| Summary: | The processing of Cu, Co, and Zn at the Boleo project in Mexico involves two-stage (oxidation–reduction) leaching to extract a total of 85–88% Cu in 4 h. The first stage is an oxidation leaching using sulphuric acid (120 kg/tonne ore) at an Eh of 900 mV for 2 h. Then, the reduction stage takes place in 2 h with SO<sub>2</sub> gas sparging for Mn and Co extraction at an Eh of 350–370 mV. The final extraction rates of metal values are 92% of Mn, 80% of Co, and 60% of Co, respectively, after 4 h of leaching at 70 °C. However, the same metal recoveries were obtained within 2 h using an equal amount of sulphuric acid and the addition of 25 kg of SO<sub>2</sub> per tonne of ore in a single stage leaching in this research. In this case, the Fe extracted from the ore as Fe<sup>2+</sup>/Fe<sup>3+</sup> is believed to have acted as an electrochemical couple contiguously leaching the Cu sulphide and Mn oxides, which also increased the Cu recovery as the Cu mineralised mostly intergrowths in these mineral structure matrices. A significant improvement was made in which the leaching time was halved to 2 h compared to 4 h in the previous plant design and current operation, involving the two-stage oxidation–reduction leaching.
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