Presentacin de PowerPoint

THE ART OF MODELING IN HYDROMETALLURGY

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

CONTENTSHydro Process-ChainModeling ApproachSelected ApplicationsWhats Next?

EW

SX

Fine Crushing

Coarse Crushing

Stacking

Leach 1Ripio

Leach 2

Blasting

HEAP LEACHING Two-stage Irrigation;dynamic pad

SX

Fine Crushing

Coarse Crushing

Stacking

1ry Leach

Ripio Leach

Blasting

HEAP LEACHING Hybrid multipleoperation

LGO Leach

LGS Leach

EW

StackingSXEW

Bioleaching

BlastingAerationIrrigation

DUMP LEACHING Multiple-floor irrigation; permanent padHYDRO PROCESS-CHAIN

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4APPROACH BASED ON EXPERIENCETech innovationProcess designMachine design

OperationMine PlanningStabilizationOptimisationControl

Overall PhenomenaSingle Properties

EmpiricalTransport PhenomenaKineticsThermodynamics

ExperimentationModelingScale upValidationSimulations

Design parameterFlowsheetEquipment sizingRisk analysis

Engineering

Continuum mediaDiscrete mediaDEMExtended DEMSoil MechanicsObject modelingObject ProgrammingThermodynamicsKineticsTransport PhenomenaHydrodynamicsPopulation BalanceChemistry

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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; two-phase 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

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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

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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

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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.MAIN OWN-DEVELOPED HYDRO-MODELS

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BLASTINGPopulation balance approachCrushing & cracking phenomena

CRUSHING PLANTPopulation balance approachProbabilistic screening

AGGLOMERATIONPopulation balance approachKinematic model

BENEFIT/COSTCost and benefit according to the plant costing structure

LEACHING PLANTFlow in non saturated porous media; reactive solute transport

SX-EW PLANTMcCabe ThieleElectrolysis

MINE-TO-PLANT SOLUTIONS

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SELECTED APPLICATIONS

S = 3.64ACF1

S = 1.38ACF1

S = 0.84ACF2

S = 3.17ACF2

S = 2.97ACF3

S = 1.31ACF3

S = 2.42ACF4

S = 3.12ACF4

S = 1.81ACF5

S = 2.23ACF5

BLASTINGCRUSHINGLEACHING

OPTIMIZATION WITH MINE-TO-LEACH APPROACHBLASTING AND CRUSHING

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AGGLOMERATION

Free flow (Agglomerating)Sticking flow(Non-agglomerating)

Increase in liquid content

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DUAL POROUS MEDIA

AGGLOMERATION

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LEACH SCALE UPOBSERVATION:

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.

Solution to the Navier-Stokes Equations in a bidimensional field:Convection-dispersion equationLiquid flow Richards equationBoundary conditions:- First type or Dirichlet type- Third type or Cauchy type- Second type or Neumann type

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TimeRTD, Time-1

COLUMNHEAP

MODERN SCALE UP PROCEDURE (Menacho, 1999)

NEW LEACH SCALE UP PROCEDURE

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INTERESTING, BUT HOW DOES IT WORK?

WHAT A TEST!100% prediction from 1 m/1 ton crib to all similar-ore strips, 18 m/7 millions tons each, processed in different periods and conditions (REAL CASE, 2011)17

Strip 7-3STUDY CASE: LEACH SCALE UP

Strip 36-2

Strip 43-3

Strip 37-6

Strip 56-2

Strip 27-3

Strip 58-5

Strip 39-1

Strip 58-4

Strip 63-1DRM.BIOLEACH MODEL

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HYDRODYNAMICS

GEOTECHNICS

DRM.FLUX MODEL

MODELS FOR OPTIMUM IRRIGATION LOS MODELOS EN EL SUEO DEL PIBENO PAD-FAILURE, NO PONDING, WORKING SAFE, HIGHER RECOVERY

PROCESS-RISK ANALYSIS MODELThe 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?

5 L/h/m27 L/h/m2Pad Height, m4646yr Clay, %Satavrg, %Satavrg, %Satavrg, %Satavrg, %20162867.169.669.772.320173167.269.769.872.520183867.670.270.373.020194868.571.271.274.120205469.171.871.974.720215569.372.072.175.020222767.169.569.672.320235769.672.372.375.220244868.571.171.274.020254167.970.570.573.320265168.971.571.674.420275268.971.671.774.520285569.372.172.175.0

ColorQualification0.0-2.5Good2.5-5.0Acceptable> 5.0Non Acceptable

PROBABILISTIC DRM MODEL FOR SAFE DESIGN OF NEW HEAP LEACH OPERATIONS

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

Application Rate, L/h/mIrrigation Cycle, days

WettingIrrigation13

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Caso 1: Nos fuimos despacito, pero igual dio poco la pila, pam que naque ver lo que dice el Menacho umhhCaso 3: Apuremos nios que falta cobre! Qu raro, se apoz por todos lados, qu nos habrn mandado los mineros?Caso 2: Vamos bien, no saquemos el pie del acelerador, Y este derrumbe, de dnde sali???PENSAMIENTOS DE METALURGISTAS:

HYDRODYNAMIC WETTING RAMP

2

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BIOLEACH MODEL

DRM.BIOLEACH: Dynamic leach model running in closed-circuit with SX-EW

SX EW PLANTCu0

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Effluent solution.Copper recovery.Copper in effluent.Acid in effluent.

BIOLEACH MODEL: STRIP 10

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Effluent temperature.Bacteria population.Ferric iron in effluent.

Effluent ORP.BIOLEACH MODEL: STRIP 10

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BIOLEACH MODEL: STRIP 210

Effluent solution.Copper in effluent.Acid in effluent.

TRIDIMENSIONAL MODELING

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BIOLEACH MODEL: STRIP 210

Effluent temperature.Bacteria population.Ferric iron in effluent.Effluent ORP.

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SIMULATING THE DUMP TEMPERATURE

D4CD3,5CSeeking options to increase temperature and bioactivity

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MODELING NEW PROCESSES:Base Case

Induced Start Up CaseAirflow (Nm3/h/m2)

EFFLUENT FLOWRATE

CALICHE HEAP LEACH MODEL

IODATE IN EFFLUENT

POTASSIUM IN EFFLUENT

NITRATE IN EFFLUENT

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PREDICTING ROM GRANULOMETRY FROM HYDRODYNAMIC MODELING

Industrial Hydraulic BalanceHydraulic Conductivity FunctionPedotransfer FunctionSize Distribution

Porphyric oreAndesite ore

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

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SIMULATION TO FIND OUT OPTIMUMSX CONFIGURATIONTONS OF COPPER/DAYHEAP103ROM118TOTAL221

TONS OF COPPER/DAYHEAP65ROM132TOTAL198

TONS OF COPPER/DAYHEAP66ROM143TOTAL209

TONS OF COPPER/DAYHEAP80ROM132TOTAL212

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

Cu in AqueousCu in Organic

The higher the variability the smaller the copper cut

Won by excess is always less than loss by lackMenacho, 1998