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TheIntecCopperProcess

October2008


TableofContents
1 Introduction....................................................................................................................................3
2 IntecProcessBackground...............................................................................................................4
2.1 HalideLixiviants......................................................................................................................4
2.2 LeachingProcesses.................................................................................................................5
2.2.1 Sulphides.........................................................................................................................5
2.2.2 Oxides..............................................................................................................................6
2.2.3 ArsenicBearingFeedstocks............................................................................................6
2.2.4 IronResidue....................................................................................................................6
2.2.5 LeachConditionsSummary.............................................................................................7
2.2.6 LeachCircuitDesign........................................................................................................7
2.2.7 CoCurrentLeaching(CupricSystem).............................................................................8
2.2.8 CounterCurrentLeaching(CuprousSystem).................................................................8
2.3 CopperRecoveryOptions.......................................................................................................9
2.3.1 CopperHalideElectrowinning........................................................................................9
2.3.2 SolventExtractionofCopperfromHalideSolutions....................................................10
2.3.3 CopperOxychloridePrecipitation.................................................................................11
2.4 ByProductCreditMetalsRecoveryOptions........................................................................11
2.4.1 Gold...............................................................................................................................12
2.4.2 Silver..............................................................................................................................12
2.4.3 Indium...........................................................................................................................12
2.4.4 Bismuth.........................................................................................................................12
3 IntecProcessAdvantages.............................................................................................................13
3.1 IntecProcessvs.Smelters.....................................................................................................13
3.2 IntecProcessvs.SulphateHydrometallurgy.........................................................................13
4 IntecProcessEconomics...............................................................................................................15
4.1 IntecProcessEconomicsvs.CompetingTechnologies.........................................................15
4.2 IntecProcessEconomicModels............................................................................................16
5 IntecProcessEnvironmentalAdvantages.....................................................................................18
5.1 LifeCycleAnalysis.................................................................................................................18

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1 Introduction

TheIntecProcess is a family ofpatentedhydrometallurgical technologies fortherecoveryof base


andpreciousmetalsfromsulphideandoxidefeedstocks.Itisbasedontheuseofhalide(chloride,
bromide and iodide) chemistry to solubilise metals through the leaching process, followed by the
recoveryofhighpuritymetalsbyelectrowinningorchemicalsalts.

Thisdocumentsummarisestheapplicationofthetechnologyforrecoveryofcopperandassociated
coproductorbyproductmetals,andisdividedintothreemainsectionswithaparticularemphasis
on its comparison with existing copper recovery technologies. Firstly, the technical aspects of the
processareexplained,especiallytheabilityoftheIntecProcesstoaccommodatelargevariationsin
feedstockwithrespecttofeedstockmineralogy,metalcontentandprojectsize.Thesecondsection
provides an economic summary at varying production rates including comparison with the
economicsof competingtechnologies. Finally,the environmental benefitsof theIntec Process are
alsodescribed.

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2 IntecProcessBackground

ThepatentedIntecCopperProcesswasdevelopedfortherecoveryofcoppermetalatLMEGradeA
purity. Essentially, the process consists of leaching, purification and product recovery
(electrowinning or other); however the unit operations can be adjusted based on the feedstock
composition,quantityandlocationinordertooptimiseeconomicreturns.

AnexampleflowsheetoftheprocessisshowninFigure21.Feweroradditionalunitoperationsmay
berequireddependingonfeedstockcharacteristics.

CARBON COLUMN
FOR GOLD GOLD BULLION
FURNACE
LIMESTONE
COPPER
CONCENTRATE LEACH LEACH LEACH
(P80<40 microns) STAGE 1 STAGE 2 STAGE 3
L LEACH RESIDUE
S

AIR

THICKENER THICKENER

CUPRIC REDUCTION Cu 25 gpl LIME


plus Halex
MERCURIC CHLORIDE RECYCLE
BY-PRODUCT (Hg)
L SILVER BULLION
S
WASH FURNACE
ALUMINIUM L SILVER RECOVERY L BY-PRODUCT
S S
(Co, Pb, Ni, Zn)
LIMESTONE S pH 9 PURIFICATION
SILVER L BY-PRODUCT (Bi, In)
AMALGAMATION
pH 4 PURIFICATION

Cu 75 gpl
_
+

ELECTROWINNING
Cuo RECYCLE FURNACE COPPER PRODUCT
(INGOT, BILLET, ROD,
ETC)


Figure21:ExampleflowsheetoftheIntecCopperProcess

2.1 HalideLixiviants

Thesolubilityofmetalsissignificantlyenhancedinthepresenceofconcentratedhalidebrines.For
examplegold,silverandleadarereadilysolubilisedintheIntecProcessliquors,whiletheyremain
virtually insoluble in the sulphate lixiviants of competing hydrometallurgical technologies.
Furthermore, a broader range of metallic species are also stable in halide liquors, such as the
cuprousoxidationstateofcopper(Cu+),whichdoesnotexistinsulphate.

TheIntecProcessbrinematrixtypicallyusesatotalhalideconcentrationof68moles/litre,witha
boilingpointof115120C.Thechloridecomponentsareamixtureofsodiumandcalciumchloride;
with the ratio depending on overall halide requirements for metal solubility, and the calcium
requiredforsulphateprecipitation.

The mixed halide system usually using sodium bromide in conjunction with sodium/calcium
chloride is at the core of Intecs patents for metal recovery by halide electrowinning. The Intec
ProcessanodeformsthepowerfuloxidantcalledHalexTM(NaBrCl2),whichissolubleintheprocess
liquorandisreadilyrecycledthroughtheclosedloopsystem,providingtheprimarydrivingforceto
theleachstep.

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Bromide and iodide also enhance the stability of precious metals such as gold and silver. In some
applications of the Intec CopperProcess,traceamounts of sodium iodide areselectively addedto
enhancegoldrecovery.

ThehighmetalleachingratesandefficienciesassociatedwiththeIntecProcessleachcreatesome
challengesforthephysicalplant.As such,theappropriateselectionof materialsofconstructionis
importanttoensurelongevityofequipment.Allwettedpartsoftheplantarefabricatedfromhigh
performanceplastics,orinsomesectionsexoticalloysortitanium.

Reactorsaretypicallyconstructedfromcomparativelyinexpensivefibreglassreinforcedplastic(FRP)
usingDerakane470300resin,whichpermitscontinuousoperationat130 C.Thecostsaresimilar
to or less than equivalent steel tanks. Various linings can be used where required for additional
protection,e.g.inhighwearzones.Titaniumorcoatedsteelagitatorshavebeensuccessfullyused,
withthe finaldesign specificforthe mixingduties required.Piping isgenerallya mixture ofPVDF,
FRPorrandomcopolymerpolypropylenedependingontemperatureandpressureduties.

The performanceof these items ofequipmenthasbeen systematicallyand successfully proven by


Intec at both laboratory and demonstration plant scales, along with ancillary items such as
instrumentation,heatexchangers,ducting,structuralframework,andcontrolsystems.

2.2 LeachingProcesses

Therearetwotypesoffeedstock;metalsulphides(egthecommoncoppersulphidemineralsCuFeS2,
CuS,andCu2S)andmetaloxides(egCuOandCu2O).

TheIntectechnologyhasbeenappliedtoawiderangeofcopperbearingminerals,andasummary
of the typical leach conditions is given in Table 21. Notwithstanding the feedstockspecific
limitations of particle size and mineral occlusion, typically 98% (9599.5%) extraction of copper is
achieved,andcoextractionofcreditmetals(e.g.gold,silver,indium,bismuth,etc)issimilarlyhigh.

2.2.1 Sulphides

Metal sulphides are oxidised by sparging air to supply oxygen and the recycling of liquid anolyte
fromthehalideelectrowinningcell(occasionally,withtopupreagentacid),asshowninReactions1
and2.

4CuFeS2(s)+5O2+20HClJ4CuCl2+4FeCl3+8S(s)+10H2O RXN1

2CuFeS2(s)+5NaBrCl2J2CuCl2+2FeCl3+4S(s)+5NaBr RXN2

Anoxidationreductioncouple(eg.Cu+QCu2++e)isemployedtofacilitatethetransferofoxygenas
showninReactions3and4.Putsimply,thecopperactsasacatalysttomaximisetheefficiencyof
oxygenuptakebytheprocessliquor.

4CuCl+O2(g)+4HClJ4CuCl2+2H2O RXN3

CuFeS2(s)+4CuCl2J5CuCl+FeCl3+2S(s) RXN4

As may be seen in Reactions 1 and 2, the sulphide component (S2) is only partially oxidised to
elemental sulphur (S), resulting in a significant reduction in the total oxygen requirement for the

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system. Bycomparison,sulphatebasedpressureoxidationtechnologies commonly oxidisesulphur
tosulphate(SO42).

2.2.2 Oxides

Metaloxidesareleachedwithacid,whichisnormallyaddedtothecircuitaccordingtoReaction5.In
thecasewheremixedoxideandsulphidemineralsareprocessed,acidcanbegeneratedinsituvia
theoxidationofsulphurorsulphides(e.g.theoxidationofpyriteasshowninReaction6)andthis
canbeacheaperalternativetopurchasingfreshacidincertainsituations.

CuO(s)+2HClJCuCl2+H2O RXN5

2FeS2(s)+15NaBrCl2+4CaCl2+16H2OJ2FeCl3+4CaSO4(s)+32HCl+15NaBr RXN6

Whereacidisaddeddirectlytotheprocess,sulphuricacidispurchased,asitisalowercostreagent
thanhydrochloricacid.Thecalciumchlorideintheprocessliquorreactswiththesulphatetoform
calciumsulphateandhydrochloricacidaccordingtoReaction7.Duetothehightemperaturesinthe
circuitandtheconcentratedhalidebrineusedintheIntecProcess,theanhydrousformofcalcium
sulphate (anhydrite) is precipitated, as opposed to the hydrated form (gypsum). The anhydrite is
highly crystalline and does not form scale on the process equipment, as is normally the case with
gypsuminsulphatebasedsystems.

H2SO4+CaCl2J2HCl+CaSO4(s) RXN7

2.2.3 ArsenicBearingFeedstocks

One of the major environmental reasons for selecting hydrometallurgical processing rather than
smeltingformanycopperconcentratesisthepresenceofarsenic.Arsenicisatoxicmetalwhichis
difficulttocontrolintheoffgasfromsmelteroperations.Assuch,anupperlimitof0.5%arsenicin
theconcentratefeedstocksisnormallyappliedbysmelters.

IntheIntecProcessleachcircuit,arsenicisreadilyleachedandreprecipitatedashighlycrystalline
ferric arsenate according to Reactions 8 and 9. The crystalline ferric arsenate readily passes
conventionalTCLPandMEPtestsasameasureofenvironmental stability. Inrecognitionofthis,a
NSWEPAapprovalwasgrantedtoIntecin1999/2000fordisposalofleachresiduecontainingferric
arsenateintoconventionallandfill.Feedstockscontainingupto10%arsenichavebeensuccessfully
treatedbythismethod.

FeAsS+7CuCl2+4H2OJFeCl2+7CuCl+S+H3AsO4+5HCl RXN8

H3AsO4+FeCl3JFeAsO4(s)+H2O RXN9

2.2.4 IronResidue

Apotentialissueforanyprocessleachcircuitiscontrolandprecipitationofsolubilisediron.Many
technologies encounter significant difficulty with the physical handling, filtration and poor
environmentalstabilityofprecipitatedironwastes.

Leaching of copper minerals using the Intec Process is conducted in the pH range of 12, where
leachable iron is reprecipitated as hematite according to Reaction 10. The acid generated in this
reactionisreusedtooxidisethecoppercationsasshowninReaction11.

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2FeCl3+3H2OJFe2O3(s)+6HCl RXN10

4CuCl+4HCl+O2J4CuCl2+2H2O RXN11

Thehematiteiscrystallineandisthusreadilyfilterable.Hematiteisoneofthemoststableformsof
iron,andextensivetestinghasdemonstratedthathematiteproductisenvironmentallystable,unlike
ironjarosites.

2.2.5 LeachConditionsSummary

The Intec Process technology has been applied to a wide range of copperbearing minerals at the
laboratory, pilot and/or demonstration plant scales. Table 21 summarises the required leach
conditionsforcopperbearingmineralssuitableforprocessingbytheIntecProcess.

Table21:SummaryofLeachConditionsusingtheIntecProcess

Mineral Formula Conditions Comments


Sulfides
Chalcocite Cu2S
7585C Rapidleachingbehaviour
Covellite CuS
Chalcopyrite CuFeS2 85C Moderateleachingbehaviour
Bornite Cu5FeS4
Enargite Cu3AsS4 Slowleachkineticswhichcanbeenhancedby
95100C
Tennantite Cu8As2S7 additives
Tetrahedrite 4Cu2SSb2S3
Oxides
Azurite 2CuCO3Cu(OH)2
Cuprite Cu2O
>30C Rapidleachingbehaviour
Malachite CuCO3Cu(OH)2
Tenorite CuO
Other
Native Cu 7585C Rapidleachingbehaviour

2.2.6 LeachCircuitDesign

Twoexampleleachcircuitdesignshavebeenprovidedtoshowingtheuseofsolublecopperinthe
cupric(Cu2+)orcuprous(Cu+)state.Acupricbasedsystemwouldbeappropriatetosmallerprojects
producing intermediate copper products or mixedtechnology projects, while a cuprousbased
systemwouldbeappropriatefortheproductionofhighpuritycoppermetalviaelectrowinning.

The simpler cupric system uses a single train of leach tanks, whereas the cuprous system uses a
threestagecountercurrentcircuit.AdiagramofeachcircuitisshowninFigure22.

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Figure22:BlockDiagramsofCoCurrentandCounterCurrentLeachCircuits

2.2.7 CoCurrentLeaching(CupricSystem)

Cupricionsareidealforthedirectprecipitationofcopperoxychloride,orsolventextractioncircuits
whichcanbelinkedtosulphateelectrowinningorsaltcrystallisationunits.

The leach conditions in the single train are highly oxidative in every tank, which affords the most
economical leach circuit. However, these savings must be weighed against the additional costs of
copperrecoveryfromthecupricstateifelectrowinningisusedasthefinalrecoverystep.Thiswould
typicallyonlybethecasewherecopperwaspresentasabyproducttoahighervaluemetalinthe
feedstock,suchasgold.

2.2.8 CounterCurrentLeaching(CuprousSystem)

Cuprous ions are ideal for direct halide electrowinning, with about half the energy cost of
electrowinning from the cupric state (used in all other sulphatebased copper electrowinning
technologies). As such, countercurrent leaching is appropriate for larger projects with dedicated
IntecProcesselectrowinningplantsforproductionofhighgradecoppermetal.

The leach conditions in the countercurrent circuit vary from tank to tank, to ensure that copper
exitingtheleachisinthecuprousoxidationstate.Additionalcostisrequiredforthethickeners,and
this also adds complexity for process control. However, at large production scales these costs are
offsetbysignificantenergysavingsfromtheelectrowinningofcuprouscopper.

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2.3 CopperRecoveryOptions

2.3.1 CopperHalideElectrowinning

Intec has developed a copper electrowinning cell specifically for cuprous (CuCl) and cupric (CuCl2)
systems. The cell is divided into two compartments via a porous diaphragm (conventional filter
cloth).Thefeedsolutionisdirectedtothecathodecompartment,wheremetalliccopperdendrites
areelectrowonontoapatentedcorrugatedtitaniumcathode(Reaction12).Thedepletedsolution
passes through the diaphragm into the anode chamber, where NaBrCl2 is generated at the anode
(Reaction13).Somepicturesofthetitaniumcathode(wipedandunwiped),copperdendrite,aswell
astheconveyoraregiveninFigure23.


Cathode CuClJCu(s)+Cl+2e
RXN12

Anode NaBr+2Cl +2e JNaBrCl2 RXN13

Overall 2CuCl+NaBrJCu(s)+NaBrCl2 RXN14

Figure23:(TOPLEFT)Titaniumcorrugatedcathode,(TOPRIGHT)Dendrite,(BOTTOMLEFT)Unwipedtitaniumcathode,
(BOTTOMRIGHT)CopperdendritesbeingremovedfromtheEWcellbyconveyorbelt

The sodium bromochlorine complex called Halex TM is a dissolved species with a low vapour
pressure. Halex behaves like chlorine gas in terms of oxidation power and chemistry, but with
obviousconsiderablehandlingadvantagescomparedtoagas.Ithasapotentialofaround+1000mV
(vs Ag/AgCl) and is highly reactive. As a liquid, the oxidant is easily recycled to the leach circuit,
whereitismoreeasilyutilisedthanagas.Halexenhancestheleachingofrefractoryminerals,which
oftenhostgold.

Importantly,theHalexspeciesisuniquetotheIntecProcess,beingderivedfromtheuseofmixed
halide lixiviants. This intellectual property is securedbyover twohundred internationalpatents in
sevenpatentfamiliesthatareconstantlybeingupdatedaspartofanevergreeningstrategy.

Intechasoperatedanumberofcellsrangingfromlaboratoryscaletothefullcommercial1tonne
perdayscale.Largerplantswouldusemultiplesofthe1tonneperdaycell.Thenominaloperating
conditionsaresummarisedinTable22.

Table22:SummaryofParametersforCopperElectrowinningUsingtheIntecCell

Parameter Value Comment


2
CurrentDensity 5001000A/m AverageinsulphateEWis400A/m2
Cellvoltage 2.43.2V
Cellefficiency >98 %
MetalPurity LMEAGrade
Electrodesperbath 32
Cathodedimensions 1.57x1m

ThekeyadvantagesoftheIntecProcesscellcomparedtocoppersulphateelectrowinningcellsare
summarisedbelow:
The Intec Process copper dendrites are removed insitu using a wiper mechanism and a
conveyor belt. This eliminates the cost of cathode removal and stripping, allowing
continuousproduction;
Three times the average current density of a sulphate cell is used in the Intec Process,
therebysignificantlyreducingtheoveralltankhousefootprint.Thecopperproductionrateis
uptoeighttimesthatofaconventionalsulphatecell;
The Intec Process cell can be fed with cuprous (Cu+) ions, thereby reducing the overall
energyrequirements;
The oxidant (HalexTM) generated at the anode is reused in the leach circuit, whereas the
oxygenfromthesulphatecellanodeiswastedtotheatmosphere.Thisalsomeansthatthe
electricalenergyappliedtothecellisfullyrecoveredascoppermetalandleachreagent.

The copper dendrites are washed and converted to oxygenfree copper wirerod, which attracts a
premiumoftypically48%overLMEAgradecathodes.Intechassuccessfullydrawn8mmwirerod,
produced from electrowon copper dendrites, to 0.1mm magnet wire, which meets normal wire
standards.

Forsomeprojects(typicallythoseofsmallscale),economicconsiderationsdictatethatacupricleach
is preferred. The electrowinning cell can be operated using Cu2+ ions, with the only detrimental
impactbeingahigherenergydemand.

2.3.2 SolventExtractionofCopperfromHalideSolutions

AnalternativetothedirectproductionofmetalliccopperbyelectrowinningintheIntecProcessis
theuseofsolventextractiontoselectivelyextractthecopperintoaseparateprocessstream.

Over the last 3040 years, copper solvent extraction followed by electrowinning has gained a 20%
marketshareoftheproductionmethodsforcoppermetal.

Most of the solvent extraction reagents contain oximes and are well developed and optimised to
transfer cupric ions (Cu2+) from a sulphatesystem,throughthe solvent. On the otherhand, in the
concentrated halide brines used by Intec, copper is complexed as a negative anion such as CuCl2,
CuCl32,CuCl3,andCuCl42,henceothertypesofreagentsmustbeused.

10

Incircuitswherecuprous(Cu+)isthemajorformofcopper,tributylphosphateisused.Caremust
be taken to ensure that the copper is not oxidised and (enclosed) pulsed columns are applied in
these circumstances. The entire copperchloride complex is transferred according to Reaction 15.
Thestrippingsolutioniscopperdepletedcatholytefromthehalideelectrowinningcell.

H2(CuCl3)+nTBPJnTBP.H2(CuCl3) RXN15

In circuits where cupric (Cu2+) is the major form of copper, 7(4ehtyl1methylocty)8


hydroxyquinoline is used. This reagent is capable of loading both cationic and anionic forms of
copperasshowninReactions16and17.Theloadedsolventisstrippedwithwatertoremovethe
halideanions,andthenwithacidtorecoverthecoppercations.Usingthismechanism,itispossible
totransfercopperfromahalideintoasulphatematrixforcopperelectrowinningorcrystallisationof
coppersulphatepentahydrate.

2NROH+Cu2+J(NRO)2Cu+2H+
RXN16

2HORNHCl+CuCl42J(HORNH)2CuCl4+2Cl
RXN17

2.3.3 CopperOxychloridePrecipitation

For small scale projects, the most economical method for recovering copper from a concentrated
halide solution is to precipitate copper oxychloride using limestone, as shown in Reaction 18. The
copper must be present as the cupric state, as cuprous ions are stable up to a pH of 66.5,
necessitatingtheuseofmoreexpensivelime.

4CuCl2+3CaCO3+3H2OJ2Cu2(OH)3Cl+3CaCl2+3CO2 RXN18

Copper oxychloride is widely used as a fungicide and also competes against copper sulphate
pentahydrateasananimalfeedsupplement.Itcommandsavalueofbetween8595%ofLMEfor
thecontainedcopper.Unfortunatelythenichemarketlimitstheapplicabilityofthisoptiontosmall
scaleproduction.

A convenient method for reprocessing copper oxychloride is to use conventional oxime solvent
extraction reagents (e.g. ACORGA 5640). The precipitate is releached in acid, with the dissolved
chloridelimitedto1M.Thecupriccationsareloadedontothesolventandstrippedwithhydrogen
cations. In this fashion the copper can be transferred to a conventional sulphate electrowinning
circuit for recovery. This technique is highly applicable to projects where existing sulphate
processinginfrastructureisavailable.

2.4 ByProductCreditMetalsRecoveryOptions

The process steps required to recover byproduct metals such as gold, silver, indium and bismuth
can vary significantly, depending on the concentration of the metals in the feedstock and their
relativevaluetoanyparticularproject.

Wherethebyproductcontentsand/orvaluesarecomparativelylow,thechosenrecoverymethods
will be simpler, producing lowergrade products at lower operating cost to maximise overall
profitability. Conversely, where the byproduct contents and/or values are comparatively higher,
there is value in using more sophisticated techniques to recover highervalue products, in many
casesinmetallicform.

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Asthe methodologycan varyquite significantly basedonthe individualprojectneeds, Section 2.4
providesonlyaroughguidetotheprocessoptionsavailableforbyproductmetalrecovery.

2.4.1 Gold

Gold recovery from Intec Copper Process leach liquors is achieved using activated carbon or ion
exchange resins in packed columns. These columns are contacted with clear leach solution
advancing from the cupric thickener, where the oxidationreduction potential is sufficient to
maintainthegoldinsolution.

Theactivatedcarboncanbesaturatedwithgoldandthenashedtorecovergoldmetal.Alternatively
the loaded activated carbon is stripped using conventional cyanide or thiourea reagents and the
eluted gold is electrowon. The eluted carbon is then reactivated as required, and returned to the
process.Testresultshaveshownthatreactivationisnotrequiredforatleastfivecycles.Thelatter
routeisalsoapplicabletoionexchangeresins.

2.4.2 Silver

The liquor exiting the gold recovery stage (or directly exiting the leach, if gold recovery is not
required) is advanced to another series of columns containing selective silver adsorption resins
developed primarily for the Intec Process. The loaded silver is stripped using acid, with the silver
precipitatedasachloridefordirectsaleorsmeltedtoproducesilvermetal.Thebarrenadsorbentis
returnedtotheprocess.

Forsolutionscontainingcuprousions,i.e.whenacountercurrentleachdesignisused,thesilveris
recovered using copper amalgamation promoted by trace mercury. A stoichiometric amount of
reducingagentisaddedtothe solution, suchascopper dendritesfromthe electrowinning cell,to
controlthepotentialofthesolution.

2.4.3 Indium

Indium in the copper leach processes is recovered directly using ionexchange resins in packed
columnsorisprecipitated to producean indiumrichcake forfurtherprocessing.Thefeed stream
mustbedepletedofFe3+andZn2+ions,whichcompetefortheactivesitesontheresin.Theloaded
resin is eluted with acid and the eluted indium is electrowon to produce high purity metal or
crystallisedtoproduceindiumsalts.Theelutedresinisrecycledtotheprocess.

2.4.4 Bismuth

Bismuthrecoveryinthecopperleachprocessesisverysimilartoindiumrecovery,wherebismuthis
recovered directly using specialty adsorbents in packed columns or is precipitated to produce a
bismuthrich cake for further processing. The loaded adsorbent is eluted with acid and the eluted
bismuth is electrowon to produce high purity metal or crystallised to produce bismuth salts. The
elutedresinisrecycledtotheprocess.

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3 IntecProcessAdvantages

Theworldssupplyofprimarycopperisproducedbytechnologiesthataresolelypyrometallurgical
in nature, or solely hydrometallurgical, or more frequently a mixture of the two. This section
compares the Intec Process to the most common industrial smelting (pyrometallurgical) and
hydrometallurgicalprocesses.

3.1 IntecProcessvs.Smelters

The pyrometallurgical treatment processes used in smelters for the production of base metals
(generallyfromsulphideores)haveanumberofwellestablisheddisadvantageswhencomparedto
hydrometallurgicalprocessing:

Highunitcapitalcostswhichbecomeeconomicallyfeasibleonlyatverylargescale.Assuch,
smelters tend to be centrally located on rail, road and/or port transport routes, accepting
feedstocksfrommultiplemines,inmanycasestransportingthefeedstocksforthousandsof
kilometrespriortoprocessing.Smeltersareonlybuiltatminesitesforverylargeprojects;
Highgrade and metalspecific concentrate feeds are required, which tend to detract from
therecoveryofbasemetalsfromtheoreintotheconcentrate(smelterfeedstock);
Thehandlingofmanycommonmetallicandothercontaminantsinbasemetalconcentrates
isdifficultandeitherpollutestheairwithsulphurdioxideand othercontaminantssuchas
arsenicandlead,orincursthehighcostsofpollutioncontainment;
Sulphuricacidisproducedasabyproductfromsulphurdioxideemissioncontrol.Itsvalueis
highlyvariabledependingonlocationandmayevenbenegative.

The Intec Process has significant advantages over existing smelting technology. These advantages
arebotheconomicandenvironmentalandinclude:

Significantlyloweroperatingandcapitalcosts;
Smallerscaleprojectsareeconomicallyviable;
Lowgradeandcontaminatedconcentratesaretolerated;
Nonoxiousgasesareproduced;and
Sulphurisconvertedfromtheleachablemineralsintoitselementalfrom,fromwhichitmay
berecoveredifrequired.

3.2 IntecProcessvs.SulphateHydrometallurgy

Many attempts have been made to overcome the various economic and environmental problems
associatedwithcoppersmelting,mostlyviathedevelopmentofhydrometallurgicalprocessesinthe
sulphate medium. These sulphatebased technologies share a number of characteristics which
impactontheireconomicandenvironmentalperformance:

All contain an SX/EW step meaning that their economics can never be better than the
economicsoftheSX/EWstep;
Allrequireasecondaryleachsteptorecoverpreciousmetalsfromtheirresidues(precious
metalsareinsolubleinsulphatesystems),whichareprocessedseparatelyatadditionalcost.
This is a significant factor, as over 80% of copper concentrates contain economically
recoverablepreciousmetals;
Cyanidation is required to recover precious metals from residues. This is an important
economicandenvironmentalconsideration;

13
Residuesmaybeexpectedtocontainjarositeswhicharephysicallyproblematictohandle,
andareenvironmentallyunstable.

The main sulphatebased copper hydrometallurgy processes that have reachedthe advancedpilot
stagearesetoutbelow:

The Total Pressure Oxidation Process or PLACER Process (ultra hightemperature/pressure


oxidationofconcentratefollowedbySX/EWforcopperrecovery);
The Activox Process (ultra fine grinding followed by moderatetemperature/pressure
oxidationofconcentratefollowedbySX/EWforcopperrecovery);
The Albion Process (ultra fine grinding followed by atmospheric pressure ferric leach
followedbySX/EWforcopperrecovery);
BioCOP and Bactech Processes (direct bacterial leaching processes followed by SX/EW for
copperrecovery);
TheDynatec Process(high temperature pressure leaching ofconcentrateswithdispersant
coaladditionfollowedbySX/EWforcopperrecovery);
TheCESLProcess(hightemperature/pressureoxidationleachwithaddedchloridefollowed
bySX/EWforcopperrecovery);
AARL/UBC(hightemperature/pressureoxidationleachwithaddedsurfactantsfollowedby
SX/EWforcopperrecovery);and
Galvanox(lowtemperatureleach)

Fewofthesetechnologieshaveprogressedtocommercialscaleapplication.

Asdistinctfromtheabovesulphatebasedhydrometallurgicalprocesses,theIntecCopperProcessas
well as the HydroCopper Process and Sumitomo Copper Process are based on halide (mixed
chloride/bromide) chemistry. Intecs unique halide chemistry facilitates the paradigm shift that is
essential to the commercially successful transformation of the copper concentrate processing
industryeconomics.

Intecsadvantagesoverthesulphatebasedhydrometallurgicalprocessesvariouslyinclude;

Atmosphericpressure,lowtemperatureleachconditions
Lowcostmaterialsofconstruction
Directrecoveryofpreciousmetals
Norequirementforsolventextraction
Norequirementforpureoxygen
Copper EW from the cuprous (one electron) state rather than the cupric (two electron)
state,greatlyreducingenergyconsumption
Regeneration of the lixiviant at the anode of the EW cell in soluble form for return to the
leachcircuitratherthanthewastageofanodicenergybythebubblingofpureoxygentothe
atmosphereinthesulphatesystem
Significantlyloweroperatingandcapitalcosts
Economicviabilitydowntosmallerscalecapacitylevels
Productionofanenvironmentallyacceptableresidue
Lowestenergyconsumption
Noliquideffluents.

14
4 IntecProcessEconomics

The Intec Process has a considerable range of advantages relative to smelting and other
hydrometallurgicalprocesses,ofwhichthemostcompellingadvantageisitsloweconomiccost.This
section provides an economic comparison of the Intec Process to other existing and developing
copper processing technologies. Additionally, a range of economic models have been prepared to
summariseandcomparevariousprojectscenarios.

4.1 IntecProcessEconomicsvs.CompetingTechnologies

Theeconomiccomparisoncontainedinthebelowfiguresistheprimarilyderivedfromindependent
analyses commissioned by Intec over a number of years, plus some of Intecs enquiries and
calculations.

ThecomparisoninFigure41isbasedonthedevelopmentofconceptualmassbalancesforeachof
theprocessesreviewed,fromwhichoperatingandcapitalcostswereestimatedina2003study.This
approachensuresaconsistentbasisforcomparisonandincludesthefollowingkeyassumptions:

Plantcapacityof100,000tpacopper
Treatmentofa25%copperconcentratefeedcontainingnopreciousmetals
Powercostof6.25US/kWh.

Intec has then incorporated into this analysis the capital and operating costs of a precious metals
recovery circuit for all of the hydrometallurgical processes reviewed. The need for the separate
recovery of precious metals by other hydrometallurgical processes is important, as approximately
80%oftheworldproductionofcopperconcentratescontaineconomicallyrecoverablequantitiesof
preciousmetals.

The comparison assumes onsite production costs and therefore excludes marketing and freight
costsandacidcredits,whilstthecostofacidneutralisationisincluded.Itshouldalsobenotedthat
these calculations incorporate an additional step for the melting and casting of the Intec Copper
Processdendriticproductintoingot,togiveaconservativeandequalbasisforcomparison.


250% 300%
% of Intec Capex

250%
% of Intec Opex

200%
200%
150%
150%
100%
100%
50% 50%

0% 0%
Intec Smelter Dynatec Activox CESL Biox Total Intec Biox Activox CESL Dynatec Total Smelter
POx POx
Processes Processes

Figure41:ComparisonofOperatingandCapitalcostsat100,000tpaCopperplantcapacityforvariousprocess
technologies

15
4.2 IntecProcessEconomicModels

More recent economic models for five Intec Copper Process production options are presented,
coveringthreedifferentproductionscales(6,000,20,000and50,000tonnesofcopperperannum);

Option1:ProductionofCopperOxychloride
Option2:ProductionofCopperSulphatePentahydrate
Option3:ProductionofCoppermetalviaasulphateelectrowinningprocess
Option4:ProductionofCoppermetalviaachloridecuprous(Cu+)electrowinningprocess
Option5:ProductionofCoppermetalviaachloridecupric(Cu2+)electrowinningprocess

Thefollowingkeyassumptionshavebeenmadetoproducethesemodels;

CopperpriceofAUD$7,000/tonne
Discountrateof10%
Projectlifeof10years
Concentratecostnotallowedfor
TheplantislocatedinAustraliaandsoAustralianreagent,utilityandlabourratesapply.

Itshouldbenoted that,tobe conservative, no credit metals such as silveror goldare included in


theseestimates.Creditmetalscangreatlyincreaserevenuesdependingonwhichprocessoptionis
selected.Similarly,theintegrationoftheplantintoexistingSX/EWplantswouldsignificantlyreduce
capitalcostforsomeoftheseoptions.

Figure 42 provides a graphical means by which process options can be compared at different
production scales in terms of their profitability index (project NPV divided by initial capital
investment)andoperatingcost/tonneofproducedcopper.


Figure42:ComparisonofProfitabilityIndex(NPV/CAPEX)versusOPEXforFiveCopperProductsat6,000,20,000and
50,000tpaScales

16
Itcanbeseenthatforsmallscaleproduction(6,000tpa),intermediatecopperproduction(copper
oxychloride or copper sulphate pentahydrate, Options 1 and 2) or cuprous (Cu+) electrowinning
would be preferable. The selection of process option would be dependent on market conditions
(especiallyproductdemandandenergycosts)intherespectiveplantregion.

Forlarger scaleproduction(>20,000 tpa), copperelectrowinning becomes preferable.Itshouldbe


noted that although the precipitation of salts at large scale still offers good profitability indices,
global demand for those products is limited and hence the revenue figures may not be as easily
achievable. Largescale copper salt production has therefore not been included in Figure 42. At
20,000tpascale,theprofitabilityindexforbothIntecProcesscoppermetalproducingoptionsisat
or greater than 2.8. At 50,000 tpa scale, the index is 4.7 5.6, and this is where the economic
benefitsoflargescaleoperationsarerealised.

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5 IntecProcessEnvironmentalAdvantages

TherearenumerousenvironmentaladvantagestotheIntecProcesswhencomparedtocompeting
pyrometallurgicalandhydrometallurgicaltechnologies.Someofthesehavealreadybeenexplored,
suchasthesuccessfultreatmentofarseniccontainingfeedstocksandtheenvironmentalstabilityof
theironresidues.ThissectiondetailsalifecycleanalysisoftheIntecCopperProcessincomparison
toanumberofcompetingcopperprocessingtechnologies.

5.1 LifeCycleAnalysis

InteccommissionedaLifeCycleAnalysis(LCA)oftheIntecCopperProcessin2001.Thisstudywas
conducted by the Commonwealth Scientific and Industrial Research Organisation (CSIRO) using
publisheddataforthecompetingtechnologies,aswellasinformationprovidedbyIntecLtdforthe
IntecProcess.

The base case of the CSIRO LCA compared the Intec Copper Process with flash smelting, four
pressureoxidationhydrometallurgicalprocesses,andtwobiohydrometallurgicalprocesses.Usinga
system boundary incorporating mining, concentrate production, and metal production & refining,
theboundaryforallprocesseswasanequivalentcradletogateforcoppermetalproduction.The
initialproductionofa25%copperconcentrate(30%S,100g/tAg,10g/tAu)asuniformfeedstockto
theprocesswasassumed,withtheelectricityusedbytheprocessesbeinggeneratedfromblackcoal
at35%efficiency.

As an Intec Copper Process plant would most likely be located at a mine site to optimise the
advantages associated with the Process flexibility of scale, improved oretometal recoveries
throughthe productionoflower gradeconcentrates atthemill,and improvedeconomicsthrough
avoidingsmelterchargesandpenalties,itwasassumedthatnotransportwouldberequiredforthe
IntecCopperProcess.Thesameassumptionwasusedfortheotherhydrometallurgicalprocesses.It
is worth noting, however, that the Intec Process benefits of most of these optimisation measures
(particularly the higher oretometal recoveries) were excluded from the analysis in the common
assumptionoftheproductionofa25%copperconcentrate.

Given that approximately half of the worlds copper production occurs at integrated smelters
(presumably involving minimal transport of concentrate), while the other half is traded on the
custom market (presumably involving long transport distances including road or rail and possibly
ship),a conservative assumptionof 500kmtransportbyrail was assumedfor smelting in the base
case.

Aftercollatingallprocessinformationfromthepublisheddata,thefiguresweresentbytheCSIROto
the appropriate companies for review, and comments or changes incorporated where applicable.
Within the context of the assumptions used for the LCA, the seven processes were compared for
TotalEnergyConsumption(TEC,MJ/kgCu),GlobalWarmingPotential(GWP,kgCO2(eq)/kgCu)and
AcidificationPotential(AP,kgSO2(eq)/kgCu).

The cradletogate system boundary applied encountered one problem in that the Intec Copper
Process produces LME Grade A copper in dendritic form, while the other hydrometallurgical and
smelting processes considered produce copper in pure cathode form. It is unlikely that the Intec
Copper Process product would be cast into ingot without any form of valueadding. Rather, the
productwouldmostlikelybemeltedandcastintoproductformsfromthemoltenstate.Eitherway,
thisleavesadisparitybetweentheproductsbeingcompared.Asnoresolutionforthiswaspossible,
theconservativeassumptionthattheIntecCopperProcessproductwouldbemeltedandcastinto
ingotwasused.

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As shown in Figure 51, the base case conclusion from the CSIRO LCA was that the total energy
requirement for the Intec Copper Process is 36% lower than the average for pressure oxidation
hydrometallurgical processes and 41% lower than the average for biological processes, but 5.9%
higherthan that forsmeltingwhen usingblack coal.However, using hydrotogenerateelectricity,
theIntecProcessimpactwaslowerthanthatofsmelting.Thedifferencesareevenmoremarkedfor
GlobalWarmingPotential(Figure51).

WithrespecttothedifferencesbetweentheIntecCopperProcessandflashsmelting,theresultis
similar to expectations, because a significant proportion of the energy obtained in smelting is
obtained from the burning of sulphur minerals instead of carbon fuels to produce the smelters
energy.Thiscreateslargeamountsofsulphurdioxide,whichifuncontrolledwouldyieldsignificant
acid rain, but reduces the apparent total energy consumption by smelters. Even incorporating
smeltergascontrols,theproductionofthissulphurdioxideisthereasonforthemarkedadvantage
fortheIntecCopperProcessforAcidificationPotential(Figure52).Effectively,smelterstradeone
formofenvironmentalimpact(GWP)foranother(AP).

Whilebothprocessesuseelectricity,thelargestsinglesourceofelectricityconsumptionassociated
withallhydrometallurgicalprocessesistheelectrowinningofmetalsfromsolution.Asmaybeseen
inFigure51,theeffectofchangingthefuelusedforpowergenerationchangestheratiosforTotal
EnergyConsumptionandGWP.Usingeithernaturalgasorhydroelectricityinsteadofblackcoal,the
Intec Copper Process maintains and extends its advantages over pressure oxidation and biological
hydrometallurgical processes, while reducing the impact versus flash smelting. Using hydroelectric
power, the Intec Copper Process offers the lowest impacts for Total Energy Consumption, Global
WarmingPotentialandAcidificationPotentialunderthesetofassumptionsemployedbytheCSIRO
LCA.


Figure51:(LEFT)CSIROLCATotalenergyresults:Basecaseandhydroelectricpowercaseand(RIGHT)CSIROLCAGlobal
WarmingPotential(GWP)results:Basecase,naturalgasandhydroelectricpowercases

0.060

0.050
AP (kg SO2-eq/kg Cu

0.040

0.030

0.020

0.010

0.000
Intec POx Average Bio Average Flash Smelting

Black Coal (Base Case) Natural Gas



Figure52:CSIROLCAAcidificationPotential(AP)results:Basecaseandnaturalgaspowercase

19
The advantages of the Intec Copper Process over smelting become even more pronounced when
lowerconcentrategradesareconsidered.Notingthatflashsmeltingmaynotevenbeeconomicat
lowergrades,thetotalenergyconsumptionassociatedwithIntecCopperProcessandflashsmelting
treatinga20%concentratewascalculatedtobealmostidenticalat51.4MJ/kgCuand51.5MJ/kgCu,
respectively. At 15% copper in the concentrate, where few if any smelters could operate
economically, the results were 52.1 and 58.5MJ/kgCu, respectively. These results include the
conservativeassumptionsofthemeltingoftheIntecCopperproductandcastingasingot,andthe
useofblackcoalpowergeneration.

Given that higher metal recoveries may often be obtained at the mill by the production of lower
gradeconcentrates,andgiventhegreaterflexibilityofscaleofferedbytheIntecCopperProcess,the
Processoffersseveralnotableadvantagesoversmeltingtotheminer:

Lower TEC, GWP and AP than smelting when using either lower grade concentrates or
alternatefuelsourcestoblackcoalforpowergeneration;
Fewerenvironmentalimpactsassociatedwiththelossofcoppermineralstothemilltailings;
Greaterprojectreturnsassociatedwithhigheroremetalrecoveries;
Greaterresourceutilisationassociatedwiththeabilitytolowertheorecutoffgradesfeeding
themill.Theymayalsoextendminelife;and
Byoperatingattheminesite,theIntecCopperProcessofferssmallerminestheopportunity
to contain the value associated with metal production from concentrate within the mine
gate,ratherthanpassingitontosmelters.

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