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I S S U E 1 V O L U M E 1 O C T O B E R 1 9 9 9
Metal Extraction Products is organized within Performance & Intermediate Chemicals and continues to be headquartered in Wilmington, Delaware, USA.
Since commissioning, some challenging technical issues have arisen. In addition to analyzing and solving problems, the experienced staff at Radomiro Tomic works very closely with MEP on issues regarding the solvent extraction circuit. One of the unique facets of this areas mineralization is the presence of atypically high levels of nitrates and chlorides which can potentially cause major problems in solvent extraction and electrowinning. The chloride must be kept at controlled levels in the tankhouse, for example, to avoid pitting of the stainless steel anodes at high concentrations. On the other hand, nitrates which is a rather new topic in SX may produce nitration of the organic, affecting the Cu transfer capacity. Radomiro Tomic has succeeded in controlling both the chloride and nitrate levels in their operation to acceptable levels.
Figure 1: Generalized Continuous Clay Treatment Circuit Plant / Recovered Organic 1. Precoat (Diatomaceous Earth) 2. Clay Addition Precoat Recycle Line
Plate Filter
clay was very fast, a matter of seconds rather than minutes. The continuous process uses either a filter press or a plate filter to clay treat the organic. A general procedure is as follows: 1. The filter cloth is pre-coated with diatomaceous earth (DE). This is effected by mixing the diatomaceous earth with a small volume of organic and then pumping the mixture through the filter. The pre-coat is necessary to prevent blinding of the filter membrane as the particle size distribution of some of the finer clays indicates a sub micron fraction of around 1% of the total mass. 2. The required mass of clay is mixed with a small volume of organic and pumped through the filter to produce a clay cake of approximately an inch thick. This organic will generally be recycled back to the mixing tank to ensure that all clay is removed prior to the organic being returned to the plant. 3. The bulk organic is passed through the filter bed, thereby effecting clay treatment. 4. The clay treated and filtered organic is returned to the circuit. Despite the capital costs, the use of filter presses and plate filters has gradually found favor as the most effective way to clay treat. The primary advantage is the very low organic loss associated with the process, though the potential of the filter to treat crud is also a significant advantage over other processes. A generalized circuit is presented in Figure 1. Clay Dosage and Measurement of Effectiveness Depending on the degree of contamination, the level of clay treatment required may vary widely from just a few grams per liter to as high as a hundred grams per liter. The most common method used to test the effectiveness of clay treatment has been to measure the static organic continuous phase break time against
plant PLS before and after clay treatment. While this procedure can be effective, careful filtering is necessary to remove fine particles which would otherwise cause the phase disengagement time to speed up and cause phase instability. Filtration of organic through glass microfibre filter paper or a bed of diatomaceous earth is recommended. Recently, Acorga developed a procedure for the plant operator to easily determine the volume of organic treatable per unit mass of clay. An example is given in Figure 2. This procedure is particularly applicable to continuous processes to determine when the clay is spent. The technique is based on a laboratory procedure which generates a curve of interfacial tension vs. volume of organic treatable per unit mass of clay. A curve is generated for each plant (one for recovered organic and another for plant organic) from which a simple calculation is made to determine the volume of organic treatable per cycle (Example 1).
Clay Treatment at Asarco Ray Mine The Asarco Ray operation recently commissioned a continuous filter circuit. The primary element of the circuit is a vertical plate Sparkler filter which is used both for clay treatment and filtration of crud and plant organic, described below. Filtration of crud One of the primary justifications for the installation of a filter circuit was to treat crud more effectively. The new circuit has proved extremely efficient in effecting complete removal of crud as well as minimizing associated organic losses. In addition, the decommissioning of the crusher circuit last August (located next to the SX plant) as well as the implementation of several other process improvements, has reduced crud build-up in the plant significantly. Consequently, crud removal is required on a weekly (and even monthly) basis rather than a daily basis. Crud generally collects in the strip settlers and is pumped out at the weir, into a holding tank. After a period of settling, the aqueous portion is drained off and, after being mixed with a small quantity of DE, the remainder is pumped through the filter and the organic returned to the circuit. Prior to filtration, the filter is pre-coated with diatomaceous earth to prevent blinding by small crud particles. Filtering of plant organic The purpose of filtering the plant organic through DE has been to remove fine crud particle moving around the circuit causing high aqueous entrainment. Although difficult to quantify, the procedure appears to work effectively and is important when the plant is upset (e.g. following severe rain events). Once again the filter is pre-coated with diatomaceous earth before use. For further information and advice on Clay Treatment, please contact your regional Acorga Office.
liters / kg
Example 1. To increase the interfacial tension from 23.5 to 28mN/n, with a filter press of 450 kg clay capacity: Volume Treatable per cycle = 32 l. kg-1 (from Fig. 2) x 450 kg = 14,500 l
The commissioning and operation of a copper sulfide pressure oxidation leach process at Mount Gordon:
REMEMBERING...
Commissioning was completed in May 1999. The circuit is now working at design capacity and at design costs. A period of only 2 1/2 years elapsed between the discovery of additional reserves at Esperanza and the successful operation of a novel hydrometallurgical process for on-site copper production from a copper sulfide ore. The cost and structure is such that the Mount Gordon operation will be highly profitable, and MEP is
proud to be associated with this unique and successful process with Acorga M-5640. Acknowledgments: Avecia MEP wishes to thank Western Metals Ltd for their permission to produce this article. A special thanks to Geoff Richmond, Chief Metallurgist Technical Services, Western Metals, for all his help and support.
Typical operational figures post-commissioning are: Grinding tph = 90 Head grade = 8.5% Copper Utilisation = 85% Leaching Temperature = 90-95% Autoclave discharge Pressure = 7 Bar total Solution Iron = 25-35 gpl PLS = 25-30 gpl Copper PLS suspended solids = 10-30 ppm SX/EW SX Reagent Acorga M5640 SX recovery = 85% (design) SX Cu:Fe selectivity = 4000:1 EW current efficiency = 87-90% Recoveries Leach = 90-93% Wash = 98-99.5% Overall = 87-90% Copper Quality All copper produced has been LME grade A cathode or better. Pb levels have averaged 1.8 ppm. Plant availability 90-97%. Cost of production The forecast cash cost of production is about US$ 0.35 /Ib copper.
Ray Dalton, a major contributor to the evolution of hydrometallurgy, passed away in early 1999 after a long and courageous battle against illness. Ray started his long association with the Mining Chemicals Business (now called Metal Extraction Products Business) in the early 1970s and has been involved with many of the major technical developments in solvent extraction. His contributions include: discovery of nonyl-salycylaldoxime, which is the basis for the current generation of copper solvent extraction reagents and discovery of modified reagent formulations, including ester modifiers (e.g. used in Acorga M-5640, one of the most widely-used reagents in the world). Ray also made significant inventions in the areas of the Cuprex process for the extraction of copper from chloride streams; an analogous system for the extraction of zinc also from chloride streams; and the invention of novel reagents for the extraction of zinc, cobalt and nickel from sulfate streams. In 1990 Ray was awarded the prestigious Beilby Medal for his contributions to the general field of hydrometallurgy and, in particular, for his work on solvent extraction of copper from low-grade ores. 7
addition of a third stream requires greater extractant concentration due to the third successive single stage of extraction. Extract O/A ratio averages ~ 1.0 overall but typically can be adjusted to equalize the recoveries in the three extractors, i.e. less than 1.0 in E3 and more than 1.0 in E1. This configuration is very sensitive to factors which influence extraction.
Example conditions Required Extractant Configuration ~15 v/o PAC Series Organic PLS pH PLS [Cu] Recovery 2.0 1.0 gpl 90% ~25 v/o PAC Series Organic 1.5 1.0 gpl 90%
The parallel aqueous configuration is PLS pH sensitive due to the single stage extraction from the aqueous phase. This occurs as a function of the configuration despite the relative pH insensitivity of modified aldoximes. Ketoximes are less suitable due to their characteristic extraction depression at low pH. Typically, recovery in this configuration is also unresponsive to changes
S1
E3
E2
E1
LO
Rich
Raffinate
Raffinate
Raffinate
Organic Loop
Lean
PLS
PLS
PLS
S1
E1A
E1B
E1C
LO
Rich
Raffinate
Raffinate
Raffinate
in extractant concentration since the extractant concentration is already in excess relative to the copper tenor. The above configuration has three parallel organic streams from the stripper extracting copper from three parallel PLS feedstreams. Its primary advantage lies in a reduced extractant concentration, at equivalent recoveries, to a PAC series organic configuration.
Example conditions Required Extractant Configuration ~25 v/o PAC Series Organic PLS pH PLS [Cu] Recovery 1.5 1.0 gpl 90% ~12 v/o Split Organic Stream 1.5 1.0 gpl 90%
Independent control of O/A in each stage is possible. Potential for processing of different or varying concentration PLS feeds without disruption of subsequent extract staging due to the cascading flow. Recovery is more responsive to changes in extractant concentration than a series organic configuration. Limitations Organic pumping and storage capacity must be increased. Strip mixer/settler capacity must be increased due to the multiplied organic flowrate. Recovery versus extractant concentration response is similar to conventional configurations operated at O/A ratio greater than 1. Recovery is sensitive to fluctuation in extract stage efficiency and requires high extract stage efficiency. Modified aldoxime extractant is required to maintain acceptable Cu/Fe selectivity. Ketoxime use limited due to slow kinetics at lower temperatures. The primary disadvantages to split organic stream configurations are the required processing in the stripper of the entire aggregate organic flow and the additional organic pumping capacity. Construction of a single strip supersettler and the multiplied organic flow capacity are two of the primary costs involved in a retrofit,
which would still be less expensive than construction of a new plant. However, since strip kinetics are more rapid than extract kinetics, the required strip mixer volume would be less than the multiplied organic flow and extract mixer retention time would indicate. Since both the loaded organic and lean electrolyte are pumped to the S1, the pumper/mixer tip speed does not define the pumping capacity. This allows for lower mixer tip speed and reduced entrainments.
Example conditions Required Extractant Configuration above 30 v/o PAC Series Organic PLS pH PLS [Cu] Recovery 1.5 1.5 gpl 90% ~15 v/o Split Organic Stream 1.5 1.5 gpl 90%
Advantages Increased production capacity due to high PLS throughput. Lower required extractant concentration than the PAC series organic configuration. Lower organic make up than PAC series organic due to lower concentration. Configuration is less pH sensitive than the PAC series organic configuration. No changes in design/operation of extract staging required.
At typical operating temperatures, 30 to 35 v/o extractant is, generally, the maximum extractant concentration. Physical parameters of the organic phase above 30 v/o involve increased density and viscosity, and can lead to slow phase disengagement and high entrainment. Metallurgical comparison of the two types of configuration, at a PLS tenor of 1.5 gpl, indicates the required v/o for the parallel aqueous configuration is in excess of 30 v/o. Operation at this concentration is at increased risk from the physical factors surrounding the high v/o. Using a split organic configuration with the organic in parallel, the extractant concentration is within the industry norm. The staff of Acorga would be happy to assist with any inquiries regarding circuit configuration modeling and optimization.
Prestigious awards recognize unique environmental achievement and an exemplary safety record
William Smith, Production Superintendent, Avecia Mount Pleasant site Chris Ferguson, International Business Manager, Metal Extraction Products, Wilmington, Delaware, USA In April 1999, MEP Business of Avecia was granted the prestigious Queens Award for Environmental Achievement for the development of a unique patented chemical process for producing Acorga metal extraction reagents. The award recognizes MEPs environmental improvements over older reagent manufacturing processes. This unique process, developed by MEPs Research and Process Development staff in Manchester, UK, has enabled MEP to reduce effluent components by up to 85 percent. It is also significant that the composition of the effluent from the new process is essentially benign inorganic salts. Development of the new process was key to justifying investment in MEPs world-scale production facility at Mount Pleasant, Tennessee, USA, where the process technology has been in commercial practice since commissioning of the Acorga plant in late 1994. The efficient and environmentally superior process reduces production costs (which we have passed along to our customers) and ensures our long-term viability, as our environmental compliance is fully assured.
In December 1998, the Mount Pleasant site celebrated four consecutive years without a lost time accident, earning it the 1998 CEOs SHE Award. The site achieved over two and one-half million work hours without a lost time accident and that performance continues today. Mount Pleasant produces a number of products for Avecia, including all Acorga reagents for solvent extraction of copper. The winning entry was chosen from almost 190 nominations from across the international Avecia Organization. The exemplary safety record at Mount Pleasant has been led by the sites STARR (Safety Through At Risk Reduction) committee, which is comprised of volunteer representatives from functions across the manufacturing site. While Mount Pleasant is a chemical manufacturing site, it shares similar challenges on safety, health, and the environment with the mining industry. Please contact us for more information on the STARR program.
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CHILE
Obviously, the growth in copper production in South America, particularly Chile, in the 1990s has been dramatic. To align with the growing requirements and demands, MEP has put in place significant expansion of infrastructure. The Santiago staff are responsible for all MEP activities in Latin and South America.
Meet our staff in Santiago: OSVALDO CASTRO (Regional Manager South America) came to Avecia, Metal Extraction Products Business in 1996 with more than twenty years experience with the mining industry (Maria Elena, Chuquicamata, Indepro and Outokumpu). Osvaldo, a chemical engineer by education, is in charge of our Santiago office and has regional responsibility for all MEP activities in South America. GONZALO ALVAREZ (Regional Technical Manager - South America) has responsibility for all MEP technical service and technical programs in South America. Gonzalo, a chemical engineer, has extensive operational and management experience from his 25 year career in places like Pudahuel, Sagasca, Chuquicamata and Quebrada Blanca. Part of his extensive experience around SX operations includes particularly strong leaching expertise. JORGE MEJIAS (Technical Specialist) joined our company in 1996. His background and education are in the field of chemistry, including teaching. His experience in solvent extraction includes extensive participation in SX plant commissioning; on-site piloting work; and customer technical assistance. VICTOR RAMIREZ (Technical Specialist) has more than 10 years practical experience working in solvent extraction. Victor has extensive experience in the industry in South America and, in fact, has provided technical service to virtually every SX plant in Chile and Peru over the past several years. BEATRIZ VALENZUELA is our secretary and administrative assist in Santiago. She takes care of many of our daily activities, including general administration, logistics, and many of our computer applications. Beatriz is often the first point of contact with our customers.
Our office laboratory is located at 147 Andres de Fuenzalida in the Providencia section of Santiago. The facility is shared with Oxiquim, S.A., our agent in Chile. The laboratory has been expanded and additional equipment installed to enable rapid turnaround on typical analyses. Through Oxiquim, local warehousing of Acorga products is maintained in the duty-free zone in Iquique. Most significantly, however, MEP have deployed a strong, experienced team of technical staff to provide service to the SX operations in Chile and throughout the region.
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Business Headquarters Avecia Inc. Metal Extraction Products 1405 Foulk Road P.O. Box 15457 Wilmington, DE 19850-5457 USA Tel: (302) 477-8243 Fax: (302) 477-8150 North American Regional Office Avecia Inc. Metal Extraction Products 3259 E. Harbour Dr., Suite 100 Phoenix, AZ 85034 USA Tel: (602) 470-1446 Fax: (602) 470-5030 South American Regional Office Avecia Inc. Metal Extraction Products Andres de Fuenzalida 147 Providencia, Santiago CHILE Tel: 56-2-3365300 Fax: 56-2-3365310
Regional Office for Europe, Africa and the Middle East Avecia Ltd. Metal Extraction Products P.O. Box 42 Blackley Manchester M9 8ZS ENGLAND Tel: 44-161-740-1460 Fax: 44-161-721-4794 Australia Stahl Australia Pty Ltd. 15 Sammut Street P.O. Box 6187 Wetherill Park NSW 2164 Australia Tel: 61-29-604-6666 Fax: 61-29-604-6467
Acorga Notes will be published approximately twice per year for the international mining industry. Editorial content will include: industry news; information on progress particularly in hydromet technology; relevant scientific articles; and news on the Metal Extraction Products Business (MEP) of Avecia Inc. Editor: Coordinator: Design/Layout: Chris Ferguson Valerie Calvarese Charles Haldeman, Inc.
Please direct any questions, comments, or requests for corrections or changes to the distribution list to Valerie Calvarese: Phone (U.S.) 1-800-435-8679 - Ext. 8113 Phone (Direct): 1-302-477-8113 email: valerie.calvarese@avecia.com
1999 Avecia Inc. Printed in U.S.A. All rights reserved. Acorga is a trademark, the property of Avecia Ltd., an Avecia Group Company.