2 0 t h A n n i v e r s a r y E v e n t
Proceedings
Nickel-Cobalt-Copper Conference
Sponsored by
6th Annual Nickel-Cobalt-Copper Event
ALTA Metallurgical Services, Melbourne, Australia www.altamet.com.au
PROCEEDINGS OF ALTA 2015 NICKEL-COBALT-COPPER SESSIONS
25-27 May 2015 Perth, Australia
ISBN: 978-0-9925094-2-2
ALTA Metallurgical Services Publications
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Celebrating 30 years of service to the global mining and metallurgical industry.
ALTA Metallurgical Services was established by metallurgical consultant Alan Taylor in 1985, to serve the worldwide mining, minerals and metallurgical industries.
Conferences: ALTA conferences are established major events on the international metallurgical industry calendar. The event is held annually in Perth, Australia. The event comprises three conferences over five days: Nickel-Cobalt-Copper, Uranium-REE and Gold-Precious Metals. Free Library: Conference proceedings and technical papers. The library will be expanded each year, providing a major ongoing resource to the industry. Publications: Sales of proceedings from ALTA Conferences, Seminars and Short Courses. Short Courses: Technical Short Courses are presented by Alan Taylor, Managing Director. Consulting: High level metallurgical and project development consulting.
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Nickel-Cobalt-Copper Contents
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CONFERENCE KEYNOTE ADDRESS 1
HPAL IN PAST, PRESENT AND FUTURE 2
Dr Naoyuki Tsuchida, Senior Managing Executive Officer, General Manager of Engineering Division, Sumitomo Metal Mining Corporation (Japan)
20TH
ANNIVERSARY DINNER KEYNOTE ADDRESS 10
ALTA: 20 YEARS AS A WINDOW INTO THE WORLD OF PAL 11
Alan Taylor, ALTA Metallurgical Services (Australia)
LATERITES 23
TECHNICAL & COST COMPARISON OF LATERITE TREATMENT PROCESSES - PART 3 24
Mike Dry, Arithmetek Inc. (Canada)
ATMOSPHERIC LEACHING OF NICKEL LATERITES WITH IRON PRECIPITATION 48
David White, Independent Consultant (Australia); James Gillaspie, Kamoto Copper Company (KCC) (DRC)
INVERSE LEACHING PROCESS FOR NICKEL LATERITE ORES 68
Kaixi Jiang, Sanping Liu, Haibei Wang , Beijing General Research Institute of Mining and Metallurgy (BGRIMM) (China)
AN ATMOSPHERIC DISSOLVING PROCESS FOR LATERITES 79
Jussi Rastas, Pekka Saikkonen, Promeca Consulting Ltd (Finland); Lars Snåre, OMG Ltd (Finland); Esa Lindell, Eduard Jääskeläinen, Norilsk Nickel Harjavalta Ltd (Finland)
ENVIRONMENTAL / SAFETY 94
A COMPARATIVE STUDY FOR NICKEL AND COPPER PROCESSING TECHNOLOGIES USING LIFE CYCLE ASSESSMENT
95
Janelle Khoo, Sankar Bhattacharya, Monash University, Department of Chemical Engineering (Australia); Nawshad Haque, CSIRO Mineral Resources Flagship (Australia)
IMPLICATIONS OF THE PRESENCE OF RADIOACTIVITY IN COPPER CONCENTRATES 103
Adrian Manis, Bob Ring, ANSTO Minerals (Australia)
PROCESS DEVELOPMENT 116
ADVANCES IN NON-FERROUS PYROMETALLURGY 117
Michael Walton, RefMet (Australia)
CAN FARMING NICKEL PAY FOR YOUR TESTWORK AND FEASIBILITY STUDIES? 126
Boyd Willis, Boyd Willis Hydromet Consulting (Australia)
FLOWSHEET OPTIONS FOR TREATMENT OF DIFFICULT NICKEL RESIDUES 139
Brett Muller, Simulus Engineers (Australia)
VERSATIC 10 ACID/NICKSYN™ SYNERGISTIC SYSTEM VERSUS D2EHPA-CYANEX 272 FOR THE RECOVERY OF COBALT (DRA and Mintek acknowledges ISEC)
150
S.J. Archer, V. Coetzee, J. Scheepers, DRA (South Africa); A.C. du Preez, M. H. Kotze, Lanxess (South Africa); Presented by Roxanne Mottay, Mintek (South Africa)
SUCCESSFULLY SUPPLYING NF AND RO MEMBRANES TO A METAL CYANIDE LEACH TO SEPARATE THE BASE METALS FROM THE PRECIOUS METALS AND RECOVER THE FREE CYANIDE
160
Nicholas Conradie, Nanoretech Systems (Pty) Ltd, South Africa
ALKALINE GLYCINE SYSTEMS AS ALTERNATIVE LEACHING REAGENTS FOR COPPER DEPOSITS OF COMPLEX MINERALOGY
168
Jacques Eksteen, Elsayed Oraby, Bennson Tanda, Western Australian School of Mines, Curtin University (Australia)
SX PROCESSES 190
SOLVENT EXTRACTION OF NICKEL - 28 YEARS OF ENDEAVOUR 191
Murdoch Mackenzie, Consultant (Australia)
A NEW SOLVENT EXTRACTION APPROACH TO NICKEL LATERITE LEACH SOLUTIONS 212
Zhaowu Zhu, Yoko Pranolo, Chu Yong Cheng, CSIRO Mineral Resources National Research Flagship (Australia)
Nickel-Cobalt-Copper Contents
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SX PROCESSES (CONT.)
DIRECT SOLVENT EXTRACTION FOR THE RECOVERY OF NICKEL AND COBALT FROM NITRIC ACID NICKEL LATERITE LEACH LIQUORS
224
Michael Hutton-Ashkenny, WA School of Mines, Curtin University, Direct Nickel, CSIRO (Australia); Don Ibana, WA School of Mines, Curtin University (Australia); Keith R Barnard, CSIRO Minerals Resources National Research Flagship (Australia)
NEW SYNERGISTIC SOLVENT EXTRACTION SYSTEMS FOR SEPARATION AND RECOVERY OF NICKEL, COBALT, COPPER AND ZINC IN SULPHURIC ACID, NITRIC ACID AND HYDROCHLORIC ACID LEACH SOLUTIONS
239
Wensheng Zhang, Nicholas Kelly, CSIRO Mineral Resources Flagship (Australia)
RECOVERY OF BASE METALS FROM CONCENTRATED CHLORIDE SOLUTIONS VIA SOLVENT EXTRACTION
253
Bryn Harris, Carl White, Neomet Technologies Inc., (Canada)
43 YEARS OF ESCAID™ DILUENTS USE IN SOLVENT EXTRACTION (SX) 265
Daniel Bien, ExxonMobil Chemical Asia Pacific (Singapore)
SX FIRE PROTECTION 272
USING PRINCIPLES OF INHERENT SAFETY FOR DESIGN OF HYDROMETALLURGICAL SOLVENT EXTRACTION PLANTS
273
Larry J Moore, FM Global (USA)
COPPER SX/EW 286
TURNING WASTE INTO VALUE: CENTRAL ASIA METALS’ KOUNRAD PROJECT – THE FIRST THREE YEARS
287
H.M. Nicholson, Central Asia Metals (UK); Aung Moe, D. Kan, N.Shirley, Kounrad Copper Company (Kazakhstan); Phil A Crane, PC Mets (Australia)
THE SUCCESSFUL COMMERCIAL IMPLEMENTATION OF THE COMBINED LEACH - ION EXCHANGE - SOLVENT EXTRACTION - ELECTROWINNING PROCESS AT THE BUCIM COPPER PROJECT
299
Todor Angelov, Georgi Savov, Aleksander Tsekov, Iontech 2000 JSC (Bulgaria); Ivan Nishkov, University of Mining and Geology “St. Ivan Rilski” (Bulgaria)
A HOLISTIC APPROACH TO ORGANIC QUALITY IN COPPER SOLVENT EXTRACTION 307
Peter Cole, Louwrens Thomas, Cytec Industries Inc (Canada); Rodrigo Zambra, Cytec Chile Limitada (Chile); Troy Bednarski, Matthew Soderstrom ,Cytec Industries, Inc (USA)
DEVELOPMENT AND IMPLEMENTATION OF SOLVENT EXTRACTION PROCESS FOR COPPER RECOVERY FROM AMMONIA LEACH SOLUTIONS
322
Alexander Tsekov, Todor Angelov, Georgi Savov, Iontech 2000 JSC (Bulgaria); Bas Nauts, Attero (The Netherlands)
SULPHIDE PRECIPITATION FOR COPPER RECOVERY FROM LEACHING CIRCUITS AS AN ALTERNATIVE TO SX-EW: THE DRIVERS
330
Hermann Scriba, Independent Metallurgical Consultant (Australia)
BIOLEACHING 345
THE APPLICATION PROSPECTIVE ON METAL MINERAL REINFORCED BIOLEACHING WITH HYPER THERMOPHILIC ARCHAEA
346
Zhaihai Zhang, Kunming Linhai Microbial Engineering Co. Ltd, Beijing Extract Metallurgy & Technology Development Co., Ltd (China); Weiwen Yang, Jiaoyong Yang, Shanglong Zang, Beijing Extract Metallurgy & Technology Development Co., Ltd (China)
BIOHEAP® APPLICATION AT COSMIC BOY NICKEL CONCENTRATOR – AN UPDATE 356
Jason Fewings, Shawn Seet, Tim McCredden, Craig Fitzmaurice, BioHeap Ltd (Australia)
THE MONDO MINERALS NICKEL SULFIDE BIOLEACH PROJECT: FROM TEST WORK TO DESIGN 373
John Neale, Mariekie Gericke, Christoph Pawlik, Mintek (South Africa); Pieter van Aswegen, P Met Consulting (South Africa); Stephen Barnett, Consultant (UK); Janne Seppälä, Mondo Minerals Nickel Oy (Finland)
PRESSURE OXIDATION 397
LEACHING BEHAVIOR OF NI/CO MIXED SULFIDE BY USING PRESSURIZED OXIDATION 398
Shinichi Heguri, Satoshi Asano, Atsushi Idegami, Sumitomo Metal Mining Corporation (Japan)
TACKLING IMPURITIES IN COPPER CONCENTRATES 406
Henry Salomon-de-Friedberg, Tom Robinson, TECK Resources Limited (Canada)
Nickel-Cobalt-Copper Contents
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PAL FORUM 416
INCREASED PLANT AVAILABILITY THROUGH IMPROVED LIFE CYCLE MANAGEMENT OF AGITATED SYSTEMS
417
Siegfried Popp, Jochen Jung, Wolfgang Keller, EKATO RMT (Germany)
DEFINING SEVERE SERVICE VALVES FOR MINERAL PROCESSING 430
Ross Waters, CG Industrial Specialties Ltd. (CGIS) (Canada)
CURRENT PLANT OPERATION OF CORAL BAY NICKEL CORPORATION 437
Laurence G. Salanga, Takao Oishi, Toru Kitazaki, Coral Bay Nickel Corporation (CBNC) (Philippines)
GÖRDES NICKEL COBALT HPAL PROJECT IN TURKEY 450
M.Mete Yesil, A.Safder Iplikcioglu, META Nikel Kobalt A.S. (Turkey); Presented by Yavus Topkaya, META Nikel Kobalt A.S. (Turkey)
RAMU NICKEL MINING PROJECT IN PAPUA NEW GUINEA 465
Peter Jolly, Highlands Pacific Limited (Australia)
ENGINEERING DESIGN AND PERFORMANCE OF THE HPAL PLANT AT TAGANITO 473
Yoji Kyoda, Takehiko Ito, Yasumasa Hattori, Taganito HPAL Nickel Corporation (Philippines); Fumio Mizuno, Sumitomo Metal Mining Corporation. (Japan)
NOT PRESENTED 488
GME’S NIWEST NICKEL PROJECT – ONGOING DEVELOPMENT OF NI LATERITE HEAP LEACH, SX-EW PROCESS
489
David Readett, Mworx Pty Ltd; Jamie Sullivan, GME Resources Ltd (Australia)
Nickel-Cobalt-Copper Proceedings
Conference Keynote Address
ALTA 2015 Nickel-Cobalt-Copper Proceedings 1
HPAL IN PAST, PRESENT AND FUTURE
By
Dr Naoyuki Tsuchida
Director Senior Managing Executive Officer
Sumitomo Metal Mining Corporation, Japan
Presenter and Corresponding Author
Naoyuki Tsuchida
ABSTRACT
Sumitomo Metal Mining Co., Ltd. (SMM) has commissioned two HPAL projects in the Philippines. Both of the plants successfully produce Mixed Sulfide (MS) of nickel and cobalt from low grade lateritic ore and the annual production of nickel is 54,000 tons in the Philippines. Three Australian laterite projects were commissioned in late 1990’s. Those projects suffered from low availability of the plant and low recovery of nickel in the ramp up stage. The first challenge of SMM was the Coral Bay Nickel Project which commenced in 2002. The project achieved the first track record to reach the name plate capacity. SMM proved operational reliability of HPAL by the CBNC project. However, we have never terminated our challenge to establish the most competitive HPAL plant in the world. The second challenge of SMM was the Taganito HPAL project, located on Mindanao Island, Philippines. As compared with the CBNC project, the project possesses disadvantages of “Wet Weather” and lower grade ore containing nickel at less than 1.1 %. The plant is designed to produce 30,000 tons of nickel and 2,600 tons of cobalt as MS. Construction of the THPAL plant commenced in 2010 and the plant was mechanically completed in June 2013. The plant has attained name plate capacity since May 2014 with excellent performance in terms of nickel recovery and plant availability. Following the success of the Taganito project, pilot studies have been conducted at CBNC and THPAL aiming at further advancement in the future. Those studies include recovery of chromite, hematite and scandium from the laterite ore. SMM believes those technologies are contributing to the development of lower grade lateritic nickel resources.
Nickel-Cobalt-Copper Keynote
ALTA 2015 Nickel-Cobalt-Copper Proceedings 2
Nickel-Cobalt-Copper Proceedings
20th Anniversary Dinner Keynote Address
ALTA 2015 Nickel-Cobalt-Copper Proceedings 10
ALTA: 20 YEARS AS A WINDOW INTO THE WORLD OF PAL
By
Alan Taylor
Managing Director ALTA Metallurgical Services, Australia
Presenter and Corresponding Author
Alan Taylor
20th Anniversary Dinner Keynote
ALTA 2015 Nickel-Cobalt-Copper Proceedings 11
Nickel-Cobalt-Copper Proceedings
Laterites
ALTA 2015 Nickel-Cobalt-Copper Proceedings 23
TECHNICAL & COST COMPARISON OF LATERITE TREATMENT PROCESSES PART 3
By
Mike Dry
Arithmetek Inc., Canada
Presenter and Corresponding Author
Mike Dry
ABSTRACT
This is the third paper in a series examining the economics of processing a hypothetical nickel-cobalt laterite using commercially applied processes and two processes that are still under development. Part 1 of this series outlined the processes examined and their applicability to limonite and saprolite. Part 2 presented the results of process modelling done to quantify reagent and utility requirements and to calculate the variable portion of the operating costs. Part 3 extends the comparison to the fixed operating and capital costs and uses simple financial modelling to compare the different processes.
The established hydrometallurgical processes examined in this exercise are:
• Pressure acid leaching;• Enhanced pressure acid leaching;• Agitated tank leaching at atmospheric pressure;• Heap leaching;• Caron reduction roast, ammonia leach.
The pyrometallurgical processes examined are:
• Rotary kiln calcination with electric furnace smelting;• Sintering with blast furnace smelting;• Sintering with submerged arc smelting.
The two developing technologies examined are:
• Neomet;• Direct Nickel (DNi).
The hydrometallurgical processes and the developing processes were assumed to produce nickel and cobalt as intermediate products (mixed nickel-cobalt hydroxide or oxide, and cobalt sulphide in the Caron process). The pyrometallurgical processes were assumed to produce nickel in metallic iron, i.e. ferronickel or nickel pig iron.
Pressure acid leaching appears to offer the best economics for treating the limonite if the Neomet and DNi processes do not produce saleable by-products. If the by-product hematite and magnesia turn out to be saleable, particularly if the hematite can be sold for more than the price of iron ore, the Neomet and DNi processes look distinctly superior.
Of the established processes for saprolite, heap leaching would appear to offer the best economics, but if the by-products are saleable Neomet offers better economics for processing saprolite.
The pyrometallurgical processes appear to be economically inferior to the hydrometallurgical processes.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 24
ATMOSPHERIC LEACHING OF NICKEL LATERITES WITH IRON PRECIPITATION
By
1David T White and 2James D Gillaspie
1Consultant, Australia 2Kamoto Copper Company, DRC
Presenter and Corresponding Author
David White
ABSTRACT
Alkali addition for iron precipitation, associated with sulphuric acid leaching of nickel laterites, has been considered periodically since the early 1970s, shortly after the development of the jarosite process for iron control in zinc refining.
In the late 1990’s a series of flowsheets were proposed and tested involving simultaneous atmospheric leaching, iron precipitation and acid regeneration. These were considered particularly suited to sequential leaching of limonite and saprolite ores. A number of laterite sulphuric acid leaching processes utilising this chemistry have been put into commercial operation.
In another parallel to the zinc industry, similar sequential leaching flowsheets involving precipitation of iron as goethite were also developed and piloted.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 48
INVERSE LEACHING PROCESS FOR NICKEL LATERITE ORES
By
Kaixi Jiang, Sanping Liu and Haibei Wang
Beijing General Research Institute of Mining and Metallurgy (BGRIMM), China
Presenter and Corresponding Author
Kaixi Jiang
ABSTRACT
High Pressure Acid Leaching (HPAL) with high metal recovery and low acid consumption has commonly been used to treat nickel limonite laterite while Atmospheric Tank Leaching (ATL) with low CAPEX and OPEX has preferably been used to treat nickel saprolite laterite. However, HPAL’s CAPEX is as high as 25 USD/lb-Ni due to the high temperature and pressure and ATL suffers high acid consumption due to dissolution of iron into solution. How to treat nickel laterite with both low CAPEX and OPEX is the most important issue for the extractive metallurgists. BGRIMM has developed an inverse leaching process for nickel laterite starting with a primary ATL stage and followed by a secondary autoclave leaching stage. The sulfuric acid together with limonite slurry was introduced into the ATL stage. This stage aimed to leach as much Ni as possible. The effects of initial pulp concentration of the feed, acid dosage and residence time on the recovery of nickel were examined. The primary leaching results showed that as much as 98% Ni could be leached under the conditions of 33% solid density, 1 ton acid/ton ore, residence time of 5 hours and temperatures of 95~100°C. The leaching of Ni in the primary leaching was predominantly accompanied by the dissolution of Fe and Mg.
Subsequently, the leached slurry from the primary leaching with the saprolite ores was introduced into the secondary autoclave leaching. The secondary leaching stage accomplished the precipitation of ferric ions and simultaneously the acid was generated to leach more nickel. At the leaching conditions of 150°C, 0.5 MPa and 2h retention time, the secondary autoclave leaching gained more than 93% nickel extraction and the leaching solution contained only 1.75 g/L Fe. The inverse leaching process is very flexible to treat a wide proportion of limonite to saprolite laterite ores with high Ni and Co extraction. A bankable feasibility study results indicated that the CAPEX and OPEX were less than 10 USD/lb-Ni and 2.6 USD/lb-Ni, respectively, just accounting for 40% of the HPAL’s CAPEX and 65~70% of the ATL’s OPEX. The process consumes at least 290 kg acid/t-ore less than the ATL and its nickel extraction reached more than 92%, at least 10% higher than ATL.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 68
AN ATMOSPHERIC DISSOLVING PROCESS FOR LATERITES
By 1Jussi Rastas, 1Pekka Saikkonen, 2Lars Snåre, 3Esa Lindell and 3Eduard Jääskeläinen
1Promeca Consulting Ltd, Finland 2OMG Ltd, Finland
3Norilsk Nickel Harjavalta Ltd, Finland
Presenter and Corresponding Author
Pekka Saikkonen
ABSTRACT
A 2-stage atmospheric recovery process for various types of laterites is described, where most of the material is recycled/recovered. Method includes a two-step counter current process, whereby, in the first step laterite is leached into solution with sulphur dioxide used as the leaching agent along with sulphuric acid containing liquid phase coming from the second step. Sulphur dioxide reduces iron, manganese, and cobalt originally contained the laterite and trivalent iron coming from the second step to bivalent soluble sulphates. Yields of the valuable metals in this stage for fresh laterite are over 50%. The solution phase is separated and solid residue is transferred to the second step atmospheric reactor, where it is treated with hot concentrated sulphuric acid. The temperature rises to over 200 oC, and reaction time is very short. All the final sulphatation is proceeding in this stage. The dry, solid residue is leached, washed well, and solution is returned to the first stage leaching reactor. After this stage the total yields of the valuable metals are about 97-98%. The residual solid phase, containing mainly silicates, is separated and removed from the process after washing.
The mother liquid from the first reactor is transferred to Me (Ni, Co)-precipitation, preferably as sulphides, because it contains iron in bivalent form.
In all the cases the liquid after Me-precipitation enters to the next precipitation stage for removal aluminium and chromium (i.e. selective precipitation stage) in the controlled pH-conditions. In the general case the next step is removal of iron and manganese with oxidation and hydroxide precipitation and the solution enters the vacuum crystallizer/ evaporator, where sulphate in solution is crystallized as magnesium monohydrate. Sulphate phase is thermally decomposed to yield sulphur dioxide, which, in turn, is sent to the acid plant to form sulphuric acid, to be recycled into the process.
Process details with different laterite types differ slightly depending on the case. Detailed process descriptions are shown for different laterite types, limonite, saprolite and mixed laterite, including full flow sheets and experimental results.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 79
Nickel-Cobalt-Copper Proceedings
Environmental / Safety
ALTA 2015 Nickel-Cobalt-Copper Proceedings 94
A COMPARATIVE STUDY FOR NICKEL AND COPPER PROCESSING TECHONLOGIES USING LIFE CYCLE ASSESSMENT
By
1Janelle Khoo, 2Nawshad Haque and 1Sankar Bhattacharya
1Monash University, Department of Chemical Engineering, Australia 2CSIRO, Mineral Resources Flagship, Australia
Presenter
Janelle Khoo
Corresponding Author
Nawshad Haque
ABSTRACT
Nickel and copper are two important metals widely used in industry. However, processing and production from mining to final products has environmental impacts. This paper presents results from a comparative Life Cycle Assessment (LCA) study conducted for nickel and copper processing technologies. For nickel, two low grade nickel laterite ore processing technologies have been considered. These are high pressure acid leaching (HPAL) using sulphuric acid and the pyro-metallurgical ferronickel route. The main goals of this study are to identify areas where improvements are possible to reduce environmental impact. The inventory data for individual unit processes was collected from publicly available sources and also by conducting a mass balance. The LCA results obtained were segregated into individual unit processes to determine the “hotspots” in the production chain. A process model using commercial software Aspen Plus and energy balance was also completed to determine the amount of fuel required in the drying unit for ferronickel. Furthermore, LCA is being carried out for copper production through conventional pyrometallurgical and hydrometallurgical routes.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 95
IMPLICATIONS OF THE PRESENCE OF RADIOACTIVITY IN COPPER CONCENTRATES
By
Adrian Manis and Bob Ring
Australian Nuclear Science & Technology Organisation (ANSTO), Australia
Presenter and Corresponding Author
Adrian Manis
ABSTRACT
It is not uncommon for copper concentrate to contain elevated uranium concentrations, which can have implications in smelting and refining. One approach is to remove radioactivity from concentrate, but this is difficult since uranium and its radioactive daughters have to be reduced to low levels to avoid potential impacts associated with smelting.
The main problem during smelting is the uranium decay chain daughters, lead-210 and polonium-210. These elements are volatile and tend to report to dusts, and downstream products in anode slimes processing. Even concentrates containing background uranium concentrations, can lead to the concentration of radioactivity in some parts of the process resulting in by-products that are classified as radioactive. Although the radiation dose levels are not necessarily a concern in smelter operations, there may be impacts on how some by-products can be traded.
The paper outlines the implications for radioactivity in smelter feed concentrates, approaches to alleviate any concerns, and the areas that need to be addressed by producers and processors of copper concentrates containing uranium.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 103
Nickel-Cobalt-Copper Proceedings
Process Development
ALTA 2015 Nickel-Cobalt-Copper Proceedings 116
ADVANCES IN NON-FERROUS PYROMETALLURGY
By
Michael Walton
RefMet, Australia
Presenter and Corresponding Author
Michael Walton
ABSTRACT
Advances in Pyrometallurgy do not come along too often, and generally take decades in development and trialling, before being accepted by operators. Thus in the last 50 years there have not been that many significant new process technologies commercialised in this field. However, those accepted, have been ones which have been able to release the ‘fuel’ value of various feed stocks, to make firstly mattes, and more recently, direct metal. Most of these have been ‘shaft’ smelters: e.g. Flash furnaces, but the most versatile has been the Top submerged lance (TSL) bath smelting processes. Some major adaptions from the ferrous side has found application in the nickel-chrome stainless steel process, and these have been incorporated into the integrated RKEF/SS flow sheet. This presentation describes the evolution of these processes and their current state of development.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 117
CAN FARMING NICKEL PAY FOR YOUR TESTWORK AND FEASIBILITY STUDIES?
By
Boyd Willis
Boyd Willis Hydromet Consulting, Australia
Presenter and Corresponding Author
Boyd Willis
ABSTRACT
Hyperaccumulator plants are plant species that are able to accumulate abnormally high concentrations of specific heavy metals in their tissues. Phytomining (or metal farming) involves the use of such plants to extract metal from the soil, followed by harvesting of the biomass and incineration to produce a bio-ore. More than 450 nickel hyperaccumulator plants have been identified around the world. Trial plantings have produced yields from 100 kg to as high as 600 kg of nickel per hectare per year. Following incineration the biomass may grade up to 30% nickel. Farming an area as small as 8 square kilometres, equivalent to an average wheat farm, has the potential to generate more than US$ 4 million per annum gross revenue, enough to fund pilot testwork and feasibility studies. Since the plants grow in the topsoil, the nickel extracted does not diminish the mining resource. Trials have determined that all of the well-established principles of agriculture, such as weed control and plant nutrition, contribute to improved yields. This means that in developing countries phytomining also presents an ideal opportunity to fulfil community engagement responsibilities.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 126
FLOWSHEET OPTIONS FOR TREATMENT OF DIFFICULT NICKEL RESIDUES
By
Brett Muller
Simulus Engineers, Australia
Presenter and Corresponding Author
Brett Muller
ABSTRACT
Residues from existing nickel process plants often contain a tantalizing amount of base and precious metals. However, economic extraction of some or all of these metals can prove more difficult than would be expected. This paper examines the technical and commercial aspects of three different leach options and subsequent down stream flowsheet implications.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 139
VERSATIC 10 ACID/NICKSYN™ SYNERGISTIC SYSTEM VERSUS D2EHPA-CYANEX 272 FOR THE RECOVERY OF COBALT
By
1S.J. Archer,
1V. Coetzee,
2J. Scheepers,
2A.C. du Preez and
3M. H. Kotze
1DRA, South Africa
2Mintek, South Africa
3Lanxess, South Africa
Corresponding Author
Sidney Archer
Presenter
Roxanne Mottay
* DRA and Mintek acknowledges ISEC
ALTA 2015 Nickel-Cobalt-Copper Proceedings 150
SUCCESSFULLY SUPPLYING NF AND RO MEMBRANES TO A METAL CYANIDE LEACH TO SEPARATE THE BASE METALS FROM THE PRECIOUS METALS AND
RECOVER THE FREE CYANIDE
By
Nicholas Conradie
Nanoretech Systems (Pty) Ltd, South Africa
Presenter and Corresponding Author
Nicholas Conradie
ALTA 2015 Nickel-Cobalt-Copper Proceedings 160
ALKALINE GLYCINE SYSTEMS AS ALTERNATIVE LEACHING REAGENTS FOR COPPER DEPOSITS OF COMPLEX MINERALOGY
By
Jacques Eksteen, Elsayed Oraby and Bennson Tanda
Western Australian School of Mines, Curtin University, Australia
Presenter and Corresponding Author
Jacques Eksteen
ABSTRACT
Recent developments in the use of alkaline glycine solutions (pH around 10) to leach a range of copper minerals will be discussed. Leaching of copper-gold ore with aerated alkaline glycine solutions at ambient conditions has shown the ability to dissolve a range of copper oxide and sulphide minerals, as well as native copper. The leaching has been found to be robust to mild pH change, and pose an alternative approach to leaching low grade copper deposits, particularly those containing a high proportion of acid-soluble gangue minerals such as calcite, dolomite, etc. Iron and silica dissolution was found to be insignificant, compared to acid leach systems. The non-volatile, non-toxic nature and high stability of glycine allows reuse and potential recovery without losses, in comparison to other alkaline leach systems such as ammonia and cyanide based systems. This allows consideration of this leach system for in-situ, heap and vat leach modes. No elemental sulfur or jarosite was detected, compared to acid-based and bioleach based systems. Copper could be recovered from its alkaline glycinate solutions fairly easily using electrowinning. The results of bench-top research will be discussed.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 168
Nickel-Cobalt-Copper Proceedings
SX Processes
ALTA 2015 Nickel-Cobalt-Copper Proceedings 190
SOLVENT EXTRACTION OF NICKEL - 28 YEARS OF ENDEAVOUR
By
Murdoch Mackenzie
Consultant, Australia
Presenter and Corresponding Author
Murdoch Mackenzie
ABSTRACT
Copper and uranium are the two metals most commonly recovered and refined by solvent extraction. Solvent extraction has however played an important role in the hydrometallurgy of nickel and its periodic table cousin cobalt. This paper is a review of the role that solvent extraction has played in the recovery and refining of nickel and its periodic table cousin, cobalt. It will first compare the solvent extraction technologies for copper, uranium, nickel and cobalt and will then examine in more detail the more important circuits which have been used for the recovery of nickel and often cobalt using solvent extraction. The use of solvent extraction in the recovery and refining of nickel differs from that of copper and uranium in that in some plants the nickel itself is not extracted. Instead other metals are extracted from a leach solution containing high concentrations of nickel leaving behind a nickel solution suitable for refined metal production.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 191
A NEW SOLVENT EXTRACTION APPROACH TO NICKEL LATERITE LEACH SOLUTIONS
By
Zhaowu Zhu, Yoko Pranolo and Chu Yong Cheng
CSIRO Mineral Resources National Research Flagship, Australia
Presenter and Corresponding Author
Chu Yong Cheng
ABSTRACT
A new solvent extraction (SX) system has been developed which selectively extracts zinc, cobalt and manganese over large amount of nickel, magnesium and calcium from the leach solution containing chloride without pH adjustment. All zinc and more than 90% of cobalt and manganese were extracted by the SX system in a single contact, whereas almost no or negligible nickel, magnesium and calcium were extracted. The extracted cobalt and manganese were readily stripped with water or saline water to reach high concentrations. The extraction distribution isotherm demonstrated that 4 stages were efficient to completely extract the cobalt and manganese at an A/O ratio of 3.5 with no pH control. The extracted zinc could be removed using water in a bleeding stream. The extraction kinetics of zinc, cobalt and manganese and the stripping kinetics of cobalt and manganese are very fast.
Using this new organic system, a novel direct solvent extraction (DSX) process has been developed including the main steps of (1) removal of impurities, mainly iron, by precipitation; (2) separation of zinc, cobalt and manganese from nickel, magnesium and calcium using the new SX system without pH adjustment; (3) Selective stripping of cobalt and manganese using water, (4) recovery of manganese using cheap SO2/O2 oxidising system, (5) recovery of cobalt by precipitation, (6) separation and concentration of nickel using established SSX system consisting of Versatic 10 and CLX50 to obtain high value product of nickel cathodes by electrowinning.
Compared with the traditional DSX process using the Cyanex 272 system, the most distinct advantage of the newly developed DSX process is its low operating cost since no base is needed for pH adjustment for the extraction of Co and Mn and the co-extraction of Mg.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 212
DIRECT SOLVENT EXTRACTION FOR THE RECOVERY OF NICKEL AND COBALT FROM NITRIC ACID NICKEL LATERITE LEACH LIQUORS
By
1Michael Hutton-Ashkenny, 2Don Ibana and 3Keith R. Barnard
1WA School of Mines Curtin University, Direct Nickel, and CSIRO, Australia 2WA School of Mines, Curtin University, Australia
3CSIRO Minerals Resources National Research Flagship, Australia
Presenter and Corresponding Author
Michael Hutton-Ashkenny
ABSTRACT
In nickel laterite solution processing three methods have been used commercially for the recovery of nickel and cobalt from pregnant leach solutions: mixed sulphide precipitation (MSP), mixed hydroxide precipitation (MHP), and direct solvent extraction (DSX). Of these three options, DSX produces higher value nickel and cobalt products whilst avoiding the requirement of precipitation, solid-liquid separation and releaching. Direct Nickel Ltd. (DNi) have developed a nitric acid leaching process (the DNi process) combined with reagent recycling for treatment of nickel laterite ores. In the current process flowsheet MHP is used to produce an intermediate product, which then requires further processing to generate nickel and cobalt products for sale.
The use of DSX has the potential to add further value to the DNi process by increasing the purity of the generated product and by minimising the required unit processes. Commercial DSX techniques only apply to sulphate-based leach liquors, which differ considerably from the nitrate-based leach liquor produced by DNi. A DSX process development programme using both desk-based and lab-based investigations was therefore carried out to determine likely solvent systems for successful nickel and cobalt extraction from the DNi leach liquor. Early results revealed three promising solvent systems: Versatic 10 / TBP, LIX 63 / Versatic 10 with pyridine carboxylate as a nickel accelerator, and Versatic 10 / pyridine carboxylate – an alternative to the system containing LIX 63. Optimisation and degradation studies on these three systems using nitrate-based aqueous feed from the DNi pilot plant revealed that the most promising solvent system for application to DSX from the DNi laterite leach liquor was the synergistic combination of Versatic 10 / pyridine carboxylate. With an organic phase consisting of 0.5 M Versatic 10 / 0.25 M nonyl-4-pyridinecarboxylate dissolved in ShellSol D70 at an operating temperature of 30°C, nickel and cobalt were extracted from DNi PLS in two stages at A:O of 1:1 and stripped from the loaded organic using 60 g/L nickel in 50 g/L sulphuric acid in one stage at A:O of 1:8.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 224
NEW SYNERGISTIC SOLVENT EXTRACTION SYSTEMS FOR SEPARATION AND RECOVERY OF NICKEL, COBALT, COPPER AND ZINC IN SULPHURIC ACID, NITRIC
ACID AND HYDROCHLORIC ACID LEACH SOLUTIONS
By
Wensheng Zhang and Nicholas Kelly
CSIRO Mineral Resources Flagship, Australia
Presenter and Corresponding Author
Wensheng Zhang
ABSTRACT
One step direct solvent extraction (DSX) for separation of nickel and cobalt from nickel laterite leach solutions provides an attractive path for producing high value nickel and cobalt products without need for producing intermediate mixed sulphide precipitation (MSP) and mixed hydroxide precipitation (MHP) products. CSIRO solvent extraction (SX) researchers previously developed several SX and synergistic solvent extraction (SSX) systems. In the present work, a new synergistic solvent extraction (SSX) system has been discovered and DSX processes employing the new SSX system developed for extraction and separation of nickel, cobalt, copper and zinc from manganese, magnesium and calcium in sulphuric acid, nitric acid and hydrochloric acid / high chloride leach solutions. The newly developed SSX system and the associated DSX processes exhibit desirable properties, including:
• Organic composition employing two commercial extractants without need for a modifier,
• Strong synergistic extraction and separation of nickel, cobalt, copper and zinc frommanganese, magnesium and calcium impurities in various matrices (sulphate, nitrate, andchloride) in one DSX step, as well as separation of copper from Fe and Al,
• Reversible extraction and stripping of all the metals,
• Appropriate complex affinity difference to offer selective extraction or stripping to separatenickel, cobalt and zinc from copper within the SSX circuit,
• Fast kinetics of metal extraction and stripping, suitable for commercial applications,
• Ability to transfer the loaded valuable metals from nitrate and chloride matrices to sulphatevia stripping to provide process options for separation and recovery of individual metalproducts in sulphate,
• Chemical stability in various matrices (sulphate, nitrate, and chloride) and in correspondingsulphuric acid, nitric acid and hydrochloric acid solutions under extraction and strippingconditions, and good phase separation properties.
Other new SSX systems have also been discovered, and are briefly described in this paper, including
(a) New SSX systems for synergistic extraction and separation of nickel and cobalt from ironand aluminium in nickel laterite heap leach solutions, and
(b) New SSX systems for separation of Cu and Zn from Ni and Co.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 239
RECOVERY OF BASE METALS FROM CONCENTRATED CHLORIDE SOLUTIONS VIA SOLVENT EXTRACTION
By
Bryn Harris and Carl White
Neomet Technologies Inc., Canada
Presenter and Corresponding Author
Bryn Harris
ABSTRACT
A series of laboratory solvent extraction shake-out tests has been carried out to study the recovery of copper and cobalt, and their separation from nickel and manganese, from concentrated chloride process solutions using two quaternary amine organic extractants, Cognis Alamine 308 and Alamine 336. The latter has been used for many years at the Glencore (formerly Xstrata and before that, Falconbridge) nickel-cobalt refinery at Kristiansand in Norway. The main objectives of the study were to observe the effects of chloride concentration, to compare the reagents, and to generate loading and stripping data such that a continuous mixer-settler circuit might be designed.
The results were generally as expected, based on theory and previous knowledge. Increasing chloride concentration increased the ability of the reagents to recover both copper and cobalt. Since it forms weaker chloro complexes, cobalt required a higher chloride concentration than did copper. As with a concurrent ion exchange study, nickel and manganese were shown to be very weakly, if at all, extracted, and hence the primary separation of copper and cobalt was demonstrated.
Finally, some observations are made on the hurdles that must be overcome when attempting to introduce and to commercialise new technologies, especially in light of the many processes and projects that have, unfortunately, not lived up to expectations. Our strategy to bring the concentrated chloride approach to commercialisation is outlined.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 253
43 YEARS OF ESCAID™ DILUENTS USE IN SOLVENT EXTRACTION (SX
By
Daniel Bien
ExxonMobil Chemical Asia Pacific, Singapore
Presenter and Corresponding Author
Daniel Bien
ABSTRACT
Diluents are an important component in solvent extraction (SX). For 43 years, ExxonMobil’s EscaidTM products have been available in the market. During this time, technology has advanced, but also requirements for diluents have changed.
The presentation will go through the history of diluents, and present both historic and more recent results related to the impact of diluent on the different performance aspects of SX processes.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 265
Nickel-Cobalt-Copper Proceedings
SX Fire Protection
ALTA 2015 Nickel-Cobalt-Copper Proceedings 272
USING PRINICPLES OF INHERENT SAFETY FOR DESIGN OF HYDROMETALLURGICAL SOLVENT EXTRACTION PLANTS
By
Larry J. Moore
FM Global, USA
Presenter and Corresponding Author
Larry Moore
ABSTRACT
An Inherently Safe (IS) facility relies on the reduction or elimination of hazardous materials or processes through changes in the chemistry, physics and physical design of a process rather than by relying entirely on layers of add-on protection. The mainstream chemical processing industry (CPI) has adopted guidelines and Best Practices to better apply IS when designing or modifying facilities against fires and explosions. The mining industry has not universally embraced IS nor are there published Best Practice Guidelines that promote IS in this industry. This paper addresses IS principles in general and explores specific IS opportunities for fire protection of hydrometallurgical SX plants using the concepts of intensification, substitution, attenuation, limitation of effects and simplification/error tolerance.
This paper was first given at the ALTA 2005 SX Fire Protection World Summit May 6-20, 2005 Perth, Australia and was published in the conference proceedings. It has also since been presented at the Society of Mining and Exploration (SME) Annual Meeting St. Louis Mo US April, 2006 and again at the ICHEME triennial meeting in Florence Italy April 2013. It is published under copywrite in the Chemical Engineering Transactions of the Italian Association of Chemical Engineering vol. 31, 2013.
Copyright previously assigned to AIDIC Servizi S.r.l.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 273
Nickel-Cobalt-Copper Proceedings
Copper SX/EW
ALTA 2015 Nickel-Cobalt-Copper Proceedings 286
TURNING WASTE INTO VALUE: CENTRAL ASIA METALS’ KOUNRAD PROJECT – THE FIRST THREE YEARS
By
1H.M. Nicholson, 2Aung Moe, 2D. Kan, 2N.Shirley and 3P.A. Crane
1Central Asia Metals PLC, United Kingdom 2Kounrad Copper Company, Kazakhstan 3PCMETS Consulting Pty Ltd, Australia
Presenter and Corresponding Author
Phil Crane
ABSTRACT
Kazakhstan’s first commercial copper-leach solvent extraction-electrowinning plant, Central Asia Metals’ Kounrad project, was commissioned in April 2012. Exploiting low grade waste stockpiles produced during Soviet era open pit mining, a 10,000tpa copper cathode plant was designed, constructed and commissioned within 18 months.
Overcoming initial challenges with a workforce unfamiliar with the technology and with extensive periods of sub-zero conditions during winter the project has consistently met targets and produced high quality copper cathodes at cash costs of less than US$1/lb., whilst providing much needed benefits to a region gripped by high unemployment through utilizing a workforce of approximately 300.
Challenges encountered during the first three years of operation are described, along with work ongoing to expand production by 50% in 2016.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 287
THE SUCCESSFUL COMMERCIAL IMPLEMENTATION OF THE COMBINED LEACH – ION EXCHANGE – SOLVENT EXTRACTION - ELECTROWINNING
PROCESS AT THE BUCIM COPPER PROJECT
By
1Todor Angelov, 1Georgi Savov, 1Aleksander Tsekov and 2Ivan Nishkov
1Iontech 2000 JSC, Bulgaria 2University of Mining and Geology “St. Ivan Rilski”, Bulgaria
Presenter and Corresponding Author
Todor Angelov
ABSTRACT
Bucim Copper Project is situated near the village of Bucim and in the south borders of Plachkovitsa Mountain in the Republic of Macedonia. Territorially and administratively the Project belongs to the municipality of Radovis. It is 95 kilometers away from the Skopje capital, and 170 kilometers from the nearest port Thessaloniki (Republic of Greece) at an altitude of 620 m above sea level.
Commissioned in January 2012 and reached steady copper production in August 2012, Bucim Copper Project, became the first commercial operation using combined Iontech’s hydrometallurgical process to treat low grade and higher grade oxide copper ores and to produce LME grade copper cathodes. The Iontech’s Leach-Ion Exchange–Solvent Extraction-Electrowinning process combines ion exchange and solvent extraction to extract and concentrate the copper from pregnant leach solution, before the final product - copper cathodes is obtained by electrowining. The process is suitable for recovery of copper from PLS with metal concentrations varying over a broad range as well as for treatment of solutions in the decommissioning of spent copper heaps and dumps, acid mine drainage /AMD/ аnd ammoniacal etch solutions. Furthermore, combining the ion exchange and solvent extraction allows (1) winter operation without troubles - solvent extraction works properly i.e. with good phase disengagement times, even at low temperatures (this is due to high temperatures of ion exchange regenerate used as a solvent extraction feed), (2) strongly reduces organic losses and crud formation, (3) control of metal/acid ratio, which is very important for solvent extraction process and (4) leads to solvent extraction plant sizes reduction.
In order to improve the whole plant performance, to expand the production capacity and to provide proper management of the excess drainage waters in 2014 it was decided to expand the Bucim Copper Project. The expansion will be completed in 2015, with the commissioning of newly constructed leach fields, the expanded ion exchange circuit as well as with total replacement of extractant originally used in solvent extraction circuit.
This paper highlights the successful implementation of Combined Leach-Ion Exchange–Solvent Extraction-Electrowinning process at the Bucim Copper Project, while providing the original operations description as well as the changes and additions within the plant, which will lead to improved overall performance.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 299
A HOLISTIC APPROACH TO ORGANIC QUALITY IN COPPER SOLVENT EXTRACTION
By
1Peter Cole, 2Rodrigo Zambra, 3Troy Bednarski, 1Louwrens Thomas and 3Matthew Soderstrom
1Cytec Industries, B.V South Africa 2Cytec Chile, Limitada, Chile 3Cytec Industries, Inc., USA
Presenter and Corresponding Author
Peter Cole
ABSTRACT
In copper solvent extraction managing the quality of the organic phase is fundamental to ensure optimal physical and metallurgical performance in the plant operation. Organic quality is however often an overlooked element of operation. The costs associated with the specialty chemical reagents that make up the organic phase makes the organic inventory a valuable capital asset. This paper emphasizes the importance of minimizing chemical losses and maintaining the quality of the organic phase. The quality of the organic phase will be reviewed with respect to understanding its meaning, the factors that negatively impact organic quality, methods used to measure organic quality and operating practices that focus on the maintenance of organic quality. Operating data will be used to analyze how organic-phase quality affects physical and metallurgical performance of the solvent-extraction processes. Poor organic quality compromises overall recovery of copper, decreases kinetics, decreases Cu/Fe selectivity, causes increased phase separation times, exacerbates crud problems and increased entrainments. These performance issues negatively affect operating costs, reagent consumption, electrolyte purity and the quality of the copper cathode. The use of interfacial-tension measurement in tracking organic-phase quality will be discussed and its importance as a tool for quality control in solvent-extraction plants demonstrated by case-study examples. The role of clay treatment in maintenance of organic-phase quality will be a focus with analysis of the impact of poor organic quality on plant capacity and methods to overcome these limitations.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 307
DEVELOPMENT AND IMPLEMENTATION OF SOLVENT EXTRACTION PROCESS FOR COPPER RECOVERY FROM AMMONIA LEACH SOLUTIONS
By
1Aleksander Tsekov, 1Todor Angelov, 1Georgi Savov and 2Bas Nauts
1Iontech 2000 JSC, Bulgaria 2Attero, the Netherlands
Presenter and Corresponding Author
Aleksander Tsekov
ABSTRACT
The Atero/Elemetal-Solvent Extraction/Electrowinning(A/E-SXEW) pilot plant is a hydrometallurgical processing plant, located at the Attero’s site Deurne in the south-east of the Netherlands. The copper Pregnant Leach Solution (PLS), obtained via ammonia leaching of bottom ash, reports to the solvent extraction (SX) section, where copper is recovered and cathode copper is produced in the electrowining (EW) circuit using stainless steel blanks. The solvent extraction section consists of 4 (four) mixer-settler units: 1 (one) for extraction, 2 (two) for washing and 1 (one) for stripping. The wash stages are employed in order to minimize transfer of ammonia and impurities between extraction and stripping. The plant design is based on the use of conventional mixer-settlers. The EW section produces 135 kg per day of cathode copper with five 9s (99.999 percent copper) quality.The A/E-SXEW pilot plant is designed to operate at low and intermittent flow rates for 6 months in order to obtain sufficient data for further process commercialization.
This paper outlines the successful piloting of solvent extraction process for copper recovery from ammonia leach solutions, while providing main operating parameters and resulting plant performance.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 322
SULPHIDE PRECIPITATION FOR COPPER RECOVERY FROM LEACHING CIRCUITS AS AN ALTERNATIVE TO SX-EW: THE DRIVERS
By
Hermann Scriba
Independent Metallurgical Consultant, Australia
Presenter and Corresponding Author
Hermann Scriba
ABSTRACT
Solvent extraction coupled with electrowinning, generally referred to as SX-EW, is a robust and well-established process, and often the primary method to be considered for recovery of copper in hydrometallurgical extraction circuits. However, there are instances when the project metallurgy, location or other project-specific issues call for consideration of alternatives. This paper considers one of these practical alternatives - sulphide precipitation.
Sulphide precipitation is extensively used in nickel laterite recovery circuits to recover a mixed nickel/cobalt sulphide intermediate product, the 60,000 tpa Ni Ambatovy project being the most recent example. The use of sulphide precipitation in copper flowsheets is less prevalent. However such processes have recently been operated at Talvivaara (15,000 tpa Cu) and Pueblo Viejo (11,000 tpa Cu). In this process copper is recovered as a copper sulphide concentrate for on-sale to a smelter or refinery.
This paper discusses the factors that drive consideration of the sulphide precipitation process as an alternative to SX-EW, including cost, technical and risk factors. Sulphide precipitation potentially offers the following benefits:
• Lower capital outlay;
• Operating cost benefits where power generation is costly;
• Options for difficult terrain;
• Options for vertically integrated copper miners; and
• Options for multi-metal recovery circuits.
Particularly relating to mixed oxide-sulphide copper-gold projects, sulphide precipitation potentially offers additional benefits as it enables smoothing production of a single copper product, (i.e. saleable concentrate) over the life of mine. The sulphide process potentially also has less of an impact in downstream gold recovery and H2S production has synergies with acid production and cyanide recovery processes.
Hydrogen sulphide, the most commonly used reductant in this process, is a lethal gas and due precautions need to be taken during project development, design and operation to ensure the safety of stakeholders. Involving personnel with experience in similar process plants can add significant value in the process.
If a number of the identified drivers apply to a project, sulphide precipitation can offer an alternative solution to SX-EW.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 330
Nickel-Cobalt-Copper Proceedings
Bioleaching
ALTA 2015 Nickel-Cobalt-Copper Proceedings 345
THE APPLICATION PROSPECTIVE ON METAL MINERAL REINFORCED BIOLEACHING WITH HYPER THERMOPHILIC ARCHAEA
By
1,2Zaihai Zhang, 2Weiwen Yang, 2Jiaoyong Yang and 2Shanglong Zang
1Kunming Linhai Microbial Engineering Co. Ltd, China 2Beijing Extract Metallurgy & Technology Development Co., Ltd, China
Presenter and Corresponding Author
Zaihai Zhang
ABSTRACT
A class of spherical protoplast collected from extreme natural environment that can grow between 5 to 100 ℃, and having it successfully domesticated and cultivated, which is named as Hyper thermophiles archaea. The reproductive ability in this type of Hyper thermophiles archaea is extremely strong, therefore, it can automatically increase the leaching process temperature, reaching 70 to 100℃, without the need for external heating. In addition, in the leaching process, this type of bacteria can cause ore particle cavitations and dissociation, so that bound-type oxidized ore and chalcopyrite which are recognized refractory minerals, have a very high rate of leaching. Pilot bioleaching and industrial leaching testing of mixed ore, copper sulfide ore, bound-type copper oxide and copper- cobalt-iron alloy showed high leaching rate. Depending on the different characteristics of mineral raw materials, leaching time is generally from 4 to 24 hours. In the continuous leaching process, the slurry can automatically maintain a high temperature (50 to 70℃) or ultra high temperature (70 to 100℃) for months. In solutions with toxic metal ions such as trivalent arsenic, high ionic strength, the outside air temperature, hypoxia and other factors had no significant effect on the effectiveness of this bacterial leaching.
This paper describes the high temperature resistance, anti toxicity etc. characteristics in the bacteria and Introduces its application in the leaching of nonferrous metals copper, nickel, cobalt etc. and rare metals, rhenium, germanium etc. Three detailed application examples are presented. One is applied under industrial production in a complex poly-metallic copper mine, the rest are industrial experiments of mixed copper sulfide and oxide. All results have showed a significant improvement in the leaching rate of copper without external heating. Copper sulfide mineral in leaching of slag is almost completely leached.
The copper concentrate bioleaching laboratory test with hyper thermophiles archaea shows a promising future, not only because the copper leaching rate exceeds 97%, but also more importantly, most of sulfur and iron remained in the leached slag. This solves the persisting problem in conventional bacterial leaching.
Keywords Hyper thermophiles archaea, Continuous agitating, Nonferrous metal; Rare metal Bioleaching
ALTA 2015 Nickel-Cobalt-Copper Proceedings 346
BIOHEAP® APPLICATION AT COSMIC BOY NICKEL CONCENTRATOR – AN UPDATE
By
Jason Fewings, Shawn Seet, Tim McCredden and Craig Fitzmaurice
BioHeap Ltd, Australia
Presenter and Corresponding Author
Jason Fewings
ABSTRACT
During 2014 and 2015 Western Areas Ltd engaged Tetratech Proteus to conduct a feasibility study on a bioleach facility at the Cosmic Boy concentrator to process a high arsenic waste stream. In conjunction with continuous leach trials, and a range of downstream processing testwork regime, high nickel recoveries were demonstrated and high grade nickel sulphide was generated suitable for blending with existing concentrate streams.
Further project development is currently being considered by Western Areas.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 356
THE MONDO MINERALS NICKEL SULFIDE BIOLEACH PROJECT: FROM TEST WORK TO DESIGN
By
1John Neale, 1Mariekie Gericke, 1Christoph Pawlik, 2Pieter van Aswegen, 3Stephen Barnett and 4Janne Seppälä
1Mintek, South Africa 2P Met. Consulting cc., South Africa
3Consultant, United Kingdom 4Mondo Minerals Nickel Oy, Finland
Presenter and Corresponding Author
John Neale
ABSTRACT
Mondo Minerals is the world’s second-largest talc producer. The company, which is headquartered in Amsterdam in the Netherlands, has mining operations located at two sites in Finland: Sotkamo and Vuonos.
A by-product of the talc mining operations at both sites is a sulfide concentrate that contains a valuable quantity of nickel and a small amount of cobalt, but also a small but significant quantity of arsenic. While concentrate sales to smelters had been the long-established method of commercially dealing with the concentrate, Mondo chose to move downstream and create a value-added nickel product to enhance its revenue and profitability streams. Mondo tested and evaluated multiple processing options before identifying Mintek’s bioleaching technology as the most suitable for the recovery of nickel and cobalt from this side stream. In December 2014, Mondo concluded a licence agreement with Mintek, which provides exclusivity to Mondo with respect to the bioleaching of side-streams from talc production, in return for Mondo’s financial and intellectual contribution to the technology development.
The licence agreement is the culmination of a metallurgical test work programme conducted at Mintek over a period of two years, in which the application of Mintek’s technology to treat the by-product from Mondo’s talc production process was developed and successfully demonstrated. A feasibility study showed that bioleaching, combined with a nickel- and cobalt-precipitation process, is an economically-viable option for Mondo to derive value from the by-product. An important aspect of the process is that it includes the production of a stable arsenic-bearing waste, suitable for impoundment.
At full production, the plant will treat approximately 12,000 tonnes of nickel concentrate per annum, producing about 1,000 tonnes of nickel annually. The product is a mixed hydroxide precipitate containing nickel and cobalt.
This paper describes the technical development of the process, from small-scale laboratory test work, piloting, to plant design. The process includes magnetic separation, flotation and regrinding prior to bioleaching, and the downstream unit operations include iron/arsenic precipitation, dewatering, and precipitation of the nickel intermediate product. The results of the economic studies are summarised, and key aspects of the process and mechanical design are presented.
The plant is already under construction, and is being designed to withstand the cold winter conditions in Finland. Commissioning is currently scheduled to begin in August 2015.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 373
Nickel-Cobalt-Copper Proceedings
Pressure Oxidation
ALTA 2015 Nickel-Cobalt-Copper Proceedings 397
LEACHING BEHAVIOR OF NI/CO MIXED SULFIDE DURING PRESSURIZED OXIDATION
By
Shinichi Heguri, Satoshi Asano and Atsushi Idegami
Sumitomo Metal Mining Co., Ltd., Japan
Presenter and Corresponding Author
Shinichi Heguri
ABSTRACT
Of the various intermediate products produced from nickel laterite ores by high-pressure acid leaching, nickel and cobalt mixed sulfide (MS) has the advantage of the being the easiest to separate from impurities such as magnesium and manganese. However, the low leachable of MS means that leaching has high energy requirements when compared to treating other intermediate nickel products such as hydroxides. One hydrometallurgical process that has been successfully used to leach MS is pressurized oxidation, and so this paper explores how this is affected by such variables as temperature, oxygen concentration in the gas phase, MS particle size and iron dissolution with a view to its optimization.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 398
TACKLING IMPURITIES IN COPPER CONCENTRATES
By
Henry Salomon-de-Friedberg and Tom Robinson
Teck Resources Limited, Canada
Presenter
Tom Robinson
Corresponding Author
Henry Salomon-de-Friedberg
ABSTRACT
Historically, concentrates with higher levels of impurities were sold to smelters with the miner facing penalties that marginally reduced his revenues. The smelters then blended the impurity concentration down to acceptable levels among the various feeds they purchased. When the miner faced unusually high levels of certain impurities, his choice of smelters could be constrained or he was forced to sell his concentrate in small lots to multiple buyers. Today, the relative amount of concentrates with challenging levels of impurities is growing and the proportion of high quality concentrates available for diluting is shrinking. This can create an opportunity for dealing with the problem impurities directly at the mine site which has potential positive environmental and material stewardship outcomes.
In the present paper, case studies are presented for dealing with copper concentrates that contain mercury, bismuth or zinc based on either batch tests or in a fully integrated continuous pilot plant test at Teck’s CESL facilities in Richmond, B.C. Extensive test work and positive results for treatment on high arsenic-bearing copper concentrates has been previously discussed. High copper and mercury extractions were confirmed with tennantite/tetrahedrite and cinnabar-bearing concentrates. The generation of a high-grade, compact mercury residue that passed TCLP requirements was demonstrated during piloting. A novel process for leaching bismuth, without leaching any copper, is also discussed. Finally, selective zinc-only leaching test results from copper concentrate are presented. The deciding factor in the success of a particular approach is highly dependent upon the minerals that contain the impurity of interest.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 406
Nickel-Cobalt-Copper Proceedings
PAL Forum
ALTA 2015 Nickel-Cobalt-Copper Proceedings 416
INCREASED PLANT AVAILABILITY THROUGH IMPROVED LIFE CYCLE MANAGEMENT OF AGITATED SYSTEMS
by
Siegfried Popp, Jochen Jung and Wolfgang Keller
EKATO RMT, Germany
Presenter and Corresponding Author
Siegfried Popp
ABSTRACT
As with other industries, the trend in the mining industry is also moving towards larger tanks, bigger production units and an increase in production quantities. This trend not only applies to open tank applications but for autoclave units as well. Along with the increase in production quantities of newly commissioned plants, the added value per hour also increases simultaneously. As a consequence, plant operators are paying more and more attention to achieving a maximum increase in plant availability.
Apart from a reliable process control and the corresponding infrastructure, it is important to design and optimize each individual component for the required long lifetime.
With respect to the agitation system in particular, this not only means that a correct selection of the appropriate agitator components is required but a deep understanding of the fluid mechanical coherences in tanks and autoclaves is a prerequisite in order to master the product rheology of the different fluids and slurries. The course of action that will help achieve the high commercial requirements set for plant availability later on is already established in the planning stage. This paper provides insights concerning the technological developments that have taken place in nickel and gold refineries to maximize the plant availability, reliability and component lifetime. By incorporating the wide variety of experiences that have been accumulated with different plants that are in operation worldwide, it is now possible to even further reduce the required amount of maintenance for not only new plants but for existing plants as well.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 417
DEFINING SEVERE SERVICE VALVES FOR MINERAL PROCESSING
By
Ross Waters
CG Industrial Specialties Ltd (CGIS), Canada
Presenter and Corresponding Author
Ross Waters
ABSTRACT
No clear or universal industry definition or mechanism exists to describe and accurately define severe service valves (SSVs) from general purpose valves, yet such a definition would allow clients to benefit from improved process performance, increased profitability, safety and environmental protection. This high level paper looks to offer an objective definition for better communication between users, specifiers and suppliers.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 430
CURRENT PLANT OPERATION OF CORAL BAY NICKEL CORPORATION
By
Laurence G. Salanga, Takao Oishi and Toru Kitazaki
Coral Bay Nickel Corporation (CBNC), Philippines
Presenter and Corresponding Author
Laurence Salanga
ABSTRACT
This paper presents the current operation and the improvements of the High Pressure Acid Leach (HPAL) Plant at Coral Bay Nickel Corporation (CBNC) in the Philippines. The plant has been in operation since 2005 with a capacity of 10,000 Ni-t/year and this annual Nickel production has exceeded the 10,000 tons target in 2007. Subsequent to the commissioning of the second production line in 2008, the production capacity has increased to 22,000 Ni-t/year. CBNC reached the annual nickel production of more than 22,000 Ni tons in 2011. By 2012, the operation advanced towards a new target production of 24,000 Ni-t/year. The concept to achieve the new target is the high availability and the reciprocally flexible operation of both production lines. Tie-in lines between the two plants were installed for the flexible operation. To improve the operational reliability, modification of the mechanical constraints and de-bottlenecking of the process were executed. Moreover, CBNC carried out a shortened annual maintenance shutdown to increase the nickel production.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 437
GORDES NICKEL COBALT HPAL PROJECT IN TURKEY
By
M.Mete Yesil and A.Safder Iplikcioglu
META Nikel Kobalt A.S., Turkey
Presenter
Yavuz Topkaya
Corresponding Author
M.Mete Yesil
ABSTRACT
META was established in 2002 with a primary aim to be a regional supplier of nickel in various forms. META developed the Turkey’s first nickel project in the Western Turkey in 2000-2001 and has been working on lateritic nickel deposits since then. Currently, META holds majority of the known laterite resources of Turkey, located in 3 different areas throughout the western part of Turkey.
Gordes is the most advanced project of all laterite projects where a 10,000 tonnes/year nickel equivalent MHP producing HPAL plant completed in mid-2014. Commissioning was completed in December 2014. Following ramp up period and optimization of the first HPAL plant, the capacity is aimed to be increased with addition of an EW/SX and/or a Nickel Chemicals Plant. R&D works are also underway for recovery of other valuable elements within the ore.
This paper presents an overview of the Gordes Project including process development testwork and establishment of process route, construction details, commissioning and operating issues and also advantages of the Gordes Project over other known projects in terms of location, investment and housing country.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 450
RAMU NICKEL MINING PROJECT IN PAPUA NEW GUINEA
By
Peter Jolly
Highlands Pacific Limited, Australia
Presenter and Corresponding Author
Peter Jolly
ABSTRACT
The Ramu nickel project started load commissioning in March 2012 and by the end of 2014 had achieved in excess of 70% of nameplate capacity, with the operation achieving a positive cash-flow. The paper will provide an overview of the unique features of the Ramu Nickel project, including the issues of mining in a wet tropical environment and the logistics and community relations aspects of managing such a large project in Papua New Guinea. Production costs will also be presented.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 465
ENGINEERING DESIGN AND PERFORMANCE OF THE HPAL PLANT AT TAGANITO
By
1Yoji Kyoda, 1Takehiko Ito, 1Yasumasa Hattori and 2Fumio Mizuno
1Taganito HPAL Nickel Corporation, Philippines 2Sumitomo Metal Mining Co., Ltd., Japan
Presenter and Corresponding Author
Yoji Kyoda
ABSTRACT
Taganito HPAL Nickel Corporation (THPAL), which is a joint venture company of Sumitomo Metal Mining Co., Ltd. (SMM) and other shareholders, produces Nickel/Cobalt Mixed Sulfide (MS) from low grade lateritic ore by a technology developed by SMM, including the High Pressure Acid Leaching Process (HPAL), at Taganito, located on Mindanao Island, Philippines. The plant is designed to produce 30,000 metric tons of nickel and 2,640 metric tons of cobalt per year as mixed sulphide.
The construction of the THPAL plant commenced in 2010 and mechanical completion was achieved in June 2013, even though construction was interrupted by a local security issue along the way. Currently, the plant has attained name plate capacity on a monthly production basis.
This paper provides the conceptual basis of the engineering design for the HPAL technology which was improved and developed in order to achieve higher leaching performance and higher availability of processing equipment based on the lessons of SMM’s previous HPAL project. Furthermore, this paper highlights the current operating updates of THPAL and reviews the major outcomes during the construction and the commissioning of the project.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 473
Nickel-Cobalt-Copper Proceedings
Not Presented
ALTA 2015 Nickel-Cobalt-Copper Proceedings 488
(Included in Proceedings but not Presented)
GME’S NIWEST NICKEL PROJECT – ONGOING DEVELOPMENT OF NI LATERITE HEAP LEACH, SX-EW PROCESS
By
1David Readett and 2Jamie Sullivan
1Mworx Pty Ltd, Australia 2GME Resources Ltd, Australia
Corresponding Author
David Readett
ABSTRACT
GME through its 100% owned subsidiary, NiWest Limited owns the NiWest Nickel Laterite Project. The project contains 100 million tonnes of nickel laterite resource that can be exploited by low strip ratio open pit mining. The NiWest Nickel Laterite Project is located 50 kilometers east of the Leonora Township in the North Eastern Goldfields of Western Australia. The project is comprised of seven separate tenement areas in close proximity, covering approximately 500 km2.
Over the past five years GME has investigated a number of options for the development of a nickel heap leach operation. During this time GME has developed patented laterite agglomeration technology and acid regeneration technology. The general outcomes of the GME testwork indicate all ore types appear to be heap leachable.
A scoping options study, considering a number of options and production rates, was conducted to establish the most economically attractive option for development and processing of the NiWest. Ultimately a 1.5Mtpa Heap Leach SX-EW flowsheet was selected as the optimal initial project producing up to 15,000tpa Ni. This option has a Capital Cost of $461M at an average LOM operating cost of US$5.68/lb Ni giving an NPV of A$864M and IRR of 37%.
A programme to progress the project through a Definitive Feasibility Study had been established and committed to by GME. A dedicated metallurgical sonic drilling programme has been completed. Over the next 12 months testing of all key aspects of the proposed flowsheet will be conducted both in batch and continuous pilot plant. Testing conditions will be based on the outcomes of metallurgical modelling. Two options for the SX will be considered, being a Nicksyn based flowsheet and the CMN Technology Flowsheet. Results from completed test work will be summarised.
ALTA 2015 Nickel-Cobalt-Copper Proceedings 489
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