. A separation agent is said to be associated with a separation agent-responsive characteristic when application of the separation agent to the material, having material fractions with distinct separation agent-responsive characteristic, effects a response, whereby the material fractions respond differently to the energy input such that separation of the material fractions, from one another, is effected.

In some embodiments, for example, the separation agent is an energy input effected by gravitational force, and the separation agent-responsive characteristic is density.

In some embodiments, for example, the separation agent is an energy input effected by magnetic force, and the separation agent-responsive characteristic is magnetic field.

In some embodiments, for example, the contacting with the reducing agent effects reduction of iron and nickel of the feed material composition 22. In some of these embodiments, the contacting with the reducing agent effects reduction of iron of an iron oxide of the feed material composition 22. In some of these embodiments, the contacting with the reducing agent effects reduction of nickel of a nickel oxide of the feed material composition 22.

In some embodiments, for example, the feed material composition 22 is derived from an ore. In some of these embodiments, for example, the ore is laterite 16. In some embodiments, for example, the ore is dried and subjected to size reduction (for example, by milling) prior to being subjected to the contacting with the reducing agent.

The following are exemplary reactions which occur in the reducing agent contacting zone 20, when the feed material composition 22 is derived from laterite which has been dried and subjected to size reduction:


Fe2O3+3H2→2Fe+3H2O


NiO+H2→Ni+H2O


CoO+H2→CO+H2O


CuO+H2→Cu+H2O

In some embodiments, for example, prior to being supplied as a carbonylation supply material composition 104 (see below), after the contacting with the reducing agent, the reaction intermediate material composition 30 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the reaction intermediate material composition 30 to copper sulphide. Excessive copper within the carbonylation supply material composition 104 to the carbonylation zone 112 may, in some embodiments, interfere with carbonylation.

In some embodiments, for example, and specifically referring to FIG. 2, the feed material composition 22 includes treated pre-cursor solid metal sulphide-comprising material 14 produced by contacting of a pre-cursor solid metal sulphide-comprising material 12, such as a size-reduced sulphide ore, with an oxidizing agent within an oxidizing agent contacting zone 10. In this respect, in some embodiments, for example, the process further includes contacting of a pre-cursor solid metal sulphide-comprising material 12 with an oxidizing agent within an oxidizing agent contacting zone 10 to effect production of a treated pre-cursor solid metal sulphide-comprising material 14, wherein the solid particulate feed material composition 22 includes the treated pre-cursor solid metal sulphide material 14. In some embodiments, for example, the oxidizing agent contacting zone 10 is disposed at a temperature of between 850 degrees Celsius and 1400 degrees Celsius (such as between 1000 degrees Celsius and 1100 degrees Celsius) and at a pressure of between one (1) and two (2) bars (such as atmospheric pressure).

The process 100, 102 further includes contacting the carbonylation supply material composition 104 with carbon monoxide in a carbonylation zone 110 so as to effect production of a post-carbonylation material composition 112. In some embodiments, for example, the carbonylation supply material composition 104 is in the form of a solid particulate, and at least 90 weight % of the solid particulate carbonylation material composition has a particle size of less than one (1) millimetre measured using a Fisher Sub-Sieve Sizer (FSSS). Generally, in some embodiments, for example, the solid particulate carbonylation material composition has a particle size of about 50 microns measured using a Fisher Sub-Sieve Sizer (FSSS).

The post-carbonylation material composition 112 is configured to be separated into a target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) and one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122), in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) would become separated from the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122), and such that one or more separations would become effected and each one of the one or more separations would be defined by the separation of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122), wherein each one of the one or more separations of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122) would be, at least partially, based on a difference between a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) and a value of the separation agent-responsive characteristic of target metal material-lean post-carbonylation material composition separation fraction 124 (or 122), and such that one or more post-carbonylation material composition separation fraction pairs would be defined, wherein, for each one of the one or more post-carbonylation material composition separation fraction pairs, a one of the pair would be defined by the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) and the other one of the pair would be defined by a one of the one or more target metal material-lean post-carbonylation material composition separation fraction 124 (or 122). For each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122) would be less than the mass concentration of the target metal material of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124). Also for each one of the one or more post-carbonylation material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122) and a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) would be greater than or equal to the maximum operative difference. In some embodiments, for example, for each one of the one or more post-carbonylation material composition separation fraction pairs, the value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122) would be greater than the value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124). In some embodiments, for example, for each one of the one or more post-carbonylation material composition separation fraction pairs, the value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction 124 (or 122) would be less than the value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124).

In some embodiments, for example, the carbonylation zone is disposed at a pressure of between 5 bar and 60 bar, and at a temperature of between 80 degrees Celsius and 120 degrees Celsius.

Exemplary reactions within the carbonylation zone include the following:


Fe+5CO→Fe(CO)5


Ni+4CO→Ni(CO)4

In some embodiments, for example, the contacting of the carbonylation supply material composition 104 with the carbon monoxide effects liberation of carbon monoxide-reactive metal material from the carbonylation supply material composition 104. The carbon monoxide-reactive metal material is defined by one or more carbon monoxide-reactive metals. In some of these embodiments, for example, the carbon monoxide-reactive metal material is at least one of nickel, iron, and cobalt. In some of these embodiments, for example, the contacting with the carbon monoxide further effects production of a metal-comprising gaseous material including carbon monoxide-reactive metal material whose liberation from the carbonylation supply material composition is effected by the contacting. In some of these embodiments, for example, the metal-comprising gaseous material includes at least one metal carbonyl. In some of these embodiments, for example, the metal-comprising gaseous material includes any one of, or any combination of nickel carbonyl, iron carbonyl, and cobalt carbonyl.

In some embodiments, for example, the metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 132 and a nickel carbonyl-rich fraction 134 from the metal-comprising gaseous material, such that the iron carbonyl-rich fraction 132 and the nickel carbonyl-rich fraction 134 become separated. In some embodiments, for example, each one of the iron carbonyl-rich fraction 132 and the nickel carbonyl-rich fraction 142 is supplied to a respective decomposition zone 140, 142 so as to effect its respective decomposition into a substantially pure form of the respective metal (ie. iron carbonyl of the iron carbonyl-rich fraction 132 is decomposed within the decomposition zone 132 so as to produce iron, and nickel carbonyl of the nickel carbonyl-rich fraction 142 is decomposed within the decomposition zone 142 so as to produce nickel). In some embodiments, for example, each of the decomposition zones is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions. Exemplary reactions within the decomposition zones 140, 142 include the following:


Fe(CO)5→Fe+5CO


Ni(CO)4→Ni+4CO

In some embodiments, for example, the target metal material, of the target metal material-rich post-carbonylation material composition separation fraction, is one or more precious metals, such that the target metal material-rich post-carbonylation material composition separation fraction would be a precious metal material-rich post-carbonylation material composition separation fraction 122 including the one or more precious metals. In this respect, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of the one or more precious metals of the target metal material-lean post-carbonylation material composition separation fraction 124 would be less than the mass concentration of the one or more precious metals of the precious metal material-rich post-carbonylation material composition separation fraction 122. In some of these embodiments, for example, the one or more target metal material-lean post-carbonylation material composition separation fractions 124 is a rare earth metal material-rich post-carbonylation material composition separation fraction 124 including one or more rare earth metals. The mass concentration of the one or more rare earth rare earth metals of the rare earth metal material-rich post-carbonylation material composition separation fraction 124 would be greater than the mass concentration of the one or more rare earth metals of the precious metal material-rich post-carbonylation material composition separation fraction 122.

In some embodiments, for example, the target metal material, of the target metal material-rich post-carbonylation material composition separation fraction, is one or more rare earth metals, such that the target metal material-rich post-carbonylation material composition separation fraction would be a rare earth metal material-rich post-carbonylation material composition separation fraction 124 including the one or more rare earth metals. In this respect, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the target metal material-lean post-carbonylation material composition separation fraction 122 would be less than the mass concentration of the one or more rare earth metals of the target metal material-rich post-carbonylation material composition separation fraction 124. In some of these embodiments, for example, the one or more target metal material-lean post-carbonylation material composition separation fractions 122 is a precious metal material-rich post-carbonylation material composition separation fraction 122 including one or more precious metals. The mass concentration of the one or more precious metals of the precious metal material-rich post-carbonylation material composition separation fraction 122 would be greater than the mass concentration of the one or more precious metals of the rare earth metal material-rich post-carbonylation material composition separation fraction 124.

In some embodiments, for example, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction by at least 25%. In some embodiments, for example, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction by at least 50%. In some embodiments, for example, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction by at least 75%.

Also, in some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich feed material composition separation fraction by at least 25%. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich feed material composition separation fraction by at least 50%. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich feed material composition separation fraction by at least 75%.

In some embodiments, for example, the one or more target metal material-lean post-carbonylation material composition separation fractions 124 (or 122), from which the target metal material-rich post-carbonylation material composition separation fraction 122 (or 124) is separable, define the remainder of the post-carbonylation material composition 112. Also, in some embodiments, for example, the one or more target metal-lean feed material composition separation fractions, from which the target metal-rich feed material composition separation fraction becomes separated upon separation of the target metal-rich feed material composition separation fraction from the feed material composition 22, define the remainder of the feed material composition 22.

In some embodiments, for example, the feed material composition 22 is defined by solid particulate material, such that the feed material composition 22 is a solid particulate feed material composition 22, and such that the target metal material-rich feed material composition separation fraction, which is separable from the solid particulate feed material composition 22, is defined by solid particulate material, such that the target metal material-rich feed material composition separation fraction is a solid particulate target metal material-rich feed material composition separation fraction. Additionally, by virtue of the feed material composition 22 being defined by the solid particulate material, each one of the one or more target metal material-lean feed material composition separation fractions is defined by solid particulate material, such that each one of the one or more target metal material-lean feed material composition separation fractions is a solid particulate target metal material-lean feed material composition separation fraction. For each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the solid particulate target metal material-rich feed material composition separation fraction.

In some embodiments, for example, the solid particulate target metal material-rich feed material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either the same or less, and the one or more solid particulate target metal material-lean feed material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration, of the target metal material, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be greater than the maximum mass concentration, of the target metal material, of the maximum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions.

In some of these embodiments, for example, at least 90 weight % of the solid particulate feed material composition material 104 has a particle size of less than one (1) millimetre measured using a Fisher Sub-Sieve Sizer (FSSS). Generally, in some embodiments, for example, the solid particulate feed material composition has a particle size of about 50 microns measured using a Fisher Sub-Sieve Sizer (FSSS).

In some embodiments, for example, the post-carbonylation material composition 120 is defined by solid particulate material, such that the post-carbonylation material composition 120 is a solid particulate post-carbonylation material composition 120, and such that the target metal material-rich post-carbonylation material composition separation fraction, which is separable from the solid particulate post-carbonylation material composition 22, is defined by solid particulate material, such that the target metal material-rich post-carbonylation material composition separation fraction is a solid particulate target metal material-rich post-carbonylation material composition separation fraction. Additionally, by virtue of the post-carbonylation material composition 22 being defined by the solid particulate material, each one of the one or more target metal material-lean post-carbonylation material composition separation fractions is defined by solid particulate material, such that each one of the one or more target metal material-lean feed material composition separation fractions is a solid particulate target metal material-lean post-carbonylation material composition separation fraction. For each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the solid particulate target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the solid particulate target metal material-rich post-carbonylation material composition separation fraction.

In some embodiments, for example, the solid particulate target metal material-rich post-carbonylation material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the solid particulate target metal material-rich post-carbonylation material composition separation fraction, would be either the same or less, and the one or more solid particulate target metal material-lean post-carbonylation material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the target metal material, which, relative to the respective mass concentration, of the target metal material, of every other fraction of the one or more solid particulate target metal material-lean post-carbonylation material composition separation fractions, would be either greater or the same, and, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mimimum mass concentration, of the target metal material, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich post-carbonylation material composition separation fraction, would be greater than the maximum mass concentration, of the target metal material, of the maximum mass concentration-defining fraction of the one or more solid particulate target metal material-lean post-carbonylation material composition separation fractions.

In some of these embodiments, for example, at least 90 weight % of the solid particulate post-carbonylation material composition 120 has a particle size of less than one (1) millimetre, measured using a Fisher Sub-Sieve Sizer (FSSS). Generally, in some embodiments, for example, the solid particulate post-carbonylation material composition 120 has a particle size of about 50 microns, measured using a Fisher Sub-Sieve Sizer (FSSS).

In some embodiments, for example, the target metal material is defined by one or more precious metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction. In some embodiments, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate target metal material-rich feed material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either the same or less, and the one or more solid particulate target metal material-lean feed material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions.

In some embodiments, for example, when the target metal material is defined by one or more precious metals, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction. In some embodiments, for example, when the target metal material is defined by one or more precious metals, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fractions, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.

In some embodiments, for example, when the target metal material is defined by one or more precious metals, each one of the one or more target metal material-lean feed material composition separation fractions is a rare earth metal material-rich feed material composition separation fraction including one or more rare earth metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the one or more solid particulate target metal material-lean feed material composition separation fractions would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and the solid particulate target metal material-rich feed material composition separation fraction would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, is greater than the maximum mass concentration of the one or more rare earth metals of the maximum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction.

In some embodiments, for example, the target metal material is defined by one or more rare earth metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction. In some embodiments, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate target metal material-rich feed material composition separation fraction would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either the same or less, and the one or more solid particulate target metal material-lean feed material composition separation fractions would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions.

In some embodiments, for example, when the target metal material is defined by one or more rare earth metals, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction. In some embodiments, for example, when the target metal material is defined by one or more rare earth metals, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fractions, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.

In some embodiments, for example, when the target metal material is defined by one or more rare earth metals, each one of the one or more target metal material-lean feed material composition separation fractions would be a precious metal material-rich feed material composition separation fraction including one or more precious metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction. In some embodiments, for example, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the one or more solid particulate target metal material-lean feed material composition separation fractions would include a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, would be either greater or the same, and the solid particulate target metal material-rich feed material composition separation fraction would include a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate target metal material-rich feed material composition separation fraction, would be either greater or the same, and, for each one of the one or more feed material composition separation fraction pairs, the minimum mass concentration of the one or more precious metals, of the minimum mass concentration-defining fraction of the one or more solid particulate target metal material-lean feed material composition separation fractions, is greater than the maximum mass concentration of the one or more precious metals of the maximum mass concentration-defining fraction of the solid particulate target metal material-rich feed material composition separation fraction.

In some embodiments, for example, one of: (i) a solid particulate target metal material-rich feed material composition fraction of the solid particulate feed material composition 22, and (ii) a solid particulate target metal material-lean feed material composition fraction of the solid particulate feed material composition 22, is defined by a solid particulate rare earth metal material-rich feed material composition fraction including one or more rare earth metals, and the other one of (i) the solid particulate target metal material-rich feed material composition fraction, and (ii) the solid particulate target metal material-lean feed material composition fraction is defined by a solid particulate precious metal material-rich feed material composition fraction including one or more precious metals.

The mass concentration of the one or more precious metals of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich feed material composition fraction. In some embodiments, for example, the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%. In some embodiments, for example, the solid particulate precious metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich feed material composition fraction, is either the same or less, and the solid particulate rare earth material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich feed material composition fraction, is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition fraction.

The mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich feed material composition fraction. In some embodiments, for example, the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more rare earth metals, within the solid particulate precious metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%. In some embodiments, for example, the solid particulate rare earth metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either the same or less, and the solid particulate precious metal material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich feed material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid particulate precious metal material-rich feed material composition fraction.

In some of these embodiments, for example, the mass concentration of an operative metal material fraction of the solid particulate precious metal-rich feed material composition fraction is greater than the mass concentration of the operative metal material fraction of the solid particulate rare earth metal-rich feed material composition fraction. The operative metal material fraction is defined by copper (Cu), cobalt (Co), nickel (Ni), iron (Fe) and precious metals. In some of these embodiments, the mass concentration, of the operative metal material fraction, of the solid particulate precious metal-rich feed material composition fraction is greater than the mass concentration, of the operative metal material fraction, of the solid particulate rare earth metal-rich feed material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.

In some of these embodiments, for example, the solid particulate precious metal-rich feed material composition fraction includes: (i) at least 1×10−6 weight % of one or more precious metals, based on the total weight of the precious metal-rich feed material composition fraction, (ii) at least 50 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the precious metal-rich feed material composition fraction, (iii) less than weight 1×10−6% of one or more rare earth metals, based on the total weight of the precious metal-rich feed material composition fraction, (iv) less than 40 weight % of one or more operative oxides, based on the total weight of the precious metal-rich feed material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), and the solid particulate rare earth metal-rich feed material composition fraction includes: (i) at least 1×10−6 weight % of one or more rare earth metals, based on the total weight of the rare earth metal-rich feed material composition fraction, (ii) at least 20 weight % of one or more operative oxides, based on the total weight of the rare earth metal-rich feed material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), (iii) less than 1×10−7 weight % of one or more precious metals, based on the total weight of the rare earth metal-rich feed material composition fraction, and (iv) less than 70 weight % of one or more operative metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the rare earth metal-rich feed material composition fraction.

In some of these embodiments, for example, the reaction intermediate material composition 30 is defined by a solid particulate precious metal material-rich reaction intermediate material composition fraction and a solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

The mass concentration of the one or more precious metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction. In some embodiments, the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction, is either the same or less, and the solid particulate rare earth material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction, is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

The mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction. In some embodiments, the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more rare earth metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either the same or less, and the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich reaction intermediate material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction.

In some embodiments, for example, the mass concentration of non-oxygen bonded metal material of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of non-oxygen bonded metal material of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction. Non-oxygen bonded metal material is defined by any metal that is not chemically bonded to an oxygen atom.

In some embodiments, for example, the mass concentration of oxygen of the solid particulate precious metal material-rich reaction intermediate material composition fraction is less than the mass concentration of oxygen of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

In some embodiments, for example, the solid particulate precious metal material-rich reaction intermediate material composition fraction includes: (i) at least 1×10−6 weight % of one or more precious metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (ii) at least 15 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iii) less than 1×10−6 weight % of one or more rare earth metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iv) less than 15 weight % of one or more operative oxides, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), and the solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes: (i) at least 3×10−6 weight % of one or more rare earth metals, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, (ii) at least 70 weight % of one or more operative oxides, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), (iii) less than 1×10−7 weight % of one or more precious metals, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, and (iv) less than 15 weight % of one or more operative metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

In some embodiments, for example, the process further includes separating the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions.

In some embodiments, for example, the separation agent-responsive characteristic is density, and the separating of the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions, is effected by gravity separation.

In some embodiments, for example, the separation agent-responsive characteristic is magnetic field, and the separating of the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions, is effected by magnetic separation.

In some embodiments, for example, the separation agent-responsive characteristic is density, and the separating of the target metal material-rich post-carbonylation material composition separation fraction from the one or more target metal material-lean post-carbonylation material composition separation fractions, is effected by flotation.

In some embodiments, for example, one of (i) a solid particulate target metal material-rich post-carbonylation material separation fraction, and (ii) a solid particulate target metal material-lean post-carbonylation material separation fraction is defined by a rare earth metal material-rich material composition 124 including one or more rare earth metals, and the other one of (i) the solid particulate target metal material-rich post-carbonylation material separation fraction, and (ii) the solid particulate target metal material-lean post-carbonylation material separation fraction is defined by a precious metal material-rich material composition 122 including one or more precious metals.

The mass concentration of the one or more precious metals of the precious metal material-rich material composition 122 is greater than the mass concentration of the one or more precious metals of the rare earth metal-rich material composition 124. In some embodiments, the mass concentration, of the one or more precious metals, of the precious metal material-rich material composition 122 is greater than the mass concentration, of the one or more precious metals, of the rare earth metal material-rich material composition 124, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the precious metal material-rich material composition 122 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the precious metal material-rich material composition 122, is either the same or less, and the rare earth material-rich material composition 124 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the rare earth metal material-rich material composition 124, is either greater or the same, and the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the precious metal material-rich material composition 122, is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the rare earth metal material-rich material composition 124.

The mass concentration of the one or more rare earth metals of the rare earth metal material-rich material composition 124 is greater than the mass concentration of the one or more rare earth metals of the precious metal material-rich material composition 122. In some embodiments, the mass concentration, of the one or more rare earth metals, of the rare earth metal material-rich material composition 124 is greater than the mass concentration, of the one or more rare earth metals, of the precious metal material-rich material composition 122, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the rare earth metal material-rich material composition 124 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the rare earth metal material-rich material composition 124, is either the same or less, and the precious metal material-rich material composition 122 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the precious metal material-rich material composition 122, is either greater or the same, and the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the rare earth metal material-rich material composition fraction 124, is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the precious metal material-rich material composition 122.

The rare earth material-rich material composition 124 is extracted and subjected to a leaching process within a leaching zone 130 to effect recovery of the rare earth metals. In this respect, it is understood that, in some embodiments, the target metal material may not necessarily be the only metal, or combination of metals, which are intended to be recovered from the feed material composition 22.

The precious metal material-rich material composition 122 is subjected to further treatment to effect production of a precious metal concentrated product. The mass concentration of the one or more precious metals of the precious metal concentrated product is greater than the mass concentration of the one or more precious metals of the precious metal material-rich material composition 122. In some embodiments, for example, the precious metal material-rich material composition 122 is supplied to a secondary carbonylation zone 150 and contacted with carbon monoxide within the secondary carbonylation zone so as to effect production of a post-secondary carbonylation product material including: (i) a post-secondary carbonylation metal-comprising gaseous material, and (ii) a metal-depleted post-carbonylation precious metal-rich fraction 152. At least one metal of the post-secondary carbonylation metal-comprising gaseous material is a carbon monoxide-reactive metal that is liberated from the precious metal material-rich material composition 122 during the contacting. The mass concentration of precious metal material, defined by one or more precious metals, of the metal-depleted post-carbonylation precious metal-rich fraction 152 is greater than the mass concentration of precious metal material, defined by one or more precious metals, of the precious metal material-rich material composition 122. In some embodiments, for example, prior to carbonylation within the carbonylation zone 150, the precious metal material-rich material composition 122 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the material 122 to copper sulphide. Excessive copper within the composition 122 may, in some embodiments, interfere with carbonylation. In some embodiments, for example, the metal-depleted post-carbonylation precious metal-rich fraction 152 is subjected to further treatment in unit operation 160 (for example, by contacting with aqua regia) to effect recovery of the precious metals.

In some embodiments, for example, the carbon monoxide-reactive metal, which is a metal of the post-secondary carbonylation metal-comprising gaseous material, is a metal selected from the group consisting of nickel and iron.

In some embodiments, for example, the post-secondary carbonylation metal-comprising gaseous material includes at least one metal carbonyl. In some of these embodiments, for example, the post-secondary carbonylation metal-comprising gaseous material includes nickel carbonyl, or iron carbonyl, or both of nickel carbonyl and iron carbonyl.

In some embodiments, for example, the post-secondary carbonylation metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 172 and a nickel carbonyl-rich fraction 174 from the metal-comprising gaseous material. In some embodiments, for example, each one of the iron carbonyl-rich fraction and the nickel carbonyl-rich fraction is supplied to a respective decomposition zone 140, 142, so as to effect its respective decomposition into a substantially pure form of the respective metal, as described above (ie. iron carbonyl of the iron carbonyl-rich fraction is decomposed within the decomposition zone 140 so as to produce iron, and nickel carbonyl of the nickel carbonyl-rich fraction is decomposed within the decomposition zone 142 so as to produce nickel). In some embodiments, for example, each of the decomposition zones 140, 142 is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions.

(B) Second Aspect

In another aspect, and also referring to FIGS. 1 and 2, there is provided a process for treating a solid particulate feed material composition 22. The solid particulate feed material composition 22 includes a solid particulate precious metal material-rich feed material composition fraction and a solid particulate rare earth metal material-rich feed material composition fraction. In some of these embodiments, for example, at least 90 weight % of the solid particulate feed material composition 22 has a particle size of less than one (1) millimetre, measured using a Fisher Sub-Sieve Sizer (FSSS). Generally, in some embodiments, for example, the solid particulate feed material composition has a particle size of about 50 microns, measured using a Fisher Sub-Sieve Sizer (FSSS).

The solid particulate precious metal material-rich feed material composition fraction includes one or more precious metals, and the solid particulate rare earth metal material-rich feed material composition fraction includes one or more rare earth metals.

In some embodiments, for example, the precious metal is any one of platinum(Pt), palladium(Pd), iridium(Ir), rhodium(Rh), ruthenium(Ru), osmium (Os), gold (Au), rhenium (Re), and silver (Ag).

In some embodiments, for example, the rare earth metal is any one of scandium (Sc), yttrium (Y), lanthanum (La), cerium (Ce), praseodymium (Pr), neodymium (Nd), promethium (Pm), samarium (Sm), europium (Eu), gadolinium (Gd), terbium (Tb), dysprosium (Dy), holmium (Ho), erbium (Er), thulium (Tm), ytterbium (Yb), and lutetium (Lu).

The mass concentration of the one or more precious metals of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich feed material composition fraction. In some embodiments, for example, the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%. In some embodiments, for example, the solid particulate precious metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich feed material composition fraction, is either the same or less, and the solid particulate rare earth material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich feed material composition fraction, is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition fraction.

The mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich feed material composition fraction. In some embodiments, for example, the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich feed material composition fraction is greater than the mass concentration, of the one or more rare earth metals, within the solid particulate precious metal material-rich feed material composition fraction, by at least 25%, such as, for example, by at least 50%, or, such as, for example, by at least 75%. In some embodiments, for example, the solid particulate rare earth metal material-rich feed material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is either the same or less, and the solid particulate precious metal material-rich feed material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich feed material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich feed material composition fraction, is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid particulate precious metal material-rich feed material composition fraction.

In some of these embodiments, for example, the mass concentration of an operative metal material fraction of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration of the operative metal material fraction of the solid particulate rare earth metal material-rich feed material composition fraction. The operative metal material fraction is defined by copper (Cu), cobalt (Co), nickel (Ni), iron (Fe) and one or more precious metals. In some of these embodiments, for example, the mass concentration, of the operative metal material fraction, of the solid particulate precious metal material-rich feed material composition fraction is greater than the mass concentration, of the operative metal material fraction, of the solid particulate rare earth metal material-rich feed material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.

In some of these embodiments, for example, the solid particulate precious metal material-rich feed material composition fraction includes: (i) at least 1×10−6 weight % of one or more precious metals, based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, (ii) at least 50 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, (iii) less than weight 1×10−6% of one or more rare earth metals, based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, (iv) less than 40 weight % of one or more operative oxides, based on the total weight of the solid particulate precious metal material-rich feed material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), and the solid particulate rare earth metal material-rich feed material composition fraction includes: (i) at least 1×10−6 weight % of one or more rare earth metals, based on the total weight of the solid particulate rare earth metal material-rich feed material composition fraction, (ii) at least 20 weight % of one or more operative oxides, based on the total weight of the solid particulate rare earth metal material-rich feed material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), (iii) less than 1×10−7 weight % of one or more precious metals, based on the total weight of the solid particulate rare earth metal material-rich feed material composition fraction, and (iv) less than 70 weight % of one or more operative metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate rare earth metal material-rich feed material composition fraction.

In some embodiments, for example, the solid particulate feed material composition 22 is derived from an ore. In some of these embodiments, for example, the ore is laterite 16. In some embodiments, for example, the ore is dried and subjected to size reduction (for example, by milling) prior to being subjected to the contacting with the reducing agent.

The following are exemplary reactions which occur in the reducing agent contacting zone 20, when the solid particulate feed material composition 22 is derived from laterite which has been dried and subjected to size reduction:


Fe2O3+3H2→2Fe+3H2O


NiO+H2→Ni+H2O


CoO+H2→Co+H2O


CuO+H2→Cu+H2O

In some embodiments, for example, and specifically referring to FIG. 2, the solid particulate feed material composition 22 includes treated pre-cursor solid metal sulphide-comprising material 14 produced by contacting of a pre-cursor solid metal sulphide-comprising material 12, such as a size-reduced sulphide ore, with an oxidizing agent within an oxidizing agent contacting zone 10. In this respect, in some embodiments, for example, the process further includes contacting of a pre-cursor solid metal sulphide-comprising material 12 with an oxidizing agent within an oxidizing agent contacting zone 10 to effect production of a treated pre-cursor solid metal sulphide-comprising material 14, such that the solid particulate feed material composition 22 includes the treated pre-cursor solid metal sulphide material 14. In some embodiments, for example, the oxidizing agent contacting zone 10 is disposed at a temperature of between 850 degrees Celsius and 1400 degrees Celsius (such as between 1000 degrees Celsius and 1100 degrees Celsius) and at a pressure of between one (1) and two (2) bars (such as atmospheric pressure).

Referring to FIGS. 1 and 2, the solid particulate feed material composition 22 is contacted with a reducing agent within a reducing agent contacting zone 20 to effect production of a reaction inteimmediate solid particulate material composition 30. In some embodiments, for example, suitable reducing agents include gaseous diatomic hydrogen and carbon monoxide. In some embodiments, for example, the reducing agent contacting zone 20 is disposed at a temperature of between 550 degrees Celsius and 850 degrees Celsius, and at a pressure of between one (1) and 12 bars. In some of these embodiments, for example, the reducing agent contacting zone 20 is disposed at a temperature of about 650 degrees Celsius.

In some embodiments, for example, the contacting with the reducing agent effects reduction of iron and nickel of the solid particulate feed material composition 22. In some of these embodiments, the contacting with the reducing agent effects reduction of iron of an iron oxide of the solid particulate feed material composition 22. In some of these embodiments, the contacting with the reducing agent effects reduction of nickel of a nickel oxide of the solid particulate feed material composition 22.

In some embodiments, for example, the reaction intermediate solid particulate material composition 30 includes a solid particulate precious metal material-rich reaction intermediate material composition fraction and a solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

The mass concentration of the one or more precious metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction. In some embodiments, the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction, is either the same or less, and the solid particulate rare earth material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction, is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

The mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich reaction intermediate material composition fraction. In some embodiments, the mass concentration, of the one or more rare earth metals, of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction is greater than the mass concentration, of the one or more rare earth metals, of the solid particulate precious metal material-rich reaction intermediate material composition fraction, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is either the same or less, and the solid particulate precious metal material-rich reaction intermediate material composition fraction includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the one or more solid particulate precious metal material-rich reaction intermediate material composition fraction, is either greater or the same, and the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid particulate precious metal material-rich reaction intermediate material composition fraction.

In some embodiments, for example, the mass concentration of non-oxygen bonded metal material of the solid particulate precious metal material-rich reaction intermediate material composition fraction is greater than the mass concentration of non-oxygen bonded metal material of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction. Non-oxygen bonded metal material is defined by at least one operative metallic element, wherein each one of the at least one operative metallic element is not chemically bonded to an oxygen atom.

In some embodiments, for example, the mass concentration of oxygen of the solid particulate precious metal material-rich reaction intermediate material composition fraction is less than the mass concentration of oxygen of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

The solid particulate precious metal material-rich reaction intermediate material composition fraction includes: (i) at least 1×10−6 weight % of one or more precious metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (ii) at least 15 weight % of one or more metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iii) less than 1×10−6 weight % of one or more rare earth metals, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, (iv) less than 15 weight % of one or more operative oxides, based on the total weight of the solid particulate precious metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn). The solid particulate rare earth metal material-rich reaction intermediate material composition fraction includes: (i) at least 3×10−6 weight % of one or more rare earth metals, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, (ii) at least 70 weight % of one or more operative oxides, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, wherein each operative oxide is an oxide of one or more elements selected from the group consisting of aluminium (Al), silicon (Si), magnesium (Mg), chromium (Cr), and manganese (Mn), (iii) less than 1×10−7 weight % of one or more precious metals, based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction, and (iv) less than 15 weight % of one or more operative metals selected from the group consisting of nickel (Ni), iron (Fe), cobalt (Co) and copper (Cu), based on the total weight of the solid particulate rare earth metal material-rich reaction intermediate material composition fraction.

In some embodiments, for example, prior to being supplied as a carbonylation supply material composition 104, after reduction, the reaction intermediate material composition 30 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the reaction intermediate material composition 30 to copper sulphide. Excessive copper within the carbonylation supply material composition 104 to the carbonylation zone 112 may, in some embodiments, interfere with carbonylation.

The process 100, 102 further includes contacting the carbonylation supply material composition 104 with carbon monoxide in a carbonylation zone 110 so as to effect production of a post-carbonylation material composition 112. In some of these embodiments, for example, at least 90 weight % of the solid particulate post-carbonylation material composition 112 has a particle size of less than one (1) millimetre, measured using a Fisher Sub-Sieve Sizer (FSSS). Generally, in some embodiments, for example, the solid particulate post-carbonylation material composition 112 has a particle size of about 50 microns, measured using a Fisher Sub-Sieve Sizer (FSSS).

In some embodiments, for example, the carbonylation zone 112 is disposed at a pressure of between 5 bar and 60 bar, and at a temperature of between 80 degrees Celsius and 120 degrees Celsius.

Exemplary reactions within the carbonylation zone 112 include the following:


Fe+5CO→Fe(CO)5


Ni+4CO→Ni(CO)4

In some embodiments, for example, the contacting of the solid particulate carbonylation supply material composition 104 with the carbon monoxide effects liberation of carbon monoxide-reactive metal material from the solid particulate carbonylation supply material composition 104. The carbon monoxide-reactive metal material is defined by one or more carbon monoxide-reactive metals. In some of these embodiments, for example, the carbon monoxide-reactive metal material is at least one of nickel, iron, and cobalt. In some of these embodiments, for example, the contacting with the carbon monoxide further effects production of a metal-comprising gaseous material including carbon monoxide-reactive metal material whose liberation from the feed material composition is effected by the contacting. In some of these embodiments, for example, the metal-comprising gaseous material includes at least one metal carbonyl. In some of these embodiments, for example, the metal-comprising gaseous material includes any one, or any combination of nickel carbonyl, iron carbonyl, and cobalt carbonyl.

In some embodiments, for example, the metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 132 and a nickel carbonyl-rich fraction 134 from the metal-comprising gaseous material. In some embodiments, for example, each one of the iron carbonyl-rich fraction 132 and the nickel carbonyl-rich fraction 142 is supplied to a respective decomposition zone 140, 142 so as to effect its respective decomposition into a substantially pure form of the respective metal (ie. iron carbonyl of the iron carbonyl-rich fraction 132 is decomposed within the decomposition zone 132 so as to produce iron, and nickel carbonyl of the nickel carbonyl-rich fraction 142 is decomposed within the decomposition zone 142 so as to produce nickel). In some embodiments, for example, each of the decomposition zones is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions. Exemplary reactions within the decomposition zones 140, 142 include the following:


Fe(CO)5→Fe+5CO


Ni(CO)4→Ni+4CO

A solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 and a solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 are separated from the post-carbonylation material composition, such that the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 becomes separated from the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124. In some embodiments, for example, the separation is effected by any one, or any combination of: gravity separation, magnetic separation, and flotation.

The mass concentration of the one or more precious metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is greater than the mass concentration of the one or more precious metals of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124. In some embodiments, the mass concentration, of the one or more precious metals, of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is greater than the mass concentration, of the one or more precious metals, of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124, by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%. In some embodiments, for example, the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122, is either the same or less, and the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more precious metals, which, relative to the respective mass concentration, of the one or more precious metals, of every other fraction of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124, is either greater or the same, and the minimum mass concentration, of the one or more precious metals, of the minimum mass concentration-defining fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122, is greater than the maximum mass concentration, of the one or more precious metals, of the maximum mass concentration-defining fraction of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124.

The mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122. In some embodiments, the mass concentration of the one or more rare earth metals of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 is greater than the mass concentration of the one or more rare earth metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 by at least 100%, such as, for example, by at least 200%, or, such as, for example, by at least 300%.

In some embodiments, for example, the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124 includes a minimum mass concentration-defining fraction including a minimum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124, is either the same or less, and the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 includes a maximum mass concentration-defining fraction including a maximum mass concentration of the one or more rare earth metals, which, relative to the respective mass concentration, of the one or more rare earth metals, of every other fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122, is either greater or the same, and the minimum mass concentration, of the one or more rare earth metals, of the minimum mass concentration-defining fraction of the solid particulate rare earth metal material-rich post-carbonylation material composition separation fraction 124, is greater than the maximum mass concentration, of the one or more rare earth metals, of the maximum mass concentration-defining fraction of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122.

In some embodiments, for example, the solid particulate rare earth metal material-rich feed material composition separation fraction 124 is extracted and subjected to a leaching process within a leaching zone 130 to effect recovery of the rare earth metals.

In some embodiments, for example, the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is subjected to further treatment to effect production of a precious metal concentrated product. The mass concentration of the one or more precious metals of the precious metal concentrated product is greater than the mass concentration of the one or more precious metals of the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122. In some embodiments, for example, the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 is supplied to a secondary carbonylation zone 150 and contacted with carbon monoxide within the secondary carbonylation zone so as to effect production of a post-secondary carbonylation product material including: (i) a post-secondary carbonylation metal-comprising gaseous material, and (ii) a metal-depleted post-carbonylation precious metal-rich fraction 152. At least one metal of the post-secondary carbonylation metal-comprising gaseous material is a carbon monoxide-reactive metal that is liberated from the solid particulate precious metal material-rich post-carbonylation material composition separation fraction 122 during the contacting. The mass concentration of precious metal material, defined by one or more precious metals, of the metal-depleted post-carbonylation precious metal-rich fraction 152 is greater than the mass concentration of precious metal material, defined by one or more precious metals, of the solid particulate precious metal-rich post-carbonylation material composition separation fraction 122. In some embodiments, for example, prior to carbonylation within the carbonylation zone 150, the composition 122 may, optionally, be contacted with a sulphur comprising-material, such as gaseous hydrogen sulphide, so as to convert copper within the solid material 122 to copper sulphide. Excessive copper within the composition 122 may, in some embodiments, interfere with carbonylation. In some embodiments, for example, the metal-depleted post-carbonylation precious metal-rich fraction 152 is subjected to further treatment in unit operation 160 (for example, by contacting with aqua regia) to effect recovery of the precious metals.

In some embodiments, for example, the carbon monoxide-reactive metal, which is a metal of the post-secondary carbonylation metal-comprising gaseous material, is at least one metal selected from the group consisting of nickel and iron.

In some embodiments, for example, the post-secondary carbonylation metal-comprising gaseous material includes at least one metal carbonyl. In some of these embodiments, for example, the post-secondary carbonylation metal-comprising gaseous material includes nickel carbonyl, or iron carbonyl, or both of nickel carbonyl and iron carbonyl.

In some embodiments, for example, the post-secondary carbonylation metal-comprising gaseous material is extracted from the post-carbonylation product material, and then subjected to fractional distillation so as to effect separation of an iron carbonyl-rich fraction 172 and a nickel carbonyl-rich fraction 174 from the metal-comprising gaseous material. In some embodiments, for example, each of the iron carbonyl-rich fraction and the nickel carbonyl-rich fraction is supplied to a respective decomposition zone 140, 142, so as to effect its respective decomposition into a substantially pure form of the respective metal, as described above (ie. iron carbonyl of the iron carbonyl-rich fraction is decomposed within the decomposition zone 140 so as to produce iron, and nickel carbonyl of the nickel carbonyl-rich fraction is decomposed within the decomposition zone 142 so as to produce nickel). In some embodiments, for example, each of the decomposition zones 140, 142 is disposed at a temperature of between 220 degrees Celsius and 500 degrees Celsius, which is sufficient to effect the decompositions.

Further preferred embodiments will now described with reference to the following non-limitative examples.

Example No. 1

4.5 kg of Ferralite was charged to the reactor, and reduced with hydrogen at 750° C. for 90 minutes. After the reduction was completed, the reactor was cooled down to 140° C., and pressurized with CO to 60 bars. After 60 hours of carbonylation, the reactor was opened and the residue was pyrophoric, and it burned. Test was aborted and the residue was analyzed.

TABLE 1 Mass balance Estimated Overall Mass Balance Test # 1 Ni Fe kg Kg % kg % Feed 4.50 0.07 1.56% 2.82 62.70% Residue 2.80 0.02 0.72% 1.20 43.00% Extraction 4.69 0.05   71% 1.62   57% Weight loss

About 2.8 g of burnt residue was collected. 71 weight % of the nickel and 57 weight % of iron was extracted from the feed material. The residue had 0.72 weight % nickel and 43 weight % iron, both values being based on the total weight of the resiude.

Example No. 2

5.1 kg of Ferralite was charged to the reactor, and reduced with hydrogen at 650° C. for 90 minutes. After reduction was completed, the reactor was cooled down to 140° C., and then pressurized with CO to 60 bars. After 60 hours of carbonylation, the reactor was opened and the residue (0.36 g) was analyzed. Referring to FIG. 2, based on the mass balance, 97 weight % of the nickel and 97 weight % of the iron was extracted. The residue had about 0.63 weight % of nickel and 28.4 weight % of the iron, both values being based on the total weight of the residue left behind.

TABLE 2 Mass balance Estimated Overall Mass Balance Test # 2 Ni Fe Kg kg % Kg % Feed 5.1 0.079 1.56% 3.2 62.7% Residue 0.36 0.002 0.63% 0.10 28.4% Extraction 4.69 0.077   97% 3.06   97% Weight loss

The residue from this run was magnetically separated using Davis Magnetic tube. 77 g of the magnetic fraction was separated from the carbonyl residue, with a yield of 95 weight %. The magnetic fraction had 2.3 weight % nickel, 95 weight % iron, 2.86 weight % cobalt and 10 weight % copper, all of which are based on the total weight of the magnetic fraction. Also, 98 weight % of the total platinum group elements (“PGE”—for purposes of the examples set out herein, the samples were analyzed for only the following PGEs: gold, platinum and palladium), from the feed material (i.e. 2.0 ppm), was in the magnetic portion, and the concentration of PGE in the magnetic portion was 46.3 ppm (grams per tonne of the magnetic portion) in total.

There was no PGE reported in the non magnetic fraction but, interestingly, about 80 weight % of all the rare earth elements were reported here.

50 grams of the magnetically separated portion was reduced at the same reduction condition as in the primary carbonylation and then secondary carbonylation was carried out with the same operating conditions.

TABLE 3 Secondary Carbonylation Feed Material - Magnetically Separated Material Ni Fe g mg % Mg % Feed 50.00 1.15 2.30% 47.5 95.00% Residue 25.86 0.03 0.10% 1.24  4.80% Extraction 1.12   98% 46.26   97% Weight loss 48%

After the secondary carbonylation, the reactor was opened and the residue was analyzed for nickel, iron, cobalt and PGE.

Referring to Table 3, the residue had 0.1 weight % nickel, 26.58 weight % cobalt, 60 weight % copper and 4.8 weight % of iron (all of which are based on the total weight of the residue) and 475 ppm (or grams per tonne of the residue) of PGE. This accounts for 98% of the PGE in the starting material.

In the above description, for purposes of explanation, numerous details are set forth in order to provide a thorough understanding of the present disclosure. However, it will be apparent to one skilled in the art that these specific details are not required in order to practice the present disclosure. Although certain dimensions and materials are described for implementing the disclosed example embodiments, other suitable dimensions and/or materials may be used within the scope of this disclosure. All such modifications and variations, including all suitable current and future changes in technology, are believed to be within the sphere and scope of the present disclosure. All references mentioned are hereby incorporated by reference in their entirety.

Claims

1. A process for treating a feed material composition, comprising:

contacting the feed material composition with a reducing agent in a reducing agent zone to effect production of a reaction intermediate material composition, wherein the feed material composition is configured to be separated into a target metal material-rich feed material composition separation fraction and one or more target metal material-lean feed material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich feed material composition separation fraction would become separated from the one or more target metal material-lean feed composition separation fractions, and such that one or more separations would be effected and each one of the one or more separations would be defined by the separation of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich feed material composition separation fraction from a one of the one or more target metal material-lean feed material composition separation fractions would be, at least partially, based on a difference between a value of a separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction, and such that one or more feed material composition separation fraction pairs would be defined, wherein, for each one of the one or more feed material composition separation fraction pairs, a one of the pair would be defined by the target metal material-rich feed material composition separation fraction and the other one of the pair would be defined by a one of the one or more target metal material-lean feed material composition separation fractions, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean feed material composition separation fraction would be less than the mass concentration of the target metal material of the target metal material-rich feed material composition separation fraction, and, also, for each one of the one or more feed material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean feed material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-rich feed material composition separation fraction would be less than a maximum operative difference;
contacting the reaction intermediate material composition with carbon monoxide within a carbonylation zone so as to effect production of a post-carbonylation material composition, wherein the post-carbonylation material composition is configured to be separated into a target metal material-rich post-carbonylation material composition separation fraction and one or more target metal material-lean post-carbonylation material composition separation fractions, in response to application of a separation agent that is associated with a separation agent-responsive characteristic, such that the target metal material-rich post-carbonylation material composition separation fraction would become separated from the one or more target metal material-lean post-carbonylation material composition separation fractions, and such that one or more separations would become effected and each one of the one or more separations would be defined by the separation of the target metal material-rich post-carbonylation material composition separation fraction from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions, wherein each one of the one or more separations of the target metal material-rich post-carbonylation material composition separation fraction from a one of the one or more target metal material-lean post-carbonylation material composition separation fractions would be, at least partially, based on a difference between a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction and a value of the separation agent-responsive characteristic of target metal material-lean post-carbonylation material composition separation fraction, and such that one or more post-carbonylation material composition separation fraction pairs would be defined, wherein, for each one of the one or more post-carbonylation material composition separation fraction pairs, a one of the pair would be defined by the target metal material-rich post-carbonylation material composition separation fraction and the other one of the pair would be defined by a one of the one or more target metal material-lean post-carbonylation material composition separation fractions, and, for each one of the one or more post-carbonylation material composition separation fraction pairs, the mass concentration of target metal material of the target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the target metal material-rich post-carbonylation material composition separation fraction, and, also, for each one of the one or more post-carbonylation material composition separation fraction pairs, the absolute value of the difference between a value of the separation agent-responsive characteristic of the target metal material-lean post-carbonylation material composition separation fraction and a value of the separation agent-responsive characteristic of the target metal material-rich post-carbonylation material composition separation fraction would be greater than or equal to the maximum operative difference;
wherein the target metal material is defined by either one of: (i) one or more precious metals, or (ii) one or more rare earth metals.

2. The process as claimed in claim 1;

wherein the one or more target metal material-lean post-carbonylation material composition separation fractions, from which the target metal material-rich post-carbonylation material composition separation fraction is separable, define the remainder of the post-carbonylation material composition;
and wherein the one or more target metal-lean feed material composition separation fractions, from which the target metal-rich feed material composition separation fraction would become separated upon separation of the target metal-rich feed material composition separation fraction from the feed material composition, define the remainder of the feed material composition.

3. The process as claimed in claim 1;

wherein the contacting of the reaction intermediate material composition with the carbon monoxide effects liberation of carbon monoxide-reactive metal material from the feed material composition, wherein the carbon monoxide-reactive metal material is defined by one or more carbon monoxide-reactive metals.

4. The process as claimed in claim 1;

wherein the feed material composition is defined by solid particulate material, such that the feed material composition is a solid particulate feed material composition, and such that the target metal material-rich feed material composition separation fraction, which is separable from the solid particulate feed material composition, is defined by solid particulate material, such that the target metal material-rich feed material composition separation fraction is a solid particulate target metal material-rich feed material composition separation fraction, and such that each one of the one or more target metal material-lean feed material composition separation fractions is defined by solid particulate material, such that each one of the one or more target metal material-lean feed material composition separation fractions is a solid particulate target metal material-lean feed material composition separation fraction, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of target metal material of the solid particulate target metal material-rich feed material composition separation fraction.

5. The process as claimed in claim 4;

wherein at least 90% of the feed material composition material has a particle size of less than one (1) millimetre.

6. The process as claimed in claim 4;

wherein the post-carbonylation material composition is defined by solid particulate material, such that the post-carbonylation material composition is a solid particulate post-carbonylation material composition, and such that the target metal material-rich post-carbonylation material composition separation fraction, which is separable from the solid particulate post-carbonylation material composition, is defined by solid particulate material, such that the target metal material-rich post-carbonylation material composition separation fraction is a solid particulate target metal material-rich post-carbonylation material composition separation fraction, and such that each one of the one or more target metal material-lean post-carbonylation material composition separation fractions is defined by solid particulate material, such that each one of the one or more target metal material-lean feed material composition separation fractions is a solid particulate target metal material-lean post-carbonylation material composition separation fraction, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of target metal material of the solid particulate target metal material-lean post-carbonylation material composition separation fraction would be less than the mass concentration of target metal material of the solid particulate target metal material-rich post-carbonylation material composition separation fraction.

7. The process as claimed in claim 6;

wherein the target metal material is defined by one or more precious metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction.

8. The process as claimed in claim 7;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction by at least 100%.

9. The process as claimed in claim 7;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction.

10. The process as claimed in claim 8;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fractions, by at least 100%.

11. The process as claimed in claim 7;

wherein each one of the one or more target metal material-lean feed material composition separation fractions is a rare earth metal material-rich feed material composition separation fraction including one or more rare earth metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction.

12. The process as claimed in claim 7;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction by at least 100%.

13. The process as claimed in claim 6;

wherein the target metal material is defined by one or more rare earth metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction would be less than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction.

14. The process as claimed in claim 13;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more rare earth metals of the solid particulate target metal material-rich feed material composition separation fraction would be greater than the mass concentration of the one or more rare earth metals of the solid particulate target metal material-lean feed material composition separation fraction by at least 100%.

15. The process as claimed in claim 13;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fraction.

16. The process as claimed in claim 13;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of carbon monoxide-reactive metal material of the solid particulate target metal material-rich feed material composition separation fractions, by at least 100%.

17. The process as claimed in claim 13;

wherein each one of the one or more target metal material-lean feed material composition separation fractions would be a precious metal material-rich feed material composition separation fraction including one or more precious metals, and, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction.

18. The process as claimed in claim 13;

wherein, for each one of the one or more feed material composition separation fraction pairs, the mass concentration of the one or more precious metals of the solid particulate target metal material-lean feed material composition separation fraction would be greater than the mass concentration of the one or more precious metals of the solid particulate target metal material-rich feed material composition separation fraction by at least 100%.

19. The process as claimed in claim 3;

wherein carbon monoxide-reactive metal material is at least one of nickel and iron.

20. The process as claimed in claim 1;

wherein the feed material composition is derived from an ore.

21.-100. (canceled)

Patent History
Publication number: 20150053049
Type: Application
Filed: Nov 3, 2014
Publication Date: Feb 26, 2015
Applicant: CVMR CORPORATION (Toronto)
Inventors: Dmitri Terekhov (Newmarket), Nanthakumar Victor Emmanuel (Richmond Hill), Kamran Khozan (Dubai), Colwyn Van Der Linde (Isando)
Application Number: 14/531,942
Classifications
Current U.S. Class: Producing Or Treating Free Metal (75/392)
International Classification: C22B 11/00 (20060101); C22B 7/00 (20060101); C22B 3/00 (20060101); C22B 59/00 (20060101); C22B 1/00 (20060101);