Ore Processing and Smelting at MPMM
Ok, I’ll just come out with it and say that I’m a big fan of YouTube. Amidst the scattered population of silly or stupid videos is a wealth of quite well-done amateur presentations on science and technology. Some favorites are Itchy Boots, Periodic Videos, Sabine Hossenfelder, Mount Baker Mining and Metals (MBMM), UATV, and many more.
In this post I’ll feature a particularly well-done group of videos on precious metals prospecting, milling and smelting. The producer of this content is Jason Gaber at Mount Baker Mining and Metals, MBMM. The website says that Jason is a geophysicist. His company manufactures small-scale industrial grade equipment for the processing of ore. He produces videos that show how things are done in prospecting, mining, and even smelting. His videos give long, lingering views of the milling and smelting processes in operation. I was interested in particular in the process of cupellation, which has always been a bit of a mystery.
Gold ore is dropped into a crusher then pulverized with a hammer mill. The finely divided ore is then fed onto a shaker table for separation by density with flowing water. The shaker table is a mechanical separation method that allows the isolation of metal fines without chemical processing methods. No cyanide or mercury here. The only waste materials are the pulverized ore tailings.
Editorial comment: To be sure, there is nothing innocent about ore tailings. The large surface area along with the presence of sulfides and water allow air to oxidize the sulfur to strong mineral acid and accelerate the leaching of hazardous metals into streams over the long term. It is very damaging to wildlife and municipalities that draw water from the stream and rivers. Water pollution is a problem all around the American West. Metals are forever.
The smelting videos are interesting for a chemist to watch. Jason uses his knowledge of pyrometallurgy to extract the values and partition impurities away from the target metal. Of course, chemists will recognize this as high temperature inorganic chemistry. Before watching this, I had a poor understanding of the importance of fluxes and slag. Jason quantitatively formulates custom fluxes to fit the problem as he sees it. He uses iron bars for redox processes to change the chemical composition of the melt and give a better partitioning of components.
The goal in smelting is to get a clean separation of the metal value from the ore by partitioning between liquid phases. Lead is often used as a “collector” metal to accumulate reduced metal species as a separate liquid phase on the bottom of the melt. The upper slag phase is a complex mixture of the ore matrix material and contains silicates, aluminates, and a dog’s lunch of other undesirable substances. And. not all metals are miscible or highly soluble in the collector phase, so there is some art in this.
Jason also discusses matte and how to deal with it. Matte is frequently discussed in 19th century works on gold smelting, but this was before atomic theory or sophisticated analytical chemistry. Matte was something to place in a reverberatory furnace and calcine. Sulfides in the matte were converted to oxides and gold residues.
Cupellation is a technique that he uses in the final isolation of gold, silver or PGMs from the collector metal. At the scale of material handling Jason works with, a small cupel and a muffle furnace is all that is necessary for this step. Cupellation for gold isolation was described by Agricola in the 16th century. The lead collector mass selectively oxidizes to the PbO, or litharge, and diffuses into the cupel leaving behind the precious metal. Cupels were formerly made of bone ash or other materials that will not combine with the molten PbO to produce a viscous layer that would prevent seeping of the PbO into the container. This is also how gold was isolated in the old days by the assay office to determine the gold content of ore samples. Today several methods are available to assayers, including x-ray fluorescence.