Documente Academic
Documente Profesional
Documente Cultură
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
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
MINE-TO-PLANT SOLUTIONS
CRUSHING PLANT
AGGLOMERATION
LEACHING PLANT
BLASTING
BENEFIT/COST
SX-EW PLANT
McCabe Thiele
Electrolysis
SELECTED
SELECTED
APPLICATIONS
APPLICATIONS
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:
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
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?
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
DRM.FLUX MODEL
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
DRM.ACIDLEACH
MODEL
Application Rate,
Rate, L/h/m
L/h/m
Application
Irrigation
Wetting
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
Effluent solution.
Copper recovery.
Copper in effluent.
Acid in effluent.
Effluent temperature.
Effluent ORP.
Bacteria population.
Effluent solution.
Copper in effluent.
TRIDIMENSIONAL
MODELING
Acid in effluent.
Effluent temperature.
Effluent ORP.
Bacteria population.
3,5C
Airflow
(Nm3/h/m2
)
IODATE IN
EFFLUENT
EFFLUENT
POTASSIUM
NITRATE
IN IN
FLOWRATE
EFFLUENT
EFFLUENT
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.
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$/year!
C
u
C
u
C
u
O
O
O
O
C
u
C
u
C
u
A
A
A
MODELING THE OPERATIONAL
SX PLANT VARIABILITY
Cu in Organic
<<
Cu in Aqueous
The
Thehigher
higherthe
thevariability
variability
the
thesmaller
smallerthe
thecopper
coppercut
cut
405
405 t/day
t/day
385
385 t/day
t/day
411
411 t/day
t/day
6.61
6.61 g/L
g/L
6.610.5
6.610.5 g/L
g/L
6.611.0
6.611.0 g/L
g/L
6.612.0
6.612.0 g/L
g/L
- -1.6
1.6USM$/yr
USM$/yr
- -9.7
9.7USM$/yr
USM$/yr
- -41.8
41.8USM$/yr
USM$/yr
Electrolyte Solution
A/O Entrainment
Estimator
: 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
No
Low
Worse Planning
No
High
NUC & WP
One more
year
Reason-why
Id
MODEL-BASED
AGGLOMERATE QUALITY CONTROL
SISTEMA MONITOREO &
CONTROL AUTOMTICO
COMANDADO POR MODELO
DINMICO DE PROCESO
SISTEMA TRANSMISIN
INALMBRICA DE DATOS
Cinta
011
CV-
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
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 #
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
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