THE ART OF MODELING

IN HYDROMETALLURGY
Dr. Jorge M. Menacho, De Re Metallica Engineering, drm@drm.cl
XII MOLYCOP SYMPOSIUM ON MINERAL PROCESSING
Termas de Chilln, Chile, November 28 December 2, 2012.

CONTENTS

Hydro Process-Chain
Modeling Approach
Selected Applications
Whats Next?

HYDRO PROCESS-CHAIN
Coarse
Coarse
Crushin
Crushin
Stacking
Stacking
gg
Stacking

Blasting

Fine
Fine
Crushin
Crushin
gg

SX

Irrigation
Leach
1ryLeach
Leach1
Ripio 2
Leach
Bioleachin
g

SX

SX

EW
EW

EW

Blasting
Blasting

HEAP
LEACHING
DUMP
HEAP
Two-stage Irrigation;
LEACHING
LEACHING
dynamic
pad
Multiple-floor
Hybrid multiple
irrigation;
operation
permanent pad

Ripio
Aeration

LGO
Leach
LGS
Leach

APPROACH BASED ON EXPERIENCE

Population Balance

Overall Phenomena
Single Properties

Experimentation

Continuum media

Transport
Phenomena
Hydrodynamics

Modeling

Soil Mechanics

Empirical

Thermodynamics

Transport Phenomena
Scale up

Kinetics

Kinetics
Chemistry

Thermodynamics
Validation
Simulations

Object modeling

Object Programming
DEM

Discrete media

Extended DEM
Tech innovation
Process design
Machine design

Engineering
Design
parameter
Flowsheet

Operation

Equipment sizing

Mine Planning

Optimisation

Risk analysis

Stabilization

Control
4

MAIN OWN-DEVELOPED HYDRO-MODELS

Blasting Model: DRM.Blast:
Population balance approach; two simultaneous fragmentation phenomena are
included; parameters linked to blast design and operation conditions. A
particular approach to predict the fines is included. ROM size distribution and
energy consumption are well predicted.

Crushing Plant Model DRM.Crush:

Based on fracture kinetic approach plus mass transport for crushing; Tromp
curve and mass transport for screening and conveyor belts are included.
Parameters linked to design and operation conditions. Mass balance per size
and energy balance are well predicted within the real capacity constrains.

Agglomeration Model DRM.Drum:

Based on population balances with particular agglomeration kinetics; twophase transport approach; parameters related to drum design and operation
conditions.
Agglomerate size distribution and drum capacity are well
predicted. A hydrodynamic characterization of agglomerates is included.

MAIN OWN-DEVELOPED HYDRO-MODELS

Permeability Model DRM.Flux:
Based on hydrodynamics in porous media of variable saturation theory;
geotechnical constrains; Parameters are linked to soil-mechanics properties;
wetting ramps as well as the whole irrigation calendar is anticipated.

Acid Leach Model DRM.AcidLeach:

Based on liquid transport in porous media of variable saturation (Richards/van
Genuchten equations); copper and acid reactive transport; different circuit
arrangement run in closed circuit with the SX-EW plant model. Effluent rate,
inventory, solution composition and production are daily predicted.

Bioleach Model DRM.BioLeach:

Based on liquid transport in porous media of variable saturation; copper,
ferrous/ferric iron and acid reactive transport; pneumatic air transport with
oxygen and carbon dioxide exchange with the liquid phase; heat transport
including losses and generation by leaching of sulphides; strain colony growth
with birth and dead rates depending on the changing dynamic conditions.

MAIN OWN-DEVELOPED HYDRO-MODELS

Chloride Leach Model DRM.ChloroLeach:
Based on liquid transport in porous media of variable saturation; reactive
cuprous/cupric copper and acid transport; pneumatic air transport with oxygen
exchange with the liquid phase; heat transport including heat generation by
oxidative dissolution of sulphides.

Salt Heap Leach Model DRM.CalicheLeach:

Based on liquid transport in porous media of variable saturation (Richards
equation); thermodynamic and kinetic approach to predict iodine, nitrate and
potasium dissolution rate; parameters related to pad design and operation
conditions.

Copper Solvent Extraction Plant Model DRM.ChemSX:

Based on McCabe Thiele and chemical kinetics approach; Isotherms are
sensitive to plant design, solution composition and operation conditions.

MAIN OWN-DEVELOPED HYDRO-MODELS

Entrainment and Contamination Model DRM.DropSX:
Based on hydrodynamic approach; entrainment generation in the mixer and
transport through the SX plant; impurity exchange is driven by thermodynamics.

Organic Composition Model in SX Plant DRM.OrganicSX:

Based on thermodynamics, kinetics and organic chemistry; Dynamic balance for
oximes, aldehydes, ketones and other organic component are considered;
Useful when strong degradation or contamination phenomena occur at the SX
plant; options to face the problem can be dynamically simulated.

Electrowinning Plant Model DRM.EW:

Based on electro-chemical kinetic for copper EW (Butler-Volmer equation);
cathode production, energy consumption and current efficiency are predicted.

Chlorine Gasification Model DRM.Chlorine:

Also based on electro-chemical kinetic (Butler-Volmer equation) to describe
chloride oxidation and rate of Cl2-gas evolution under different conditions.

MINE-TO-PLANT SOLUTIONS
CRUSHING PLANT

AGGLOMERATION

LEACHING PLANT

Population balance approach

Probabilistic screening

Population balance approach

Kinematic model

Flow in non saturated porous

media; reactive solute transport

BLASTING

BENEFIT/COST

SX-EW PLANT

Population balance approach

Crushing & cracking phenomena

Cost and benefit according to the

plant costing structure

McCabe Thiele
Electrolysis

SELECTED
SELECTED
APPLICATIONS
APPLICATIONS

BLASTING AND CRUSHING

BLASTI
BLASTI
NG
NG

CRUSHI
CRUSHI
NG
NG

LEACHI
LEACHI
NG
NG

ACF1
ACF3
ACF2
OPTIMIZATION
ACF4 WITH
OPTIMIZATION
WITH MINE-TOMINE-TOACF5
S
= =1.38
LEACH
S
=S
0.84
LEACH APPROACH
APPROACH
S =1.31
2.42
S = 2.23

ACF1
ACF2
ACF3
ACF5
ACF4
SS= =3.64
=3.17
SS
=S1.81
=2.97
3.12

AGGLOMERATION
1
1
2
i

Sticking flow
(Nonagglomerating)

t + dt

Increase
Increase in
in
liquid
liquid content
content

Free flow
(Agglomerati
ng)

AGGLOMERATION
DUAL
DUAL POROUS
POROUS MEDIA
MEDIA
K K Intra aglom 1 K Inter aglom

LEACH SCALE UP
Solution to the Navier-Stokes
Equations in a bidimensional field:

OBSERVATION:

Liquid flow Richards equation

Flow is constrained by the

column wall thus changing
the flow pattern and also the
Cu extraction kinetics, driving
to a FLAT liquid front, that is
a flow pattern close to PLUG
FLOW condition.

A h

K izA
K K ij
t xi
xi

Convection-dispersion equation

c s
c
qic

Dij

s s
t
t
xi
xj
xi
Boundary conditions:
- First type or Dirichlet type
- Third type or Cauchy type
- Second type or Neumann type

RTD, Time-1

NEW LEACH SCALE UP PROCEDURE

COLUMN
HEAP

Time

MODERN
MODERNSCALE
SCALEUP
UPPROCEDURE
PROCEDURE(Menacho,
(Menacho,1999)
1999)

(t)

R Column (t)
R Heap

Column t * R P t, t * dt *

Heap t * R P t, t * dt *
15

INTERESTING,
INTERESTING, BUT
HOW DOES IT WORK?

STUDY CASE: LEACH SCALE UP

Strip
7-3
Strip36-2
7-3
Strip
Strip
36-2
Strip
Strip43-3
43-3
Strip
37-6
Strip
56-2
Strip
37-6
Strip
56-2
Strip
58-5
Strip
27-3
Strip
58-5
Strip
27-3
Strip
39-1
Strip
39-1
Strip
58-4
Strip
58-4
Strip
63-1
Strip
63-1

WHAT A TEST!
100% prediction from 1
m/1 ton crib to all similarore strips, 18 m/7
millions
DRM.BIOLEACH
MODEL
tons each, processed in
different periods and
conditions (REAL CASE,
17

MODELS FOR OPTIMUM IRRIGATION

HYDRODYNAMICS

DRM.FLUX MODEL

LOS MODELOS EN EL SUEO DEL PIBE

NO PAD-FAILURE, NO PONDING, WORKING SAFE,
GEOTECHNICS
HIGHER RECOVERY

PROCESS-RISK ANALYSIS MODEL

The Mine Plan gives AVERAGE value of the clayish/competent ores; daily
variability drives to a statistical distribution of saturation in the pads.
WHAT IS THE PROBABILITY TO HAVE PONDING/COLLAPSE?
PROBABILISTIC DRM MODEL FOR SAFE DESIGN OF NEW HEAP LEACH OPERATIONS

5 L/h/m2
7 L/h/m2
Pad Height, m
4
6
4
6
yr
Clay, % Satavrg, % Satavrg, % Satavrg, % Satavrg, %
28
2016
67.1
69.6
69.7
72.3
31
2017
67.2
69.7
69.8
72.5
38
2018
67.6
70.2
70.3
73.0
48
2019
68.5
71.2
71.2
74.1
54
2020
69.1
71.8
71.9
74.7
55
2021
69.3
72.0
72.1
75.0
27
2022
67.1
69.5
69.6
72.3
57
2023
69.6
72.3
72.3
75.2
48
2024
68.5
71.1
71.2
74.0
41
2025
67.9
70.5
70.5
73.3
51
2026
68.9
71.5
71.6
74.4
52
2027
68.9
71.6
71.7
74.5
55
2028
69.3
72.1
72.1
75.0

S ,
P;N
0

;N

L ,L

Color
0.0-2.5
2.5-5.0
> 5.0

Qualification
Good
Acceptable
Non Acceptable

MODELING THE LEACH RAMP UP

Ramp up is a difficult stage in
any new project as all is
transient; dynamic models
have been successfully used
to assist this task.

This is a Ripios Secondary

Leach operation started up in
June 2012. Questions are:
How the effluent rate is going
to behave? How about Cu
levels? How much are we
going to produce this year
and next one?

DRM.ACIDLEACH
MODEL

FLUX: SOAKING & IRRIGATION MODEL

IRRIGATION FOLLOWS HYDRODYNAMICS

PENSAMIENTOS
DE
METALURGISTAS:
Caso 1: Nos fuimos despacito, pero igual

Application Rate,
Rate, L/h/m
L/h/m
Application

Irrigation

Wetting

dio poco la pila, pam que naque ver lo

que dice el Menacho umhh
Caso 2: Vamos bien, no saquemos el pie del
acelerador,
Y este derrumbe, de dnde
sali???
Caso 3: Apuremos nios que falta cobre! Qu
2raro, se apoz por todos lados, qu nos
habrn mandado los mineros?

3
1

Irrigation
Irrigation Cycle,
Cycle, days
days

HYDRODYNAMIC
HYDRODYNAMIC
WETTING
WETTINGRAMP
RAMP

BIOLEACH MODEL
DRM.BIOLEACH: Dynamic leach model running in closedcircuit with SX-EW

SX
SX
EW
EW
PLANT
PLANT

Cu0

BIOLEACH MODEL: STRIP 10

Effluent solution.

Copper recovery.

Copper in effluent.

Acid in effluent.

BIOLEACH MODEL: STRIP 10

Effluent temperature.

Effluent ORP.

Bacteria population.

Ferric iron in effluent.

BIOLEACH MODEL: STRIP 210

Effluent solution.

Copper in effluent.

TRIDIMENSIONAL
MODELING

Acid in effluent.

BIOLEACH MODEL: STRIP 210

Effluent temperature.

Effluent ORP.

Bacteria population.

Ferric iron in effluent.

SIMULATING THE DUMP TEMPERATURE

Seeking
Seeking options
options to
to increase
increase temperature
temperature
and
and bioactivity
bioactivity
4C

3,5C

MODELING NEW PROCESSES:

Base Case

Airflow
(Nm3/h/m2
)

Induced Start Up Case

CALICHE HEAP LEACH MODEL

IODATE IN
EFFLUENT

EFFLUENT
POTASSIUM
NITRATE
IN IN
FLOWRATE
EFFLUENT
EFFLUENT

PREDICTING ROM GRANULOMETRY

FROM HYDRODYNAMIC MODELING
Industrial
Industrial Hydraulic
Hydraulic Balance
Balance
Porphyric
ore
Hydraulic
Conductivity
Function
Hydraulic
Conductivity
Function

Pedotransfer
Pedotransfer Function
Function
Andesite ore

Size
Size Distribution
Distribution

Agreement
Agreement between
between the
the limit
limit
measured
measured size
size distributions
distributions and
and
the
the estimated
estimated strip-granulometry
strip-granulometry
resulting
resulting from
from Hydrodynamics.
Hydrodynamics.

SIMULATION TO FIND OUT OPTIMUM

SX CONFIGURATION

TONS OF COPPER/DAY

TONS OF COPPER/DAY

HEAP

65

HEAP

80

ROM

132

ROM

132

TOTAL

198

TOTAL

212

TONS OF COPPER/DAY

TONS OF COPPER/DAY

HEAP

66

HEAP

103

ROM

143

ROM

118

TOTAL

209

TOTAL

221

Net profit difference between the worse and the best option is
over 30 USM$/year!

C
u

C
u

C
u

O
O
O
O

C
u

C
u
C
u

A
A
A
MODELING THE OPERATIONAL
SX PLANT VARIABILITY

Cu in Organic

<<

Won by excess is always

less than loss by lack
Menacho,
Menacho, 1998
1998

Cu in Aqueous

The
Thehigher
higherthe
thevariability
variability
the
thesmaller
smallerthe
thecopper
coppercut
cut

MODELING THE OPERATIONAL

VARIABILITY
410
410 t/day
t/day

405
405 t/day
t/day

385
385 t/day
t/day

411
411 t/day
t/day

6.61
6.61 g/L
g/L
6.610.5
6.610.5 g/L
g/L

6.611.0
6.611.0 g/L
g/L

6.612.0
6.612.0 g/L
g/L

- -1.6
1.6USM$/yr
USM$/yr

- -9.7
9.7USM$/yr
USM$/yr

- -41.8
41.8USM$/yr
USM$/yr

Realistic SX forecast is obtained when STOCHASTIC

SIMULATION is performed! Running DETERMINISTIC
SIMULATION is clearly not correct!

MODELING DROP ENTRAINMENT

AND ELECTROLYTE CONTAMINATION
A NEW METHOD TO MEASURE DROP SIZE DISTRIBUTION WAS
Estimator of
the Chloride Level in the
DEVELOPED

Electrolyte Solution

A NEW METHOD TO MEASURE TRIDIMENSIONAL VELOCITY

PROFILES WAS DEVELOPED

A/O Entrainment
Estimator

MODEL FOR OPTIMUM MINE PLANNING

Same Mine Plan was dynamically simulated in 3 ways: (i) year-basis; (ii)
monthly-basis; and (iii) daily-basis. The first two are real Mine estimation
and last one was randomly generated according to real plant variability.
THE
THE STANDARD
STANDARD MINE-BLOCK
MINE-BLOCK MODEL
MODEL
HANDLES
HANDLES AVERAGE
AVERAGE VALUES
VALUES

VARIABILITY IMPACT ON PRODUCTION

Year average
Monthly variation
Daily variation

: 204,708 t Cu/yr
: 199,828 t Cu/yr
: 196,169 t Cu/yr

Where the 8
ktons
difference is?

BIAS

VARIABILITY-MODELING:
THE NEW MANAGEMENT TOOL
VIRTUOUS CYCLE: SUSTAINABLE
BUSINESS
Got the target? Variability?
Diagnosis
Yes

Low

Optimum

Yes

High

Non Used Capacity

No

Low

Worse Planning

No

High

NUC & WP

One more
year

Make changes and set new

KPIs assisted by the
dynamic simulator

Reason-why
Id

OVERALL MINING BUSINESS INDICES YOU SHOULD CONSIDER:

- Production (t Cu)
- Water (m3/t Cu)

- Cost (US$/t Cu)

- Carbon emision (t C02/t Cu)

- Energy (kWh/t Cu)

- PROCESS VARIABILITY

MODEL-BASED
AGGLOMERATE QUALITY CONTROL
SISTEMA MONITOREO &
CONTROL AUTOMTICO
COMANDADO POR MODELO
DINMICO DE PROCESO
SISTEMA TRANSMISIN
INALMBRICA DE DATOS
Cinta
011

CV-

DRM PROPERTY: AVAILABLE FOR COMMERCIALIZATION

De Re Metallica, Cluster BHP Billiton, 2010 2011.

MODEL-BASED
LEACH AUTOMATIC CONTROL
Main Application + DB Server
CONTROL MODEL-BASED
Gateway
Flushing
Control

Irrigation
Flow + Rate
Plant Network

Main Matrix
Pressure + Flow
Repository Level

Sub Matrix
Control
Pressure + Flow

MiningSystems-De Re Metallica, BHP Billiton, Minera Escondida , 2011 - 2012.

MODEL-BASED
LEACH AUTOMATIC CONTROL
8-month plant run (2012): +2 higher copper
recovery points

0 .8 5

0 .8

Leach
DRM.Acid
Model

C o b r e S o lu b le , %

0 .7 5

0 .7

0 .6 5

0 .6

0 .5 5

0 .5
11

12

13

14

15

16

G r a n u lo m e t r a , % - 1 0 0 #

We do not irrigate just to promote uniform application, but to

MAXIMISE COPPER RECOVERY
MiningSystems-De Re Metallica, BHP Billiton, Minera Escondida , 2011 - 2012.

17

18

R a z n d e L ix iv ia c i n , L /h /m 2

2 .3 5
2 .3
2 .2 5
2 .2
2 .1 5
2 .1
2 .0 5
2
1 .9 5
1 .9
1 .8 5
1 .8
1 .7 5
1 .7
1 .6 5
1 .6
1 .5 5
1 .5
1 .4 5
1 .4

WHATS NEXT?
CONTINUUM MECHANICS MODELING
Phenomenological modeling, requiring
constitutive equations.
Finite element, finite difference and
boundary element

DISCRETE ELEMENT MODELING

Particle multiphysics modeling
DEM (dynamic of granular material)
XDEM (DEM + thermodynamics state,
stress/strain state or similar)

CLOUD COMPUTING ENVIRONMENT

Control

NEW TECH
DEVELOPMENT

Optimisation

Design
R&D; IT

DRM EVOLUTION

Plant optimisation
Plant ramp up
Production planning
Geometallurgy
Project auditing
Process risk analysis
Environmental solutions

Irrigation
Automatic
Control

Metallurgi
cal
Services
TECH
INNOVATION CO.

Fundamental studies
Design of new process
Experimentation
Modeling & simulation
Engineering
Economical evaluation
Business development

Tech
Business
Developm
ent

Automatic
control solutions
(MiningSystemsTelemmetry
transmision
DRM)
Web data mining
On site sensor-nets Web Monitoring &
Energy & water
Process oriented solutions
management
Environmental solutions Control Solutions
Remote optimisation
Single/Overall solutions
(DRM-WiseConn)
Mine-to-Plant services
Metallurgical services

UN MODELO
MATEMTICO ES COMO
UNA GUITARRA
PERO EN
OBJETO FRO Y SIN
MANOS
VIDA
DE UN
VIRTUOSO