Enhancing Copper Leaching from Refractory Copper Oxide Ore Using Organic Cationic Surfactant

The copper oxide ore in Zambia exhibits complex mineralogical characteristics, with copper primarily occurring in mica. The local hydrometallurgical plant employs heating–agitation acid leaching, which is hindered by a low leaching rate and prolonged leaching period, resulting in high energy consumption. To enhance the copper leaching efficiency, a systematic study was conducted on the use of organic cationic surfactants to enhance the leaching of the copper oxide ore. The results indicated that the primary copper-bearing mineral in the raw ore is cupriferous biotite, which is the reason for the difficulty in leaching. Under optimal conditions: a sulfuric acid dosage of 45 kg/t, a CTAB dosage of 75 g/t, a leaching temperature of 65 °C, a liquid-to-solid ratio of 2:1, and a leaching time of 120 min, the copper leaching rate reached 78.32%. Compared to the optimal result of regular heating–agitation acid leaching, this approach increased the copper leaching rate by 3.06%, reduced the leaching time by 80 min, and lowered leaching energy consumption without destroying the structure of cupriferous biotite. Mechanistic studies show that organic cations in CTAB neutralize excess anions, thereby weakening the electrostatic Coulomb forces between the interlayer cations and the hexagonal structure. This increases the interlayer spacing of biotite, facilitating the entry of H+ from sulfuric acid into the interlayer. The H+ then reacts with the copper in the biotite, enhancing the copper leaching rate and reducing leaching time. Because CTAB has high degradability, it will not cause persistent pollution to the environment. The use of CTAB as a leaching aid can reduce the energy consumption of heating–agitation acid leaching and reduce the heating cost per ton of ore by USD 6.11–9.36.