Leaching behaviour of low and high Fe-substituted chlorite clay minerals at low pH

The behaviour of low-Fe and high-Fe substituted chlorite mineral dispersions was investigated under industrially-relevant, atmospheric leaching conditions typical of low grade, uranium-bearing lateritic ore processing. The main focus was on the influential role played by the clay mineral chemistry. Preferential leaching of Al(III), Fe(II/III) and Mg(II) metal ions over tetrahedral Si species was indicated at pH 1 and 70 °C by supernatant speciation, the kinetics of which was faster at high-Fe than at low-Fe substitution. For the low-Fe chlorite, the incongruent leaching behaviour of Al(III), Fe(II/III) and Mg(II) species was substantially similar. In the case of the high-Fe chlorite however, despite its lower Mg(II) content, Al(III) and Fe(II/III) species leaching rates were relatively lower than that of Mg(II). Crystallo-chemical (XRD, XRF and EM) and spectroscopic (FTIR and XPS) analyses indicated that the incongruent leaching led to significant bulk particle and interfacial layer structures' modification, impacting dramatically upon pulp chemistry, mineralogy and particle interactions. Mineral chemistry-mediated formation of polycondensed, sub-crystalline aluminosilicate gel structures and secondary mineral phases prevailed in the course of leaching. A greater increase in high-Fe pulp particle interactions, in contrast with the low-Fe pulp, was observed during leaching, reflecting remarkably high, time-dependent shear yield stresses, reminiscent of highly viscous gels. The development of viscous gel structures whose strength is strongly dependent upon chlorite mineral chemistry has important implications for the efficacy of aqueous processing of clay-rich lateritic ores.

► Incongruent leaching behaviours at pH 1 revealed for chemically different chlorites.
► High-Fe chlorite displayed faster leaching rate and greater pulp chemistry change.
► Stronger pulp yield stresses displayed at high- than at low-Fe chlorite leaching.
► Formation of secondary minerals/amorphous aluminosilicate products occurs.
► Pivotal role mineral chemistry plays in acid leaching of clay minerals underscored.