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Hydrometallurgy 2003
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Hydrometallurgy 2003
Case Study Objective Review selected current practice, design updates and new technologies applicable to modern solvent extraction and electrowinning plant design and operation
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Drum Agglomeration
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7m
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Advance stacking
30 m
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Solution Management
Objective: minimize SX plant size/costs Use of intermediate solution ponds as unit operations Solution Stacking
High grade/low grade areas on common heap Sulfide/oxide operations Acid control opportunity if relevant (may be considered as intermediate SX operation to reduce metal content/acid control)
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Flood Surge
Operating Level*
Pregnant Pond(s)
Raffinate Pond
Pump Sumps Or Low Areas * Maximum and Minimum Operating Levels Due to Normal Seasonal Fluctuations and Heap drain-down
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Raffinate
PLANT AREA
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Distribution pipes
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Extraction Reaction
Cu2+(aq) Impure Copper Sulfate Solution + 2RH(org) + Extractant CuR2(org) Copper Complex
+ 2H+(aq) + Acid
Stripping Reaction
CuR2(org) Copper Complex + 2H+(aq) + Conc. acid Cu2+(aq) Purified Conc, Copper Sulfate + 2RH(org) + Regenerated Extractant
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Cu2+ 2 Ni2+
Co2+
pH
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Chemical Leaching SX
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Multi-component
Ni2+
Co2+
Zn2+
pH
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AQUEOUS SOLUTION
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Coalesing Fence(s)
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Determined by PLS Copper Tenor and Flow rates Parallel Series Considerations Flexibility of Operation Wash Stages for Impurity Transfer (Chemical / Physical) pH control required Economic Considerations
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CONVENTIONAL SX CIRCUIT
COPPER BEARING SOLUTION E1
S1 LOADED ORGANIC
E2
ORGANIC
COPPER BEARING SOLUTION
AQUEOUS
E1 RAFFINATE RETURNED TO LEACH LOADED ORGANIC
S1
E2
STRIPPED ORGANIC
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AQUEOUS
RAFFINATE RETURNED TO LEACH
ADVANCE SOLUTION
E2
S1
ADVANCE SOLUTION
E1 STRIPPED ORGANIC
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Parallel-Series SX
Parallel Extractor Series Extractors
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HDPE Flooring
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New SX ideas/technology
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Adjoining mixers on same side of layout Common Wall 30% less material Open access pipe/mixer area
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Strip stages
Extraction Stages
Wash Stages
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Entrainment reduction/recovery
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Sparger location
Column Outlet
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SLIDE2.TIF SLIDE2.TIF
All HDPE Column Cell Spiral Wound Construction
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Employs static mixer and reactor pair Coalescer separation technology as primary phase
separation Optional coalescer based or other phase polishing to minimize entrainment Pumped solution do not require subsurface tank farms for gravity flow Piloted at 100 gpm concept design developed for 3,000 gpm train units
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New technology
High current density EW chemistry/quality Acid/bleed control
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Anodes
Electrolyte Flow
Distribution Manifold
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New old concept: 1m wide x 2m tall Adaptation of current zinc technology 50% lower cell area required Improved in-cell circulation New inert anode technology (DSA, Eltech, or other inert) Material handling to optimal size for sale (automated or manual shearing) Lower total cell voltage; amperage change dependent on configuration, same power total power
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In cell devices
Polypropylene brushes attached to anodes Polypropylene balls and beads Foams (FC-1100 for copper)
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V30.GIF V30.GIF
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Air Flow
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SAME Ventilation
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V42.GIF V42.GIF
ANODE DESIGN
Roll Plate (Pb/Ca/Sn) Inert/coated & dimensionally stable DSA ALE
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Conventional technology 250 A/m2 360 A/m2 High current density technologies:
Desom 400-600 A/m2 with agitation (gas or mechanical/high flow) Lurgi 1500-1800 A/m2 (gas or mechanical/high flow) Inert anodes most practical for agitation
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Contamination sources
Feed water (Cl, Si, NO3) contaminant control critical to EW Acid make-up to electrolyte must be routinely checked for contamination (As, Bi, Se, Te, Cl, NO3)
Solutions
Purchase acid at 2 qualities (larger use is typically leaching) to reduce costs Treat water (Reverse Osmosis) for EW needs and other plant applications as required
Positive temperature control in EW critical to qualityheat losses to ventilation choice and climatic conditions must be considered
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Acid removal and recovery with IX Cobalt recovery from bleed (acid removal required) Re-extraction of bleed (directed into SX) Bleed advance for acid control in upstream leaching applications (POX and high acid consuming minerals)
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Final Products
The final plant product does not always have to be EW cathodes in all cases Electrowinning is typically 50 to70% of SXEW plant capital cost & 65 to 80% of plant power requirements Copper: sulfate crystals (off site EW, fertilizer); sulfide precip to off site smelter, foil, copper powder, oxide Zinc: sulfate crystals (off site EW, fertilizer); sulfide precip to off site smelter, oxide & carbonate final product Nickel/Cobalt: sulfide or carbonate precip to off site smelter
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Leach Piles
3VI.gif-3IV 3VI.gif-3IV
new9.tiff
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