The core of the company's activities is client-driven experimental research for process development and optimization. We specialize in experimental design, bench-scale laboratory work, mini-pilot campaigns, flow sheet development,
unit operation selection, and process modeling to provide clients with conceptual process designs.
Click on the material or process below for more information and related projects:
MATERIALS
KPM performed a wide range of projects related to base metal production and recycling. Projects in copper (Cu), nickel (Ni), lead (Pb), and zinc (Zn) address a variety of issues and use a range of technologies. Work is also regularly perform work on base metal by-products, including tellurium (Te), selenium (Se), cadmium (Cd), arsenic (As), tin (Sn), bismuth (Bi), indium (in), etc. Sample projects at KPM involving base metals are:
Copper slag slow cooling
Nickel laterite novel processing
Control and reduction of arsenic emissions
Lead de-tinning optimization
Scrubbing of selenium emission from stack of recycling operation
Tellurium slag casting environmental control
Copper oxide ore processing through segregation process
Lead blast furnace slag optimization
Indium/gallium recovery from oxidized waste stream
Copper/bismuth concentrate smelting and refining
The production of light metals was at the base of KPM business since inception. Over the years, we performed a large number of projects in aluminum (Al), magnesium (Mg), sodium (Na), lithium (Li) and titanium (Ti).
Some examples of projects are:
Aluminum chloride (AlCl3) production and aluminum (Al) electrolysis
Inert anodes and cermet cathode fabrication and testing for aluminum (Al) production
Improvements to Al electrolysis efficiency
Magnesium chloride (MgCl2) production and magnesium (Mg) electrolysis
Lithium chloride (LiCl) production and lithium (Li) electrolysis
Improvements to sodium (Na) electrolysis
Titanium (Ti) and titanium powder production
Aluminum demagging
Titanium oxides carbochlorination for TiCl4 production
Electrode properties and selection for molten salt electrolysis applications
Optimization of electrolyte composition for light metals production
Role of impurities during light metals electrolysis
Cell sludge formation and impact on operation
Magnesium dross cleaning
Aluminum salt cake recycling
Cryolite treatment and recovery
Spodumene ore upgrading
Dehydration of MgCl2
Aluminum spent pot lining treatment
Titanium powder production
A significant number of KPM's projects have involved various types of uncommon metals. KPM is accustomed to taking on projects that deal with uncommon metals, compounds and products. Some examples of projects are:
Antimony (Sb) concentrate treatment
Thermal upgrading of platinum group metals (PGM) concentrate
Mercury (Hg) sludge retorting, stability, and gas handling
Tellurium (Te) slag casting environmental control
Metal hydride stability study
Antimony (Sb) concentrate upgrading
Calcium (Ca) hydride production
Scandium (Sc) extraction from lateritic ore
Scandium (Sc) alloys preparation
Mercury sulphide (HgS) synthesis
Indium (In) and gallium (Ga) recovery from oxidized waste stream
Bismuth (Bi) concentrate smelting and refining
Rare earth metals production
Strontium (Sr) purification
KPM is experienced with laboratory scale methods for gold (Au), silver(Ag), and platinum group metals (PGM) treatment. We have all the methods for determination of optimal process flow sheets and operating conditions when treating refractory gold ore, concentrate, and tailings. KPM has also worked on upgrading PGM concentrates for base metal removal, using various methods including chlorination (Cl2) and hydrochlorination (HCl). Methods available include atmospheric and pressure leaches for precious and base metal recovery, pre-oxidation and cyanidation bottle roll tests for gold recovery, one and two-stage roasting (sulphuric and arsenic removal), and the Albion process. We have worked on a number of combined hydro/pyro flowsheets for processing a wide range of ores for clients. With autoclave capacity ranging from 1 to 20 litres, as well as a range of fluid bed and rotary reactors, KPM is well equipped to optimize gold extraction from complex refractory ores. KPM is also able to support all hydrometallurgical test work with a full range of analytical (Fire Assays, AAS, ICP-OES, ISE, etc.) and microscopy (optical, SEM-EDS, MLA, QEMSCAN) services.
KPM works on a number of projects related to recycling metals and treating secondary materials. Projects include the treatment of base metal production slag for further metal recovery, recycling and treatment of by-products from base metal production, recycling of light metals, and removal/neutralization of toxic elements from hazardous waste. Often, the work is combined with a techno-economic analysis to ensure that the process being developed is economically justified. Example of projects include:
Zinc slag fuming
Stabilization of aluminum spent pot lining
Recycling of magnesium metal
Electric arc furnace dust treatment
Treatment of aluminum salt cake waste
Indium and gallium recovery from oxidized waste stream
Magnesium dross cleaning
Cryolite treatment and recovery from aluminum smelter operation
Mercury and arsenic compound stabilization
Recycling of lithium ion (Li-ion) batteries, nickel-cadmiun (Ni-Cd) batteries, and nickel metal hydride batteries (NimH)
PROCESSES
KPM performed a wide range of projects related to base metal production and recycling. Projects in copper (Cu), nickel (Ni), lead (Pb), and zinc (Zn) address a variety of issues and use a range of technologies. Work is also regularly perform work on base metal by-products, including tellurium (Te), selenium (Se), cadmium (Cd), arsenic (As), tin (Sn), bismuth (Bi), indium (in), etc. Sample projects at KPM involving base metals are:
Copper slag slow cooling
Nickel laterite novel processing
Control and reduction of arsenic emissions
Lead de-tinning optimization
Scrubbing of selenium emission from stack of recycling operation
Tellurium slag casting environmental control
Copper oxide ore processing through segregation process
Lead blast furnace slag optimization
Indium/gallium recovery from oxidized waste stream
Copper/bismuth concentrate smelting and refining
KPM runs bench-top scale and small pilot size tests for a wide range of hydrometallurgical processes including conventional and column leaching, solvent extraction, ion exchange, solution purification (e.g. iron control), electrorefining and electrowinning.
Methods available include atmospheric and pressure leaches for precious and base metals recovery, pre-oxidation and cyanidation bottle roll tests for gold recovery, one and two-stage roasting (sulphuric and arsenic removal), and the Albion process. SX-EW processes can be tested from the ore leaching to the metal production. We have worked on a number of combined hydro/pyro flowsheets for processing a wide range of ores for clients. With autoclave capacity ranging from 1 to 20 litres, as well as a range of fluid bed and rotary reactors, KPM is well equipped to optimize gold extraction from complex refractory ores or tailing re-treatment. KPM is also able to support all hydrometallurgical test work with a full range of analytical (Fire Assays, AAS, ICP-OES, ISE, etc.) and microscopy (optical, SEM-EDS, MLA, QEMSCAN) services.
Examples of projects include:
Refractory Gold Ore Diagnostic Leach
Kinetic Cyanidation
Copper Oxide Ore Colum Leach
Arsenic Residue Stabilization
High Purity Copper Double-Electrorefining
H2S Production from Bio-Waste
Base Metal Leaching and IX Trials
Various Immersion Corrosion Tests
Control of Cadmium in Nickel Electrolytes
Brine Leach Applications
Manganese Recovery SX/IX Trade-Off Study
During roasting, a concentrate, ore, or secondary material is reacted with a gas at high temperature to remove impurities or effect a transformation. Common roasting operations include sulphur removal and oxidation. Roasting reactors usually are kilns and fluid beds, but other type of reactors can be used (rotary hearth, recirculating bed, etc.). KPM has a range of available reactors (static, rotary, or fluid bed) which can be used with exposure to diverse environments to test reactions, reproducing industrial operation. When required, our equipment can be modified in-house or new reactor built and commissioned on site.
Samples of work involving roasting and calcination are:
Zinc slag fuming
Base metal sulfide ore roasting
Refractory gold ore and concentrate roasting
Treatment of enargite for arsenic stabilization
Limestone calcination
Smelting is a common operation in base metal extraction from sulphide ore, used to separate the metals from the host rock. It requires an understanding of reduction kinetics and slag chemistry. The equilibrium between the phases involved (slag, matte, and metal) can be modeled using thermochemical database (FACTSage), allowing to plan experimental work to understand industrial operations or to validate the smelting conditions of new ore. A number of projects have been performed at KPM in smelting of copper, nickel, ferro-nickel, iron, and lead, with a focus on slag chemistry, property measurements, reaction kinetics, impurity deportment, and arsenic control.
Sample projects include:
Reduction of SO2 generation during nickel smelting
Reaction mechanisms during reduction of saprolite
Optimization of copper slag cooling circuit
Liquidus determination of nickel slags
KPM has been involved in a range of projects related to metal refining using pyrometallurgical, electrochemical, and hydrometallurgical methods. This can involve base metals (copper, lead, zinc, nickel), light metals (aluminum, magnesium, titanium, sodium, lithium), or precious metals (gold, silver, PGM). Examples of projects include:
Examples of projects include:
Lead drossing and de-tinning
Aluminum de-magging
Copper double-electrorefining
Nickel pregnant solutions purification and electrowinning
KPM has extensive experience in molten salt electrochemistry and molten salt processing, and maintains one of the most active molten salt laboratories for commercial metal production in the world. KPM molten salt electrochemistry work includes potentiostatic tests to observe the behaviour of anode and cathode materials and impurities in the salts. Potentiostatic tests can be used to improve existing electrolysis reactions, monitor corrosion reactions of metal samples, material characterization, and for the selection of appropriate molten salt electrolyte composition and additives to be used in industrial applications.
KPM has developed methods to quantify anode wear in electrolytic systems using surface profilometry to study electrodes after 24 hour electrolysis. As well, electrolysis tests can be done using visual cells to see through the molten salt and observe metal formation at the cathode and gas evolution at the anode. Material compatibility tests (refractory corrosion) in molten salts are done in custom apparatus.
We use molten salt electrolysis and molten salt processing for projects like:
Aluminum chloride (AlCl3) production and aluminum (Al) electrolysis
Inert anodes fabrication and testing for aluminum (Al) production
Improvements to Al electrolysis efficiency
Magnesium chloride (MgCl2) production and magnesium (Mg) electrolysis
Lithium chloride (LiCl) production and lithium (Li) electrolysis
Improvements to sodium (Na) electrolysis
Titanium (Ti) and titanium powder production
Molten salt energy storage technologies
Rare earth metals production
Electrode properties and selection for molten salt electrolysis applications
Optimization of electrolyte composition for light metals production
Role of impurities during light metals electrolysis
Cell sludge formation and impact on operation
Reduction and control of air emissions from light metals electrolysis
Corrosion test of refractories in Al, Li, and Na molten salt electrolytes
KPM is recognized world-wide for its performance of projects using chlorine (Cl2) and hydrogen chloride (HCl) for a range of applications and new processes development. We have in-line distribution of Cl2 and HCl throughout our laboratories, with associated gas detectors and laboratory procedures to ensure safe use and delivery. Chlorination (Cl2), hydrochlorination (HCl), and carbochlorination projects are performed routinely at KPM.
Examples of projects include:
Titanium oxides carbochlorination for TiCl4 production
Chlorination and carbochlorination of various oxide ores
Selective hydrochlorination of PGM concentrate
Purification of graphite by carbochlorination
Upgrading of ores by chlorination
Production of aluminum chloride (AlCl3) by carbochlorination
KPM performs projects using a variety of reactive gases, including CO, H2S, H2, CH4, Cl2 and HCl, all of which require safe delivery, handling, and treatment.
Examples of projects include:
Graphite purification
Coke desulphurization
Hydrogen reduction of chloride gas species
Metal hydride stability study
H2S conversion of chloride salts
Variety of controlled atmosphere thermal treatment
KPM has done extensive work in purification of metals and upgrading of ores. This work ranges over many types of feeds, using a variety of methods, including:
High purity graphite production
Petroleum coke treatment
Lead purification circuit improvements
Chemical upgrading of PGM concentrate
Aluminum demagging
Production of ultra-high purity copper (6N5) and nickel (5N)
Magnesium dross cleaning
Aluminum salt cake recycling
Cryolite treatment and recovery
Iron ore and copper oxide ore upgrading by segregation
Antimony (Sb) concentrate upgrading
Spodumene ore upgrading
Aluminum spent pot lining upgrading
Copper slag slow cooling
KPM has experience with commercial use of electrowinning and electrorefining for the production of a variety of metals and compounds, including copper, nickel, tellurium, and silver. Methods for the production of high purity base metals (> 5N nickel and > 6N copper) through careful control of secondary electrolytic refining were developed. Aqueous electrochemistry is also used for potentiometric evaluation of the corrosion of various metals, alloys, and compounds in a range of media.
KPM performs inorganic synthesis of a variety of products and compounds, both in experimental work and process flow sheet development. Often these involve small volumes which require special consideration to produce economically viable processes. Some examples of this type of work includes:
Calcium hydride production
Scandium alloys preparation
Mercury sulphide synthesis
Lithium compounds development
MgO extraction and synthesis from process residues
Master alloys preparation
New process development is a significant component of work at KPM. We have worked on a wide range of novel projects on contractual basis, many of which are on-going and confidential. However, we also work on in-house projects and have developed a number of technologies that could be commercialized with the right industrial partner. Examples of novel process development work include:
Production of hydrogen from H2S
Dehydration of MgCl2
H2 storage and delivery for fuel cell applications
Spent pot lining treatment
Cermet development and testing for molten salt electrolysis
Sulfur injection in ferro-nickel production
Aluminum demagging
Titanium powder production
Production of ultra-high purity copper (6N5)and nickel (5N)
Inert anodes for aluminum production
Direct coal fuel cell reactor
- Development and piloting of lithium-ion batteries (LIBs) recycling process”
