08/23/2003

Hydrometallurgy 2003

Hydrometallurgy 2003 Short Course

Case Study 1: Leach SX-EW Practices Technology Updates & New Ideas James L. Sorensen, Joe Milbourne and Brian Kennedy AMEC E&C - Mining & Metals

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Leach SX-EW Practices Technology Updates and New Ideas

Case Study Objective Review selected current practice, design updates and new technologies applicable to modern solvent extraction and electrowinning plant design and operation

Leach SXEW System Overview

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Case Study Outline Leach SX-EW Practices

Leaching Application Implications

Heap Leaching Concentrate Leaching Considerations

Solvent Extraction Technology Updates

Conventional SX plant design improvements New ideas/technology

Electrowinning Technology Updates

Conventional plant design improvements New technology ideas

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Case Study Outline - Leaching

Leaching Application Implications

Heap Leaching
Materials handling Solution management

Concentrate Leaching Considerations

Pressure oxidation Bio-Leaching Chemical oxidation Concentrate Heap Leach

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Heap Leaching Materials Handling

Agglomeration for crushed ore systems now common

but not always required
Acid mixing and distribution improved Fines segregation lessened Drums not required for P80>10mm, fines content >12% minus 100 mesh and /or >8% minus 200 mesh Belt mixing of acid/water (or raffinate) a lower cost option for materials that do not require agglomeration

Materials placement by stacking systems now proven

at high tonnage rates and for on-off pad applications

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P80 Minus 19 mm (3/4 inch)

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Drum Agglomeration

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Grasshopper conveyors Grasshopper conveyors

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Conveyor stacking/on-belt acid addition

Acid addition points

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Large scale stacking system

Retreat stacking

7m

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Advance stacking

30 m

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Solution Management
Objective: minimize SX plant size/costs Use of intermediate solution ponds as unit operations Solution Stacking
High grade/low grade areas on common heap Sulfide/oxide operations Acid control opportunity if relevant (may be considered as intermediate SX operation to reduce metal content/acid control)

High grade low grade SX feed Parallel-series integration of

low grade feed to parallel unit / higher grade feed to series units Metal inventory increases and affect on leaching kinetics must be considered in all application decisions

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Pond Design Considerations

Heap Drain down & Flood Flow Pregnant Liquor Overflow Emergency Overflow

Flood Surge

Emergency Overflow Pond (If Required)

Operating Level*

Pregnant Pond(s)

Raffinate Pond

Pump Sumps Or Low Areas * Maximum and Minimum Operating Levels Due to Normal Seasonal Fluctuations and Heap drain-down

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General Arrangement of Heap Leach

DIVERSION DITCH

Raffinate

HEAP HEAP LEACH PAD LEACH PAD

PLANT AREA

INTERMEDIATE INTERMEDIATE POND POND PREGNANT POND

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Drip tube irrigation to minimize evaporation losses/wind borne loss

Pipe arrangement for two 15.tif 15.tif different feed streams

Distribution pipes

Emitter tubing @ 1 meter spacing x 1 meter gap

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Case Study Outline - Leaching

Concentrate Leaching New technologies in or near production
Pressure oxidation Bio-Leaching (heap and reactor) Chemical oxidation
SO4, Cl, CN, NH3/NH4 lixiviant matrices

Concentrate Heap Leach

Challenge to SX acid control

Higher copper tenor solutions acid production in SX Higher acid content in leach solutions

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Solvent Extraction Chemical Process

Extraction Reaction
Cu2+(aq) Impure Copper Sulfate Solution + 2RH(org) + Extractant CuR2(org) Copper Complex

1.54 moles Acid per mole Cu Extracted

+ 2H+(aq) + Acid

Stripping Reaction
CuR2(org) Copper Complex + 2H+(aq) + Conc. acid Cu2+(aq) Purified Conc, Copper Sulfate + 2RH(org) + Regenerated Extractant

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pH Isotherms for LIX 984

3

Organic (Metal Organic (Metal content) in g/l content) in g/l

Cu2+ 2 Ni2+

Co2+

1 Loading capacity diminishes with pH 1 2 Zn2+ Fe3+

pH

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Acid control and operation options

Medium grade feed solution ( 12 -16gpl Cu) Parallel-series organic/raffinate
Additional parallel extractor fed with raffinate and stripped organic Increased O:A ratios Up to double organic flow to stripping or parallel strip stage

Pre-neutralization to pH 3 to 3.5 (can also reduce iron to SX in

high iron PLS) may include mixing with leach pad operations with acid consumption requirements Modest inter-stage neutralization (non-precipitating) with NaOH, NH3, etc. (economically driven) Ion exchange recovery of acid and acid re-use (solvent based or resin based)

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Acid control and operation options

High grade feed solution (>16 gpl Cu) Pre-neutralization to pH 3 to 3.5 (can also reduce iron to SX in high iron PLS) Inter-stage neutralization (non-precipitating) with NaOH, NH3, etc. (economically driven) Intermediate SX neutralization stages (precipitate and solution cleaning external to SX process) lower cost carbonates, lime or high acid consuming ores may be used Ion exchange recovery of acid and acid re-use (solvent based or resin based)

Best solution may be combinations of above

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Chemical Leaching SX

Leaching/SX Extraction and Stripping/Electrowinning

do not need to be performed in the same chemical regime, commercial examples:
Metal recycle: NH3/NH4 leach/extract and SO4 strip/EW Zinc/Copper: Cl leach/extract and SO4 strip/EW

Multi-component extraction/strip in series now piloted

or commercial (Ni/Co, Cu/Zn, Cu/Co, Au/Cu) requires pH control

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Some pH Isotherms for LIX 984

3
Stripping Loading

Multi-component

Cu2+ Organic (Metal Organic (Metal content) in g/l content) in g/l 2

Ni2+

Co2+

1 Fe3+ Loading capacity diminishes with pH 1 2 3 4 5

Zn2+

pH

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Case Study Outline Solvent Extraction

Solvent Extraction Technology Updates

Conventional SX plant design improvements
Layout Equipment

New technology ideas

Static Mixing Technology Column Technology

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Typical SX Mixer-Settler Typical SX Mixer-Settler

EMULSION DISPERSION BAND ORGANIC SOLUTION CRUD LAYER ADJUSTABLE LEVEL

AQUEOUS SOLUTION

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Typical Settler Design Considerations Typical Settler Design Considerations

Distribution Fence Decant weirs

Inlet Flow Avoid center jet flow

Even flow distribution across settler

Coalesing Fence(s)

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Conventional Mixing System Design Conventional Mixing System Design

Minimize Pumping Head/Power Minimize Pumping Head/Power
Pumping :: N2D2 Power Pumping N2D2 Power Shear :: N3D5 Power Shear N3D5 Power More power goes to fluid shear than pumping = finer More power goes to fluid shear than pumping = finer droplets and more difficult separation characteristics droplets and more difficult separation characteristics Optimum Droplet Size Distribution 0.7 to 1.1 mm (85%) Optimum Droplet Size Distribution 0.7 to 1.1 mm (85%) Dmixer // Dtank (Conventional) Dmixer Dtank (Conventional) Primary 0.6 - 0.65 (pump turbine mixer) Primary 0.6 - 0.65 (pump turbine mixer) Auxiliary 0.5 (axial flow) Auxiliary 0.5 (axial flow) Square tanks are self baffling, round tanks are easier Square tanks are self baffling, round tanks are easier design and construction design and construction

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Conventional plant design improvements

Mixing technology has been updated to reduce over-shearing
Use of pumped phases (axial flow pumps) primary and recycles Multiple hubs/locations on shaft to separate pumping and mixing duties in pump/mixers Use of gravity flow layouts to assist fluid movement Improved mixer design and technology (Outokumpu VSF design separates pumping/initial dispersion and mixing operations)

Above ground SX plants to eliminate piping trenches operator

access consideration important More attention to plant layout arrangement of units to minimize costs (close packed, parallel-series for lower grade solutions) Loaded and barren organic tanks both used to facilitate cold start-up and contamination control can have lower overall organic inventory requirements

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Outokumpu SX Mixing Technology Outokumpu SX Mixing Technology

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Outokumpu Mixer-Settler Concept Outokumpu Mixer-Settler Concept

Section

Mixers located in settling areas

Weir Decant boxes Plan View

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SX plant configuration and layout SX plant configuration and layout

Determined by PLS Copper Tenor and Flow rates Parallel Series Considerations Flexibility of Operation Wash Stages for Impurity Transfer (Chemical / Physical) pH control required Economic Considerations

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CONVENTIONAL SX CIRCUIT
COPPER BEARING SOLUTION E1

S1 LOADED ORGANIC

ADVANCE SOLUTION ELECTRO WINNING

E2

RAFFINATE RETURNED TO LEACH

SPENT ELECTROLYTE STRIPPED ORGANIC

ORGANIC
COPPER BEARING SOLUTION

AQUEOUS
E1 RAFFINATE RETURNED TO LEACH LOADED ORGANIC

S1

ELECTRO WINNING SPENT ELECTROLYTE

E2

STRIPPED ORGANIC

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SERIES PARALLEL SX CIRCUIT

ORGANIC
E1

AQUEOUS
RAFFINATE RETURNED TO LEACH

ADVANCE SOLUTION

E2

S1

ADVANCE SOLUTION

ELECTRO WINNING SPENT ELECTROLYTE

E1 STRIPPED ORGANIC

SPENT ELECTROLYTE LOADED ORGANIC

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Parallel-Series SX
Parallel Extractor Series Extractors

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Ground level settler/open access trenches

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HDPE lined concrete settler

HDPE piping where practical

Side weir discharge box to eliminate pipe turn distance/depth

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Settler Interior Settler Interior

HDPE Flooring

External fence supports

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New SX ideas/technology

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Conventional vs. Deep Settler Conventional vs. Deep Settler

Conventional Settler: Conventional Settler: Settling Area Requirement is Approx. 4.0 m3 // hr // m2 Settling Area Requirement is Approx. 4.0 m3 hr m2 Velocities Velocities Linear Bulk flow 3 cm // sec Linear Bulk flow 3 cm sec O/A Differential 1.5 :: 1 Maximum O/A Differential 1.5 1 Maximum Organic Depth 250 -- 300 mm; Aqueous Depth 450 -- 600 mm Organic Depth 250 300 mm; Aqueous Depth 450 600 mm Deep Settler: Deep Settler: Settling Area Requirement is Approx. 8.0 m3 // hr // m2 Settling Area Requirement is Approx. 8.0 m3 hr m2 Velocities stay the same Velocities stay the same Organic Depth 500 -- 600 mm; Aqueous Depth 900 -- 1200 mm Organic Depth 500 600 mm; Aqueous Depth 900 1200 mm Less emulsion carryover, better decantation, room for crud variations Less emulsion carryover, better decantation, room for crud variations Pumping head similar to reverse flow design with the added benefits Pumping head similar to reverse flow design with the added benefits

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Plant Layout Deep/Close Packed Settlers

Integral launder Walkway Return/recycle piping in settler 42% less area 18% less piping length

Setter depth > 1.5m

Adjoining mixers on same side of layout Common Wall 30% less material Open access pipe/mixer area

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Close-packed plant layout Reverse Flow*

* Bateman & Kvaerner
Technologies Distribution fences Reverse flow launder 24% less area 13% less piping length

Common walls and deeper settlers possible

Launders & mixers on same side

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Close packed settlers

Strip stages

Extraction Stages

Wash Stages

Loaded Organic Surge Tank

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All modular/unitized HDPE/FRP construction

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Entrainment reduction/recovery

After settlers/in-settler media (50% to 70% recovery

from >70 ppm 40 ppm minimum) Column Cells (50% to 70% recovery from > 50 ppm 20 ppm minimum product) Coalescers (60% to 80% recovery from > 40 ppm 10 - 15 ppm minimum product design dependent) Filters (80% to 90% recovery from >40 ppm minimum product 5 -10 ppm) Carbon columns (80% to 90% recovery <20 ppm minimum product 1-2 ppm) NEW TECHNOLOGY APPLICATION Cyclones (Krebs) in testing phase

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Minimum entrainment from SLIDE5.TIF series applications SLIDE5.TIF

Electrolyte Feed inlet

Column Cells initial coarse separation L/D >3:1 working zone

Sparger location

Column Outlet

Dual Media Filters final polishing

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Column Cell Operation Column Cell Operation

Level control quiescent tube Intermittent froth recovery minimize electrolyte carryover Froth < 1 mm Bubble size Organic recovered

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CESL Column Cell

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SLIDE2.TIF SLIDE2.TIF
All HDPE Column Cell Spiral Wound Construction

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All modular/unitized construction

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Static mixing technology

Separates mixing and pumping operations

Reduced energy going to shearing of fluid vs. pumping yields less fine droplets to settle and better energy use Plug flow mixing requires less volume Closed system reduces design concerns (VOC emissions, oxygen degradation, air emulsions, airborne contaminants) Mixing/settling control not phase specific (mixer continuity) Recycles for phase control not required

Can employ alternate phase separation technology

Coalescers, separation columns, high specific settling rate units

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Static mixing technology Case Example Koch-Glitsch/Otto York

Employs static mixer and reactor pair Coalescer separation technology as primary phase
separation Optional coalescer based or other phase polishing to minimize entrainment Pumped solution do not require subsurface tank farms for gravity flow Piloted at 100 gpm concept design developed for 3,000 gpm train units

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Static mixing technology Case Example Koch-Glitsch/Otto York

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Case Study Outline - Electrowinning

Electrowinning Technology Updates

Conventional plant design improvements
Layout Equipment

New technology
High current density EW chemistry/quality Acid/bleed control

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TYPICAL ELECTROWINNING CELL

Cathodes

Anodes

Electrolyte Flow

Distribution Manifold

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Electrowinning Cell Electrowinning Cell

Dog bone inter-cell bus bar Polymer concrete cell & furniture Clip type anode insulators

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Cell flow distributor

Top capture cathode design

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Permanent Cathode Size Plating Area

Conventional Cathode: ~ 1m wide x 1m tall

New old concept: 1m wide x 2m tall Adaptation of current zinc technology 50% lower cell area required Improved in-cell circulation New inert anode technology (DSA, Eltech, or other inert) Material handling to optimal size for sale (automated or manual shearing) Lower total cell voltage; amperage change dependent on configuration, same power total power

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Cell house ventilation and mist control

In cell devices
Polypropylene brushes attached to anodes Polypropylene balls and beads Foams (FC-1100 for copper)

Building ventilation options in practice

Heat convective building design (least effective) Air curtain (cross flow louver/fan and fan/fan option) Localized cell capture (covered and uncovered)

Mist is an industrial hygiene, materials of

construction, maintenance and air quality issue

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V30.GIF V30.GIF

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DESOM Cross-flow ventilation DESOM Cross-flow ventilation

Stainless steel siding Fresh air plenum for motors

Air Flow

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SAME Ventilation

Mist Scrubbers Ventilated Cell Covers

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Dimensionally stable & inert

Titanium substrate, inert coated (technology

dependent)
Mesh, perforated plate, rolled plate Eltech DSA, ALE

Titanium/coated anodes issues/opportunities

Approx. 3.5X more costly than Pb rolled plate Electrode life 5 years, coatings life ~2 years (no long term data), dependent on damage from handling & shorts, reapplication off site @ 25-50% of initial cost No Pb contamination or scale flaking issues No CoSO4 required for PbO/PbO2 stabilization Permits gas agitation or high-flow cell flow circulation

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V42.GIF V42.GIF
ANODE DESIGN
Roll Plate (Pb/Ca/Sn) Inert/coated & dimensionally stable DSA ALE

Electrolyte flow window improved circulation

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Cathode corrugations improved melting

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High current density technology

Conventional technology 250 A/m2 360 A/m2 High current density technologies:
Desom 400-600 A/m2 with agitation (gas or mechanical/high flow) Lurgi 1500-1800 A/m2 (gas or mechanical/high flow) Inert anodes most practical for agitation

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Feed water quality & EW chemistry

Contamination sources
Feed water (Cl, Si, NO3) contaminant control critical to EW Acid make-up to electrolyte must be routinely checked for contamination (As, Bi, Se, Te, Cl, NO3)

Solutions
Purchase acid at 2 qualities (larger use is typically leaching) to reduce costs Treat water (Reverse Osmosis) for EW needs and other plant applications as required

Positive temperature control in EW critical to qualityheat losses to ventilation choice and climatic conditions must be considered

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Reverse Osmosis water treatment facility

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Hot Water Heater or Boiler for temp control

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Excess acid/bleed control

Acid removal and recovery with IX Cobalt recovery from bleed (acid removal required) Re-extraction of bleed (directed into SX) Bleed advance for acid control in upstream leaching applications (POX and high acid consuming minerals)

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Final Products
The final plant product does not always have to be EW cathodes in all cases Electrowinning is typically 50 to70% of SXEW plant capital cost & 65 to 80% of plant power requirements Copper: sulfate crystals (off site EW, fertilizer); sulfide precip to off site smelter, foil, copper powder, oxide Zinc: sulfate crystals (off site EW, fertilizer); sulfide precip to off site smelter, oxide & carbonate final product Nickel/Cobalt: sulfide or carbonate precip to off site smelter

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Leach Piles

3VI.gif-3IV 3VI.gif-3IV

new9.tiff

Final Objective Quality Product Consistently & Cost Effectively Produced

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