Clean mining and clean energy: what technology makes it possible?

Doris Hiam-Galvez, Director, HATCH PERU September 2011

Membrane treatment process for Water Reuse

Background Straits Resources Limited operates an Antimony metal, Gold bullion and Tungsten facility at Hillgrove Mine in Australia. A build up of inorganic impurities in the Tailings Storage Facility (TSF) led to poor metal recoveries Operations were suspended while seeking for a viable solution for treating TSF water Reverse Osmosis (RO) treatment was unsuccessfuly tested by a third party due to membrane fouling issues.

Flow through a spiral wound membrane

Membrane classification & types

In H2O MF
0.2 to 0.4

Particulates Detergents Protein Bacteria Starch Gelatin Metal ions Dyes SO42+ Ca2+ Acids RO
1 to 5

UF1
0.01 to 0.04

UF2
0.003 to 0.00 30 to 50

NF
5 to 10

Na NO3 Cl5

Process Block Diagram

Pretreatment

Membrane Tech.

Benefits
Nano filtration membrane technology (NF) allowed lowered operating pressures, hence energy savings and reduced operating costs in comparison to Reverse Osmosis RO. NF plant produced a permeate of sufficient quality to achieve very good metallurgical recoveries in the flotation circuit. Good pre treatment guarantees continuous operation with minimum membrane cleaning and replacement

Results

Recovery data from flotation tests

Test Potable Water TSF Water NF permeate Sb recovery (%) 99 7.5 97 Au recovery (%) 94 15 95

Clean Water

Slag heat recovery

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Overview of Ferronickel Flowsheet

Run of Mine Ore
Run of Mine Ore

Blend Pile Blend Pile

290 wt/h Ore, 25% Moisture

Fuel (Coal/NG/HSFO) Air Hot G as Ge nerator

Wet Ore (20% Lim / 8 0% Sap)

"Dried " Ore

230 wt/h Ore, 15% Moisture

W.C. Comb. Chamber Off G as < 1.0% CO Air

Rotary Drier
Fuel (Coal/NG/HSFO) Air ESP

Rotary Dryer

Coal (50-7 0 kg / tonn e DO)

Pre -reduced Calcine

ESP

Off Gas > 10 % CO

Rotary Kiln 160 t/h Calcine, 750 deg C

Rotary Kiln

Infiltra tion Air

80
Slag MW Ferron ickel

110 MW
10 t/h Metal 1450 deg C
Ladle Refining (de-S and P)

144 t/h Slag 1600 deg C

Gr anulated Slag to Dewate ring and Dump

Electric Furnace Water (~7 5 p si)

Electric Furnace

Shotting

Water

Power Plant
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Sho tted FeNi to Market

Evaluation of SHR Technologies

Conceptual Level Test/Pilot Full-scale Granulation Slag Energy Recovery @ Full Scale

Continuous Casting Double Rotating Drum Mechanical Granulator Rotating Cup/Disc Air Blast
* Trials ongoing

(40 t/hr)

(150 t/hr) (120 t/hr)

* ~ 80%
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Evaluation of SHR Technologies

AIR BLAST (Full scale implementation NKK 1983) Granule formation (80 t/hr BOF slag), Heat Recovery to Steam (40%) and Air (40%) Granulation and Heat Recovery Operated for ~10 years (80 t/h)

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Energy Integration Opportunities Slag Heat Recovery Energy Balance

INPUTS Ambient Air 110,500 Nm3/h 0 MW 24 MW Hot Air 110,500 Nm3/h (600oC) 125,000 Nm3/h (550oC) 173,500 Nm3/h (400oC) Steam/ preheated water OUTPUTS USERS Ore drying Kiln secondary air Boiler secondary air Power generation (integration into captive power plant or dedicated slag heat recovery power plant). Heating (boiler feedwater, utilities) 19 MW Losses

Slag 144 t/h 1600oC

98 MW

63 MW

Oxidation of FeO

8 MW

TOTAL ENERGY

106MW

106MW

Overall efficiency of slag energy recovery ~ 82%

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Hot air applications

Desalination, Preheating the sea water

Dryer wit hot air 15

Pressure Hydrometallurgy

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Autoclave Process

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Autoclave Vessel

3450 kPa(g), 230oC operating conditions 100 mm thick SA-516 Gr.70N, 5.6 m ID, 34.8 m T/T, 718 tonnes ASME Section VIII, Div. 1 & 2 Compress Codeware WRC 107 Zicks Analysis

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Benefits

Zero fugitive emissions Inertization and stabilization of Arsenic. Minimum generation of residues.

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Mixing Efficiency and Gas dispersion

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Autoclave technology
Pueblo Viejo Autoclaves: 780 t each (largest in the world by weight) Brick lined Designed by Hatch with quality assurance during fabrication

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Autoclave technology

Rio Tinto, QIT-Fer et Titane, UGS ALP Reactor Relining Project, Sorel, Quebec. The new reactor membranes and refractory linings have performed exceptionally well, with no failures after 6 10 years of service.
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Autoclave technology

BHP Billiton, Ravensthorpe Nickel Operations, Pressure Letdown Modifications. These improvements enabled RNO to become the first high pressure acid leach plant in the world to achieve design throughput within a 12 month ramp-up period.

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Autoclave technology

Companhia Vale Rio Dolce, Usina Hidrometallurgical Carajas, Brazil. The autoclave circuit operation opens the door for the application of the CESL process to a variety of ore bodies in South America.

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Autoclave technology

Lihir Management Pty. Ltd., Lihir Heat Recovery Project, Papua New Guinea. The heat recovery project successfully returned Lihir to profitability within 30 days of start-up.

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Clean Energy

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GHG Emissions
1200 1000 Lifecycle CO2/kWh 800 600 400 200 0 Coal

Oil

Gas

Nuclear

Hydro

Wind

Solar

Source: Weisser, D. A guide to life-cycle greenhouse gas (GHG) emissions from electric supply technologies. IAEA

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Costs
$580/MWh

200 180 160 Capital Cost [$/MWh] 140 120 100 80 60 40 20 0 Nuclear Coal Hydro ROR Hydro Wind Solar

O&M

Investment

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Cost reduction of energy

25 Cost / KWh (cents US) 20 15 10 5 0 1980 1985 1990 1995 2000 2005 2010

and bigger turbines ( MW) & efficient

1 American Wind Energy Association

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Growth of Solar Power

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Balancing Supply and Demand

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Power Storage

Pumped Storage CAES

Power [MW]

Hydro Flywheeling Capacitore s Bateras

Wh

kWh

MWh

GWh and higher

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Hydropower plants in construction in the world

Plants >2,000MW to be completed between 2010 2022

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Source: 3Tier

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Hydro with storage + solar

The Andean region of the world has the perfect combination of location and topography for the solar generation of electricity and the storage of that electricity using pumped energy storage. The availability of hydroelectricity in the region is well-established. However, the potential for solar energy generation is as great, if not greater.

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Typical Pumped Storage Plant

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Hydroelectric/Solar Energy Storage

Demand Day 150 MW Night 120 MW Day Hydro 100 MW Solar 70 MW 0 MW

Capacity Night Hydro 100 MW Solar Day + 20 MW

Capacity Imbalance Night - 20 MW

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Solar Thermal Energy Storage with Molten Salts

Molten salt thermal energy storage has been suggested for two main applications: thermal concentrated solar power plants and conventional thermal power plants that cannot easily turn down their power output.

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Concentrated Solar Power with Thermal Energy Storage

Power Tower
Receiver Hot Salt

Parabolic Trough

Cold Salt Steam Generation Solar Field (Flat Mirrors)

Hot Salt

Cold Salt Steam Generation Oil Circuit

Solar Field (Parabolic Mirrors)

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Conclusions

Membrane technology is effective for recovery of valuable products and contaminants Membranes produce prime potable standard water 80% of energy in slags is recoverable Recovered slag energy can be recycled through the process to reduce costs and for electricity generation Autoclaves are very effective for complex ores, contaminants such as arsenic, high altitude, no emissions Solar energy can be combined with hydroelectric energy to balance supply and demand fluctuation
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THE ART OF INNOVATION

Questions or comments.

Please contact to: jvidal@hatch.com.pe www.hatch.ca

Av. Conquistadores 626 , San Isidro, - Lima, Per Tel: (51-1) 714 4000

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