All Abstract Symposium

Economics and Markets
SYMPOSIUM: 01 ECONOMICS AND MARKETS

COD AUTHOR TITLE ABSTRACT
EM01 Jorge Valverde PROJECTING LONG-TERM PRICE OF COPPER
EM02 Carlos Barros THE IMPACT OF CAPEX IN MINING PROJECT
EVALUATION: A NEW PARADIGM?
EM03 Patricio Meller ANALYSIS OF CHILEAN ECONOMIC AND
DEVELOPMENT PERFORMANCE FROM THE COPPER
PERSPECTIVE
EM04 Rene Silva FINANCIAL BARTERING, BY EREDDOLLAR.COM
EM05 Jose Cabello COPPER EXPLORATION AND MINING
DEVELOPMENT IN CHILE: A FORTY YEARS REVIEW
EM07 Patricio Perez
Oportus
WHY DO MINING COMPANIES SUBCONTRACT IN
CHILE?
EM08 Carlos Risopatron ICSG GLOBAL COPPER MARKET RESEARCH IN 2007-
2012: LESSONS LEARNED AND CHALLENGES FOR
THE FUTURE
EM09 Edmundo Tulcanaza MINERAL RESOURCES, RESERVES, AND THE IFRS
EM10 A.I. Ramirez LOOKING FOR METALLURGICAL SOLUTIONS TO
OPEX AND CAPEX INCREASE IN COPPER PROJECTS
EM11 A.I. Ramirez CAPITAL EFFECTIVENESS AS OBJECTIVE OF THE
MINING PROJECT DESIGN
EM12 Chris Du Plessis TECHNOLOGY LEVERAGING OPPORTUNITIES FOR
IMPROVING THE ECONOMICS OF LOW GRADE
COPPER DEPOSITS
EM13 Ricardo Torres QUANTITATIVE ANALYSIS OF FOUR RISKS FACING
CHILEAN MINING PROJECTS
EM14 Manuel Viera MINING ASSET VALUATION BY REAL OPTIONS FOR
RISKY AND UNCERTAINTY SCENARIOS.
EM15 Pr. Levenson ENGINEERING A SAFER WORLD, 2011
EM16 R.D. Hunt ASSESSMENT OF MULTIPLE MINE CONCEPTS
USING LIFE CYCLE ANALYSIS AND DIVERSE
CRITERIA
EM17 Alexander
Leibbrandt
COPPER PRODUCTION IN CHILE: A LOOK TO THE
PAST AND FUTURE PERSPECTIVES


EM01
PROJECTING LONG-TERM PRICE OF COPPER
Jorge Valverde Carbonell
Strategies and Public Policy Analyst
Copper Chilean Commission

ABSTRACT
This paper analyses the copper market structure by modeling the observed dynamics
seen on the side of supply, demand and stocks, to thereby obtain a copper price projection
based on its fundamentals. The transition from the theoretical model to the empirical model
is performed through the reduced form of the structural system, obtaining long term
parameters by the estimation of the cointegration equation, discarding the spurious
relationship between variables.
First, based on the independent projection of the explanatory variables, we
forecasted a copper real price up to 2020, where it evidences a negative trend with an initial
value of US$354 c/lb for 2013 and US$302 c/lb for 2020.
Similarly, but based on an appreciative analysis of the copper market which
includes the study of super-cycles of copper prices, the behavior of production costs over
the past decades and the prospects for global growth of sustained copper demand in China
and structural changes in emerging countries, we estimate a long-term copper price with a
basis of US$2.2 c/lb and an expected value of US$2.67 c/lb.


EM02
THE IMPACT OF CAPEX IN MINING PROJECT EVALUATION: A NEW
PARADIGM?
Carlos Barros, Carlos Deck, Juan Ignacio Guzmn

ABSTRACT
OPEX used to be the most critical variable for copper projects until the early 2000s,
and it was the main factor for discriminating between good and bad projects. With ever
decreasing ore grades worldwide, nowadays most copper projects have similar quality ore
deposits and, since a projects OPEX is highly dependent on the deposits quality, a large
number of projects have now very similar OPEX.
This is reflected in the flattening of the cash cost curve, which shows that projects in
the second and third quartiles are much more similar now than they used to be a decade or
more ago. In this new scenario, differences in the projects CAPEX become much more
relevant in their evaluation. This phenomenon, coupled with large recent increases in many
copper projects CAPEX and their resulting financing problems, have lately put many
projects on hold for reevaluation.
This paper discusses the increased importance of CAPEX in project evaluation, the
structural and cyclical reasons of the recent CAPEX increases, and some evaluation
considerations that mining companies should account for. With the new CAPEX paradigm
looming over current copper projects, it is clear that mining companies should evaluate
projects differently by incorporating more sophisticated tools.


EM03
ANALYSIS OF CHILEAN ECONOMIC AND DEVELOPMENT PERFORMANCE
FROM THE COPPER PERSPECTIVE
Patricio Meller

ABSTRACT
Chile has comparative advantage in copper; mining is the main economic sector.
Copper affects the Chilean economy through different mechanisms. This influence has
increased from 1990 up to the present. In 1990 copper exports were less than US$4 billion;
in recent years Chilean copper exports have increased to (around) US$45 billion. Copper
represents now 20% of GDP.
In this paper we examine the role of copper upon the Chilean macroeconomy
(copper is the main mechanism in the generation of foreign exchange, copper is the second
main source of fiscal revenues, and it is the main factor behind the successful
implementation of equilibrium macro policies). There will be an intersectorial comparison
related to investment, capital, labor productivity and fiscal taxation of Chilean main
economic activities. Moreover, we will analyze the role of copper in economic growth and
its fundamental position in the strategy of development. In this respect we will criticize the
natural resources curse hypothesis.
In short, the outcome of this paper is that copper has been a fundamental factor in
Chilean present successful economic achievements.


EM04
FINANCIAL BARTERING, BY EREDDOLLAR.COM

Ren Silva
CEO eRedDollar.com Latin America

ABSTRACT
The eNetDollar Corporation, founded in Palo Alto, California, presents a
revolutionary financial product for the worldwide mining industry: www.eRedDollar.com

Factoring and leasing were ground-breaking innovations from the financial industry, now
the mining industry must meet Financial Bartering.

Structuring Financial Bartering operations through eRedDollar.com will allow the mining
industry to become more efficient, reducing costs and improving customer-supplier
relationships, thus increasing its profitability as whole.

Since a Financial Bartering operation is a big challenge to any single mining company,
eRedDollar.com will allow them to coordinate their Finance, Purchases, Supplies
Procurement and Asset Sales areas to achieve company wide profitability and leverage a
comprehensive online mining supplier network.

Basic Concepts:
Financial Bartering
Accounts Recievable
Derivates
Forward Contract
Private circulation currency for the world Mining industry.
Problems eRedDollar.com solves for Mining Companies:
Low profitability or financial losses in used and residual fixed asset sales
Transform difficult to liquidate fixed assets into cash or equivalent commodity for
purchases.
Member Supplier Benefits:
Increased Sales
Customer Loyalty
Competition entry barriers
Reduced marketing and sales budget
eRedDollar.com provides the mining industry a win-win solution for all participants
involved. Currently in pilot phase in Chile and launches officially in Exponor 2013.

EM05

COPPER EXPLORATION AND MINING DEVELOPMENT IN CHILE:
A FORTY YEARS REVIEW.

Jos Cabello
Mineralium Consulting Group

ABSTRACT

The most important country for both current copper production and future growth in
the global mining industry is Chile.

In 2001 Chile produced 5,262,800 t of fine copper. This corresponds to 32.4% of
world production.

Over the last decade mining production of copper increased by 17%. And during
this decade, copper production is expected to growth in another 29%. Several facts explain
this large increase in copper production, with a key one being the success of exploration
over the last forty years. This resulted in the discovery of several worldclass copper
deposits which when developed into mines, account for much of the production increases.

This review summarizes the successes of basic exploration carried out during the
last four decades in Chile. The analysis is based on data published in different specialized
mining books or magazines. It mainly includes those discoveries important at a world or
regional scale, not the lesser discoveries important at the local scale. The economic impact
of these discoveries is presented here regarding the value of the mineral resources
identified, the investments and metals production generated.


EM07

WHY DO MINING COMPANIES SUBCONTRACT IN CHILE?

Patricio Prez Oportus Pablo Villalobos Dintrans
Economista Economista
Universidad de Valparaso
prperez@puc.cl

ABSTRACT
The available data indicate that the phenomenon of subcontracting has gained force
among companies and has characterized the evolution of the job market in Chile in recent
years. Mining is not immune to this phenomenon. In the mid-90s, there were 0.68 contract
workers per own worker, while a decade later the ratio is nearly two contract workers per
own worker. This paper analyzes the causes behind subcontracting in copper mining in
Chile. Panel data for 18 mines are used from the period 2003-2012. It is concluded that
prices, cost pressures and the size of the plant are important in explaining the levels of
subcontracting.

EM08
ICSG GLOBAL COPPER MARKET RESEARCH IN 2007-2012: LESSONS
LEARNED AND CHALLENGES FOR THE FUTURE
Susanna Keung and Carlos Risopatron
International Copper Study Group

ABSTRACT
This study covers a review and analysis of the main findings of the research projects
developed by ICSG in the last six years, including an analysis of the statistics on copper
production, trade, use and stocks in 2007-2012. A discussion on the trends observed in
industrial use, demand, production and capacity of copper across the value chain is
presented, looking to identify bottlenecks to be faced downstream and upstream the copper
industry in recent years and in the future. Lessons learned and challenges to improve
publicly available information on market transparency of the global copper market are
identified.


EM09

MINERAL RESOURCES, RESERVES, AND THE IFRS

Fermn Cceres (IDN), Leonardo Torres (KPMG)
Alberto Salas (SONAMI), Edmundo Tulcanaza (Centromin Chile)

ABSTRACT
In recent years, financial information sustained by transparent, competitive, and
material technical data regarding mineral resources, reserves, and assets has become
relevant for the entire mining industries but especially for medium size companies in
emerging markets.
Even though the copper industry in Chile is one of high standards for decades,
Chilean mining companies have not yet adopted, entirely, the International Accounting
Standards and the International Financial Reporting Standards (IAS/IFRS). These
accounting bodies will transversally impact the mining industry no matter the size of a
company.
The IASB (International Accounting Standards Board) has already issued IFRS 6
which establishes the directions for accounting entries in the Exploration and Evaluation
of Mineral Resources phase. At the same time, the IFRIC has issued the IFRIC 20 on the
Mine Stripping Costs interpretations.
A complete standard for the entire chain of value of a mining project is still
pending. With the support of CRIRSCO, other national organizations, and institutions
associated with the international mining industry there have been improvements in this
task.
Using Chile as a case study, the objective of this paper is to make an assessment of
the relevant accounting information included in the IASB/IFRS rules as applied to the
international companies in the copper emerging markets. The paper deals with the
fundamental aspects of these new financial standards, their expected impacts in the mining
industry, and the configuration of a reasonable and practical optional policy.


EM10
LOOKING FOR METALLURGICLA SOLUTIONS TO OPEX AND CAPEX
INCREASE IN COPPER PROJECTS

A.I. Ramirez, L. Carrion, C. Cancino y F. Castillo
Sinclair Knight Merz (Chile)

ABSTRACT

The copper industry is facing a detention of projects due to the increase in the Capital
Expenditure (CAPEX) and Operations Expenditure (OPEX) they demand. On the other
hand, the copper demand continues to grow and it does not show signs of slowing down.
Coupled with this is the need to ensure the production of minerals that the U.S. government
agencies have classified as strategic for a "green future" in the developed world and
developing countries.

Performing a quick chemical analyses of the chilean copper industry tailings, one can
find that these strategic elements are present in interesting cut off grades within their
scarcity context, and have already paid their highest unit processes price (comminution);
but currently are qualified only as environmental liabilities. In addition, there are mature
technologies available on the market that could be feasibly diagrammed to concentrate
and/or dissolve them to become commercial products and by mean of by-products
aggregate value to the core business.

This paper reviews the opportunities that break the paradigm of "our business is
producing copper and all the rest is for super-specialists" and that improve the effectiveness
of the invested capital, adding only a delta of CAPEX and OPEX, improving revenue sales.


EM11
CAPITAL EFFECTIVENESS AS OBJECTIVE OF THE MINING PROJECT
DESIGN

A.I. Ramirez, F. Reyes y R.F. Dewhirst
Sinclair Knight Merz (Chile)

ABSTRACT

Everyone in the mining business agrees with the diagnosis of the current scenario and
the short-term forecast increasing raw materials cost, lowering cut off grades, etc, but
they still insist on the implementation of the current paradigms expecting different and
better technical and economic results of the projects. The application of these paradigms
occurs without questioning or re-evaluation, but it continues to limit the degrees of freedom
of the models that are used for the definition, study, design and implementation of projects,
especially if such application is made without discriminating origin and the impact of these
paradigms.

This document reviews and discusses the current paradigms applied to the copper
mining industry and their impact on the effectiveness of capital invested in a project,
defined as "the CAPEX That Fits the Purpose", meaning the capital spending required to
produce a commercial product of the quality demanded by the market but complying with
the Business Model (Business Case) that is restricted by technical and economic feasibility
metallurgical extraction of valuable species contained in the mineable reserves of a project.

EM12

TECHNOLOGY LEVERAGING OPPORTUNITIES FOR IMPROVING THE
ECONOMICS OF LOW GRADE COPPER DEPOSITS

C.A. du Plessis, C.Ward and J. Cucuzza
AMIRA INTERNATIONAL
Level 2,
271 William Street,
Melbourne,
VIC 3000,
Australia
chris.duplessis@amirainternational.com

ABSTRACT

The exploration pursuit of high grade deposits (typically >0.5% Cu) also results in
an increasing inventory of known deposits of sub-economic grades. Importantly, economic
viability is dependent upon the available processing options and economic parameters
imposed by the use of such methods. Current processing options are limited to either
concentrate production or leaching and have not fundamentally changed for several
decades. The exponential increase in comminution power, per unit of contained copper,
generally precludes economic concentrate production from ore with grades below 0.5% Cu.
In some instances, low grade ore is economically treatable via heap leaching methods,
where the mining costs are carried by higher grade ore.
Heap leaching economics are, however, challenged by the presence of high acid
consuming gangue minerals, poor hydraulic control of heap leach solutions, and copper
mineralization occurring as refractory primary sulfide. Technical and economic viability of
in-situ leaching is limited to a very small number of high grade oxide copper deposits in
highly fractured and relatively porous deposits. A number of significant technology
advances in non-mineral industries may provide opportunities for economic step-changes to
copper project developments. Such technologies range from rock fracturing and solution
containment technology developed in the petroleum industry, to drug delivery
methodologies developed in the pharmaceutical industry. This article explores the impact
of such step-change technology opportunities on copper ore deposit economics.


EM13

QUANTITATIVE ANALYSIS OF FOUR RISKS FACING CHILEAN MINING
PROJECTS

Ricardo Torres S. y Fredy Varas V.

ABSTRACT

Investment projects are the most important source of growth of a country, without
which it is not possible to improve the living standard of its society. In this context, the
Chilean mining investment projects, particularly copper, are ahead, for several reasons: the
high grade of the deposits; big volumes of metal available; topographical advantages that
result in lower production costs; availability of a well qualified human resource base;
political tranquility; and clear and stable legal and tax rules.

However, on the Chilean mining scenario have become more important new risk
events involving environmental and social matters. They are: a) future shortage of skilled
mining human resources, b) uncertainties associated with power supplies, c) uncertainties
associated with environmental permits and d) lack of industrial water for ore processing.
These risks are reaffirmed each other making difficult to quantify needs and so generate
delivery strategies.

From a technical economic model built on a platform stochastic, in this paper we
investigate the potential impact on the profitability of a mining project caused by the risks
mentioned above.


EM14

VALORACIN DE ACTIVOS MINEROS POR OPCIONES REALES EN
ESCENARIOS DE RIESGOS E INCERTIDUMBRE.

Phd Manuel Viera Flores Senior Mining Engineering
CEO Metaprojetc Ingeniera e Innovacin
Dr. Carlos Charln 1521, Providencia Santiago Chile
mviera@metaproject.cl

ABSTRACT

Opciones Reales, es la tcnica que acerca las finanzas a la estrategia y al modelo de
negocios, ayudando a los directivos, ejecutivos, consultores de empresas, empresarios,
banqueros, ingenieros de minas, gelogos de proyectos, que se desenvuelven en la prctica
de la evaluacin de proyectos de inversin y valoracin de activos y empresas mineras a
explicitar cual es la mejor decisin y cuando es el mejor momento para ejercitarla, haciendo
que el riesgo trabaje a favor del negocio y no en contra.

Opciones Reales, provee los mecanismos de Financiamiento, Valoracin y Tasacin
de Activos Mineros, tratamiento del Riesgo y la incertidumbre y de cmo se calcula el
valor del activo para su venta a travs de herramientas avanzadas, como es la Simulacin de
Montecarlo o Hipercubo Latino con Reversin a la Media con Saltos Aleatorios y el Valor
en Riesgo VAR (Value at Risk).

La Valoracin de Activos Mineros por Opciones Reales, junto al Anlisis de Riesgo
es la mejor herramienta para valorar activos mineros bajo Riesgo e Incertidumbres, como
apoyo a las decisiones estratgicas de comprar o vender un Activo, hacer o no hacer un
proyecto minero, y sus flexibilidades operacionales como expandir, paralizar, posponer,
cerrar o abandonar un proyecto minero.

Se muestran casos reales y exitosos evaluados por esta metodologa.


EM15

ENGINEERING A SAFER WORLD, 2011

Nancy G. Leveson
Professor of Aeronautics and Astronautics and Engineering Systems at MIT

ABSTRACT

Engineering has experienced a technological revolution, but the basic
engineering techniques applied in safety and reliability engineering, created in a
simpler, analog world, have changed very little over the years. In this
groundbreaking book, Nancy Leveson proposes a new approach to safety--more
suited to todays complex, sociotechnical, software-intensive world--based on
modern systems thinking and systems theory. Revisiting and updating ideas
pioneered by 1950s aerospace engineers in their System Safety concept, and testing
her new model extensively on real-world examples, Leveson has created a new
approach to safety that is more effective, less expensive, and easier to use than
current techniques.

Arguing that traditional models of causality are inadequate, Leveson
presents a new, extended model of causation (Systems-Theoretic Accident Model
and Processes, or STAMP), then shows how the new model can be used to create
techniques for system safety engineering, including accident analysis, hazard
analysis, system design, safety in operations, and management of safety-critical
systems. She applies the new techniques to real-world events including the friendly-
fire loss of a U.S. Blackhawk helicopter in the first Gulf War; the Vioxx recall; the
U.S. Navy SUBSAFE program; and the bacterial contamination of a public water
supply in a Canadian town. Levesons approach is relevant even beyond safety
engineering, offering techniques for reengineering any large sociotechnical
system to improve safety and manage risk.


EM16

ASSESSMENT OF MULTIPLE MINE CONCEPTS USING LIFE CYCLE
ANALYSIS AND DIVERSE CRITERIA

R.D. Hunt
WorleyParsons
Av. Apoquindo 4501, Piso 15
Las Condes, Santiago, Chile
Roy.Hunt@worleyparsons.com

M. Marinovic and W. Funk
WorleyParsons
Calgary, Canada
Wes.Funk@WorleyParsons.com

ABSTRACT

This paper outlines a novel approach for the identification, framing, and assessment
of conceptual mine options that are acceptable according to economic and socio-
environmental criteria. This method was applied to a base metals mine being developed in a
high altitude, harsh environment. The concept options were subject to a variety of technical
challenges as well as non-technical risks all of which have the ability to strongly affect the
project outcomes. Through the comparison of diverse options according to complex criteria
and considering diverse risks, an optimal concept and strategic measures were identified.


EM17

COPPER PRODUCTION IN CHILE: A LOOK TO THE PAST AND FUTURE
PERSPECTIVES

Alexander Leibbrandt von Neefe
Codelco Chile
Hurfanos 1270, Santiago, Chile
aleibbra@codelco.cl

ABSTRACT

Copper processing in America started with the Andean cultures of the current Peru.
Since 2000 BC it is possible to prove copper was used in utensils; and as it happened in
other continents, there was a slow dissemination of metallurgical experiences to the North
and South (Fig. 1). Naturally, it took more than 1000 years to have copper also produced in
the north of Chile, that is, in the zone near San Pedro de Atacama. From that moment
onward, copper production in the Chilean Andes was expanded and continuously
consolidated until transforming that region into the largest world supplier of this noble
metal during the last two centuries, taking advantage of what nature gave to the Los Andes
Mountain Range, with nearly 40% of the worlds copper reserves. Hence, its no surprise to
see that Chile has nearly 35% of the share of the world`s copper mining production.

This geological feature positioned Atacama Desert as copper generator long before
the discovery of America. During the colonial period it supplied the South American
Spanish colonies with copper and crowned Chile as the largest copper producer after its
Independence in mid XIX century. This fact also resulted in the development of the Chilean
mining industry, which is the essential pillar of the countrys economy. Therefore, the
contribution of the Chilean Mining sector to the countrys development can be compared to
the influence of the German Mining Industry to the development of Central Europe that
started in the Middle Age.

Mineral Processing

SYMPOSIUM: 02 MINERAL PROCESSING

MP01 Lorenzo Reyes USE OF BIOSOLIDS AND ITS MAIN COMPONENTS AS
FROTH FLOTATION REAGENTS FOR THE CONCENTRATION
OFF COPPER SULPHIDE ORE
MP02 Winston Rocher THE EVOLUTION OF MILL RELINING TECHNOLOGY
MP03 Luis Vinnett GAS DISPERSION MEASUREMENTS IN INDUSTRIAL
FLOTATION EQUIPMENT
MP04 Carlos Rabanal EMPIRICAL CORRELATION FOR ESTIMATING GRINDING
MEDIA CONSUMPTION
MP05 Ursula Kelm CHARACTERIZATION OF COPPER CLAYS AND
GEOMETALLURGICAL IMPLICATIONS
MP07 R. Fuentes PROGRESS MADE IN PILOT AND LABORATORY
THICKENING STUDY
MP08 N. Rojas EFFECT OF FINES CONTENT ON YIELD STRESS OF COPPER
TAILINGS
MP09 Shigeto Kuroiwa STUDY ON SEPARATION OF ARSENIC FROM COPPER
CONCENTRATE
MP10 Lina Maria Chica MECHANICAL ENERGY BALANCE IN HYDROCYCLONE
MP11 Sergio Arellano TECHNICAL EVALUATION OF THE REPLACEMENT OF
CONVENTIONAL FLOTATION CELLS BY FLOTATION
CELLS PNEUMATIC IN THE BENEFIT OF COPPER ORES
MP12 C. Muoz THE EFFECT OF THE QUALITY OF THE MAINTANCE
WORKS OF THE FLOTATION CELLS ON AIR DISPERSIN
PROPERTIES AND FLOTATION PERFORMANCE
MP13 T. Wisdom NEXT GENERATION PRESSURE FILTERS FOR HARD ROCK
TAILINGS
MP15 Yue Hua Tan SURFACTANT STRUCTURE - PROPERTY RELATIONSHIP:
EFFECT OF POLYPROPYLENE GLYCOL ETHERS ON
BUBBLE RISE VELOCITY
MP16 Francisco Abbott SEAWATER USE IN ANTOFAGASTA MINING GROUP
MP17 D. Garcia ANTAPACCAY - TINTAYA EXPANSION
MP18 E.Visariev GRINDING CYCLE OPTIMIZATION FOR PROCESSING OF
COPPER SLAG AT AURUBIS BULGARIA
MP19 V. Murariu IMPROVED DEM MODEL FOR PREDICTING CONE
CRUSHERS' PERFORMANCE
MP20 L. Valderrama PYRITE CONCENTRATE OBTAINED FROM COPPER
TAILINGS
MP21 Montes-Atenas, G INSIGHTS ON PYRITE ACTIVATION IN COPPER-IRON
BEARING SULPHIDE ORE FROTH FLOTATION:
LABORATORY VS PLANT RESULTS
MP22 S. Castro THE EFFECT OF FLOCCULANTS AND THEIR
DEGRADATION PRODUCTS ON MOLYBDENITE
FLOTATION
MP23 Guillermo Maturana TWO DIMENSIONAL STOCKPILES PHENOMENOLOGICAL
MODELATION
MP24 Fernando Pino ADVANTAGES AND DISADVANTAGES OF BROWNFIELD
PROJECTS
MP26 C.O. Gomez FROTHER ROLES CHARACTERIZATION IN A LABORATORY
FLOTATION CELL
MP28 David Meadows SAG MILL DISCHARGE SECTION OPTIMIZATION STUDIES
Mineral Processing

AND REDESIGN
MP29 Felipe Henriquez INSTALLATION OF INTERNAL LAUNDERS ON 130 M
FLOTATION CELLS AT MINERA LOS PELAMBRES
MP30 H. Nematollahi CONCENTRATION OF COPPER OXIDE MINERAL WITH
HYDROXAMATE
MP31 Christopher J Greet GRINDING CHEMISTRY - THE APPLICATION OF GRINDING
MEDIA TO IMPROVE METALLURGICAL RESPONSE OF
COPPER ORES
MP32 Zanin Massimiliano AMIRA P260 SILVER JUBILEE - 25 YEARS OF BENEFITS TO
MINERALS FLOTATION
MP33 Jose Davila NASH IN THE OPTIMIZATION OF COPPER FLOTATION
CONCENTRATOR CUAJONE
MP34 Vishal Gupta A REVIEW OF BENEFICIATION SCHEME FOR COPPER-
ARSENIC ORE DEPOSITS
MP35 O. Angulo PREVENTING COPPER LOSS PRODUCTION AND FLOW
PROBLEMS BY MEASURING THE MATERIALS FLOW
PROPERTIES
MP36 Mira Bissengaliyeva THERMODYNAMIC CONSTANTS OF MINERALS OF THE
OXIDATION ZONE OF COPPER - ANTLERITE AND
PSEUDOMALACHITE
MP38 Rene Del Villar RECENT DEVELOPMENTS IN FLOTATION COLUMN
INSTRUMENTATION AND CONTROL
MP39 Raul Jara Iturre OPTIMIZACIN METALRGICA DE UN MINERAL DE
COBRE CON ALTA DISEMINACIN Y DUREZA
MP40 David Gwyther MARINE TAILINGS PLACEMENT: EXPERIENCES AND
LESSONS FROM THE ASIA PACIFIC REGION
MP41 C.O. Gomez MODELLING BUBBLE HYDRODYNAMICS IN FLOTATION
MP42 G. Debernardi PRIMARY CRITERIA FOR PRESSURE COPPER LEACHING
PROCESS SELECTION
MP45 Jorge M. Menacho
and Juan Rodrguez
MODELLING BUBBLES GOING THROUGH FLOTATION
CELLS
MP48 Jorge M. Menacho REMOTE SOLUTIONS TO IMPROVE PROCESS RESULTS AT
CONCENTRATOR PLANTS

Mineral Processing

MP01

USE OF BIOSOLIDS AND ITS MAIN COMPONENTS AS FROTH FLOTATION
REAGENTS FOR THE CONCENTRATION OF COPPER SULPHIDE ORE

Lorenzo Reyes-Bozo
Departamento de Ciencias de la Ingeniera, Facultad de Ingeniera, Universidad Andres
Bello.

Alex Godoy-Fandez
Facultad de Ingeniera, Universidad del Desarrollo, Santiago, Chile.

Jose Luis Salazar, Hctor Valds-Gonzlez, Eduardo Vyhmeister
Escuela de Industrias, Facultad de Ingeniera, Universidad Andres Bello.

Ronaldo Herrera-Urbina
Departamento de Ingeniera Qumica y Metalurgia, Universidad de Sonora, Hermosillo,
Sonora, Mxico.

ABSTRACT

According to achieve a sustainable development, Chilean mining industry needs to
embrace the best practices to its sustainable growth as engine developments. Relationships
between mining industry and society have been historically complex due to its
environmental impacts. Whereas the ore grade has declined continuously, this has involved
an intensive energy and water consumption correlated to operational costs at different
stages of process. Indeed, the amount of organic chemical reagents used in froth flotation of
copper sulphide ores has a big impact on production costs as well as a huge effect on the
environment. In this research was evaluated, via standard methodologies at laboratory
scale, the use of biosolids and its main components (i.e., humic substances) as froth
flotation reagents for sulphide ore concentration. These substances interact through
physical and chemical ways due to differential affinities to mineralogical species such as
chalcopyrite and pyrite. Aqueous solutions prepared with biosolids show good frothing
characteristics whereas humic acid was found to act as collector for the concentration of a
copper sulphide ore. Therefore, biosolids and its main components may open an
opportunity to be used in copper sulphide flotation plants to partially replace conventional
reagents, which are more hazardous and less environment-friendly.
Mineral Processing

MP02
THE EVOLUTION OF MILL RELINING TECHNOLOGY
Winston Rocher

ABSTRACT
Over the past fifty years, technology has advanced quicker than in any other time
and this has impacted greatly on peoples lives, on the equipment and at work.
The small grinding mills had an entry in the mill feed end for the spout feeder that
didn't allow the entry of a person. The discharge of many of them had grates and the only
way for people, liners and tools to get into them was via the manhole. The liners were
installed manually with brute force, using tools like chain blocks, rope and chains,
extending mills shutdown for many hours and increasing the risk of accidents.
The increased size of mills and the high prices for metals means equipment
designers and mining companies need to work constantly to surpass their mechanised
technology, the quality of the materials and their components, increasing their capacity, by
making them faster, more accurate and safer. In addition, the operators are working more
strategically. The result has been a significant decrease of relining time and an increase in
operator's safety.
Mineral Processing

MP03

GAS DISPERSION MEASUREMENTS IN INDUSTRIAL FLOTATION
EQUIPMENT

Luis Vinnett, Juan Yianatos

ABSTRACT

An extensive database of Sauter mean bubble diameters, D
32
, and superficial gas
rates, J
G
, measured in different industrial flotation plants, is presented. Results involved
mechanical flotation cells of 10 300 m
3
from Rougher, Cleaner and Scavenger circuits
and columns from Cleaner circuits. A significant effect of superficial gas rate on bubble
diameter was observed in mechanical cells with different bubble generation mechanisms,
cell design (self-aerated or forced air) and under different operating conditions (frother
dosage, impeller speed). This result implies a dominant effect of the superficial gas rate on
the gas dispersion. Also, higher D
32
values were observed in flotation columns because of
the bubble sparger system and mainly due to lack of maintenance. From the D
32
and J
G

values, the bubble surface area flux, S
B
, was evaluated in order to determine normal
operating conditions. The gas dispersion database is useful to select proper operating
conditions and to define control criteria in flotation circuits.

Mineral Processing

MP04

EMPIRICAL CORRELATION FOR ESTIMATING GRINDING MEDIA
CONSUMPTION

Carlos Rabanal
Moly-Cop Adesur S.A.
crabanal@adesur.com.pe

ABSTRACT
The concern regarding grinding media wear is as old as the invention of the
tumbling mills. Over the years many materials and grinding media shapes have been tested,
through all this, steel grinding balls have proved to be the most effective media for
comminution in tumbling mills.
In the same way, no accurate technique for estimating the wear of the ball charge
has been developed. The mining industry still utilizes the Bond Abrasion test that was
developed in the 60s, this test is based in the ore properties having an error higher than
60%.
Lately in 2007, Radziszewski proposed a decouple total grinding media wear model,
this model is based in decoupling the effect of abrasion, corrosion and impact wear
mechanism, this new decoupled model gets an error of +/- 17% which is an improvement in
comparison to Bond model, but still shows high degree of error.
Also In 2007, Benavente from Moly-Cop Group presented an empiric model based
in operational conditions that affect wear mechanism. This new model shows an average
error of +/- 10% which represent a higher improvement in comparison with other models.
This paper present the research developed by Moly-Cop in order to improve the
capability of the empiric model developed by Benavente to estimated grinding media wear.
The work performed includes extensive determination of Bond Abrasion Index for different
kind of ores, operational information from concentrators and statistical analysis to
determine the more significant variables over the wear.
The result of the research let us to build a more robust and confident model to
estimate grinding media wear rate. The average error of this new model was in order of +/-
5.0% which means a higher improvement over the models previously described.

Mineral Processing

MP05

CHARACTERIZATION OF COPPER CLAYS AND GEOMETALLURGICAL
IMPLICATIONS

Ursula Kelm, Oscar Jerez, Sonia Helle, Marcos Pincheira
Instituto de Geologa Econmica Aplicada, Universidad de Concepcin, Chile

ABSTRACT

Copper clays are a common mapping term to describe parts of argillic and advanced
argillic alterations associated with Andean type copper deposits. They are very fine grained
materials with a bluish hue, which may or not expand when humidified. These copper
clays accompany chrysocolla, atacamite and secondary sulphide mineralization. Copper
clays have been characterized by X-ray diffraction, Qemscan, Transmission Electron
Microscopy and complemented by determination of cation exchange capacity.
Observations are contrasted with literature data on (1) the attempts of synthesis of Cu-
phyllosilicates, (2) the modification of phyllosilicates with Cu bearing molecules for
catalysis and (3) larger than clay-size phyllosilicates incorporating Cu phases between
individual sheets. For the studied copper clays, discrete copper phases were found to be
intercalated between individual phyllosilicate layers on a nanometric scale. For acid
extraction of Cu from these combined clay and Cu phase aggregates, rock texture and acid
stability of the phyllosilicate species are of fundamental importance.
Mineral Processing

MP07

PROGRESS MADE IN PILOT AND LABORATORY THICKENING STUDY
R. Fuentes, P. Garrido, T. Watt
Centro de Investigacin JRI S.A., Santiago, Chile

ABSTRACT
When designing thickeners, it is necessary to take into account the variety of
geological units of different lithologies and alterations that may appear during the useful
life of the mine, especially during the first five years. Ignoring these aspects leads to
different operational problems in industrial thickeners of copper tailings and concentrate,
which are unable to comply with the overflow quality or the percentage of solids required
in the output. On the other hand, precision in determining the thickener unit area has great
impact on the thickener CAPEX.
Centro de Investigacin JRI S.A. (CdI-JRI) is developing a research line (I+D)
oriented to studying thickening processes and whose main objective is focused on design.
Standard measuring of geological attribute variability conducted in a laboratory is being
contrasted with measuring carried out in batch and continuous pilot tests.
CdI-JRI has designed and built two pilot columns for this purpose, 1 and 4 meters
high respectively, equipped with a rake and different feedwells. Both implemented columns
allowed Cdl-JRI to develop its own methodology for characterizing the thickening of
mining slurries in batch and continuous tests.
This paper presents the main results obtained: thickener unit area, concentrations of
solids in underflow and overflow, the effect of the feedwell on the quality of the overflow,
and the effect of the rake on the concentration of solids in the discharge.
Mineral Processing

MP08

EFFECT OF FINES CONTENT ON YIELD STRESS OF COPPER TAILINGS

N. Rojas.
Instituto de Minerales CIMEX, Universidad Nacional de Colombia, Medelln, Colombia.

P. Garrido
.

ABSTRACT
Thickening calculation and design, hydraulic transport of mine slurries, and final
disposition of tailings are some of the areas in which a rheological characterization
containing at least viscosity and yield stress is indispensable.
These rheological parameters depend on a number of variables. Among others,
concentration of solids, pH, particle size distribution, Zeta potential, and the reagents
eventually added. On the other hand, this rheology is intrinsic to each treated slurry, and
varies throughout the life of a mining operation mainly due to changes in the geological
units and/or modifications in operating conditions.
This paper studies the influence of particle- size distribution on the rheological
characteristics of tailings. Three sizes known as fines are considered: material under mesh
200 (74 micron), material under mesh 400 (37 micron), under mesh 500 (25 micron). Each
of these is incorporated into the original tailings at different percentages, generating tailings
with a new particle-size distribution, which are then rheologically characterized.
With these results we are able to conclude that the three sizes of fines that were
studied, especially the 37-micron size (under Tyler mesh 400), generate an increase in yield
stress, shifting the yield stress curves versus the percentage of solids towards the left. This
may have a decisive impact on the thickening, transport and disposition of slurries.

Mineral Processing

MP09

STUDY ON SEPARATION OF ARSENIC FROM COPPER CONCENTRATE

Shigeto Kuroiwa, Daisuke Sato, Tatsuya lto, Misturu Sawada
Metallurgist, Niihama Research Laboratories, Sumitomo Metal Mining Co., LTD
Tsuyoshi Hlrajima
Professor, Department of Earth Resources Engineering, Faculty of engineering,
Kyushu University

ABSTRACT
Sumitomo Metal Mining Co.LTD, Niihama Research Laboratories (NRL) has been
developing Cu/As separation technology from chemical approach (investigating and
optimizing solid-liquid interfaces) and physical approach (studying the effect of flotation
equipment).
lnfluence of oxidization on the contact angle of tennantite, chalcopyrite, bornite and
pyrite was investigated. When the surface was not oxidized, tennantite indicated similar
contact angle to non-arsenical copper minerals, chalcopyrite and bornite. The contact angle
of tennantite became smaller than that of the non-arsenical copper minerals when weak
oxidization was applied.
Effect of physical parameters of flotation equipment on separability of arsenic was
also investigated. Results agreed with proposed flotation models, however above mentioned
effect was small.
Mineral Processing

MP10

MECHANICAL ENERGY BALANCE IN HYDROCYCLONE

Lina Mara Chica, M. Oswaldo Bustamante
Cimex. Universidad Nacional de Colombia. Sede Medelln, Colombia.
Arturo Barrientos Ros
Dimet. Universidad de Concepcin, Chile.

ABSTRACT

This work shows experimental results from a mechanical energy balance for
hydrocyclones in only fluid operation, and a theoretical study of the mechanical energy
dissipation at underflow.
The main conclusions from this investigation reveal that discharge conditions are
important in size separation efficiency and mechanical energy dissipation inside the body
controls hydrocyclone performance.
In this work, energy dissipation from the continua media approximation results in a
relevant concept to understand the hydrocyclone performance and improving industrial
installations.

Mineral Processing

MP11

TECHNICAL EVALUATION OF THE REPLACEMENT OF CONVENTIONAL
FLOTATION CELLS BY FLOTATION CELLS PNEUMATIC IN THE BENEFIT
OF COPPER ORES

Sergio Arellano G., Gonzalo Reyes M., Vctor Conejeros T.

Universidad Catlica del Norte

ABSTRACT

A company of the mining medium, located in the II Region of our country, requires
to increase the treatment capacity of the current plant. Long enough to make the
modifications, settled into place 2 G-Cell 18 type pneumatic cells that replace 100% to the
primary circuit. The implementation of this type of cells relies mainly to the reduced space
that they occupy and almost no structural alteration of what already exists, in addition,
update the process to a technology that most recent flotation that could result in
improvements mainly metallurgic.

The general objective of this work, is to evaluate technically and economically the
use of pneumatic cells, type G-Cell in a primary circuit of copper concentration.

The methodology of work considered historical results of conventional circuit, a
physical, chemical and mineralogical characterization of minerals to evaluate, samplings of
workflows to obtain data that will assist in the preparation of comparative balances of
technical results and the economic assessment that will affect the final decision of what
mineral is that will benefit. Two types of sulfide minerals were evaluated: Sulfurado 1 and
Sulfurado 2.

The main conclusion, derived from the results, both technical and economic, is
achieved by processing ore from the Sulfurado 2.

Mineral Processing

MP12

THE EFFECT OF THE QUALITY OF THE MAINTENANCE WORKS OF THE
FLOTATION CELLS ON AIR DISPERSION PROPERTIES AND FLOTATION
PERFORMANCE

C. Muoz, C. J. Suazo, A. Candia
Compaa Minera Doa Ins de Collahuasi, Chile.

C. Gomez
Mcgill University, Canada.

ABSTRACT

Air dispersion properties have a big impact on the metallurgical performance of
flotation. Air dispersion can be quantified in several ways, for example through bubble
mean diameter, bubble surface area flux, superficial gas velocity and gas holdup
measurements.
Additionaly the mechanical conditions of flotation cells have a big impact on the
hydrodynamics and then on the flotation performance. The quality of the maintenance
works within an concentrator plant may have a huge impact on the hydridynamics when
the original sizes of spare parts are changed and a good mechanical condition is not
provided.
The Collahuasis flotation circuit was characterize using air dispertion properties
and a kinectic survey. This work was perfomed before and after a complete overhaull of
the concentrator plant. Results are prersented in this work.
Mineral Processing

It was found that a better air dispersion can be achieve when original sizes of spare
parts are used and a good mechanical conditions of the flotation cells is provided. Fine
liberated sulphide particles lost in tailings were reduce improving the copper and
molybdenum recoveries.
Mineral Processing

MP13

NEXT GENERATION PRESSURE FILTERS FOR HARD ROCK TAILINGS

T. Wisdom

ABSTRACT

The use of slurry impoundments have traditionally been the primary method of
disposal of waste slurry resulting from the recovery of metals and minerals. However,
current difficulties in obtaining permits to build new impoundments for grass-roots plants,
or as the existing ones near the end of their projected life, has made it necessary to explore
other alternatives for tailings disposal. Fresh water resources are becoming more precious,
and environmental pressures are increasing leading to the elimination of slurry tailings
impoundments.
It is becoming more prudent to consider filtration and dry stacking as a reasonable
and sustainable alternative. There are several obstacles to filtration as a way to treat these
tailings. Many tailings slurries are difficult to filter and higher plant throughputs have in
the past made filtration operations both costly to buy and to operate.
But as with the equipment used to mine and move the harder lower grade ores,
equipment to process the resulting tailings slurries have increased in size, efficiency, and
capacity to meet the demand, as well as to reduce the number of people needed to operate
them. This paper discusses the technical and financial considerations, OPEX and CAPEX,
that influence equipment selection and optimization of the filter pressing system to produce
a satisfactory, transportable and stackable tailings product. Multiple tailings samples have
been investigated incorporating lab and pilot scale testing. The impact of different
minerologies and grain size will be discussed.

Mineral processing

MP15
SURFACTANT STRUCTURE PROPERTY RELATIONSHIP:
EFFECT OF POLYPROPYLENE GLYCOL ETHERS ON BUBBLE RISE
VELOCITY

Yue Hua Tan and James A. Finch
Department of mining and Materials Engineering, McGill University

ABSTRACT
The paper is part of our study of the frother structure-property relationship using
bubble rise velocity. Single bubble rise velocity profiles were determined in a 350 cm
column. Velocity at 300 cm as a function of concentration is used to estimate the
concentration to reach minimum velocity, CMV. The structure variables alkyl chain (n,
number of carbons) and number of propylene oxide (m) groups were investigated. The
effect of increasing n and m is to decrease CMV. Linear correlations with log CMV vs.
hydrophilic-lipophilic balance (HLB) as a function of n and m were observed. The
correlations are compared with previous correlations between critical coalescence
concentration (CCC) and HLB.

Mineral Processing

MP16
SEAWATER USE IN ANTOFAGASTA MINING GROUP

Francisco Abbott
Minera Esperanza

Gustavo Tapia
Antofagasta Minerals S.A.

ABSTRACT

The Antofagasta plc mining group has been pioneer in the use of raw sea water in
metallurgical process at big scale. In the 90 decade, Minera Michilla began successfully the
use of sea water in the process of leaching copper oxide and secondary sulfide ore followed
by SX-EW. At the end of 2010, Minera Esperanza commissioned a grinding and flotation
plant processing 97 ktpd of sulfide ore, using raw sea water and applied an alternative
depressant for pyrite in the cleaning stage.
Mineral Processing

1

MP17
ANTAPACCAY TINTAYA EXPANSION
D. Garca and J. Villanueva
Concentradora Antapaccay, Xstrata, Peru

ABSTRACT

Xstrata recently completed construction of a new 70,000 tonne per day copper
concentrator near Cusco, Peru. Plant start-up was accomplished during the last quarter of
2012. Comminution will be accomplished by primary crushing, SAG milling and pebble
crushing followed by ball milling. The Concentrator is a single line configuration,
comprising of one 40 ft. diameter x 22 ft. long (EGL) SAG mill driven by a 24,000 kW
gearless drive. The SAG mill feeds two ball mills each 26 ft. in diameter x 40 ft. long
(EGL), each driven by a 16,400 kW through gearless drive. This represents the higher
power of SAG in the world and the first 40 ft. SAG in Peru. This paper reviews the
projects technology.

This represents the first Xstratas Standard Concentrator, the higher power of SAG
in the world and the first 40 ft. SAG in Peru, an overland conveyor of 6.5 km with gearless
drive, the use of an old pit as tailings dam in big mining and the higher torque of tailings
thickener. This paper reviews the history, the background, the grinding circuit design and
the operations start-up considering focus in safety, start-up strategies, main issues,
improvement opportunities.

Mineral Processing

MP18

GRINDING CYCLE OPTIMIZATION FOR PROCESSING OF COPPER SLAG AT
AURUBIS BULGARIA

E.Visariev
D. Kirilov; V. Stoilov; E. Djurova; I. Bonchev; V. Stoyanova;
aurubis bulgaria
Industrial zone
Pirdop, Bulgaria 2070

ABSTRACT

At Copper smelter Aurubis Bulgaria, the slag from Flash furnace and Converters is
processed by flotation. The scheme of slag processing comprise: crushing, two stage
grinding and flotation.

Till 2010 the first grinding stage was AG Mill 7023 worked with classifier and the
second stage - ball mill 3.6/5.5 with hydrocyclone. In 2010, a new AG Mill 65x78 with
hydrocyclone was commissioned in order to increase the plant throughput. The second
stage of grinding cycle was not changed.

The Old AG mill processed 55-60 t/h slag with 75% content of size - 0.071 mm or
over 75 t/h with 35-40% content of size -0.071 mm.

The new AG Mill was designed for throughput of 105 t/h with over 70 % content of size -
0.071 mm. After start-up some problems with the equipment occurred block-up of AG
Mills grate and pumps for cyclone feeding. One of the main problems was a fast wearing
of new AG mill hydrocyclone sand nozzles. Different nozzles materials (rubber, ceramic
and metallic) were tested.

This paper presents:
Comparison of optimal working parameters of old and new working scheme;
Change of technological parameters with different sands nozzles and its effect on
circulating load;

Mineral Processing

MP19

IMPROVED DEM MODEL FOR PREDICTING CONE CRUSHERS PERFORMANCE

Dr. V. Murariu and Dusty Jacobson
Metso Minerals Industries, Inc.

ABSTRACT

Cone crushers have been applied in mineral processing or comminution circuits for more
than five decades. In that period of time, the principle of machine selection and optimization
have evolved from purely empirical methods (capacity tables and product size curves based on
best practice) to include newer simulation based approaches.
These simulation techniques combine the strength of theory with traditional population
balance techniques. Metsos crusher simulation employs DEM with a proprietary fast breakage
technique using the concept of incremental damage. This paper provides an overview of the
Metso cone crusher simulation technology, and highlights the value of the virtual machine for
equipment design and optimization.

Mineral Processing

MP20

PYRITE CONCENTRATE OBTAINED FROM COPPER TAILINGS

L. Valderrama and J. Chamorro
Department of Metallurgy, University of Atacama

D. Olguin and M. Carmona
Plant Management, National Mining Company

ABSTRACT

This paper aims to present the results in the recovery of pyrite concentrate from
tailings of copper produced in the plant Manuel Antonio Matta Ruiz of the National Mining
Company ENAMI. The flotation tests performed at laboratory scale, in a cell Denver D-12,
indicated that it is feasible pyrite flotation, using A-404 as a collector and MIBC and D-250
as a frothers, in a pH range between 6 to 8, obtaining a concentrate grading 91.6 % pyrite
and a recovery of 92 %.

The flotation circuit proposed included the steps: rougher, cleaner, recleaner and
scavenger. The flotation tests at industrial scale were conducted on the proposed laboratory
scale circuit in the ENAMIs plant, from the copper tailings generated, producing
concentrates with grades greater than 92% pyrite and recoveries of 80%.

Mineral Processing

MP21

INSIGHTS ON PYRITE ACTIVATION IN COPPER-IRON BEARING SULPHIDE
ORE FROTH FLOTATION: LABORATORY VS PLANT RESULTS

Montes-Atenas, G., Escudero-Acevedo, M. and Cayunao, B.
Minerals and Metals Characterisation and Separation (M
2
CS) Research Group. Mining
Engineering Department. Universidad de Chile, Av. Tupper 2069, Santiago, Chile.

ABSTRACT

This research aims at evaluating the activation of pyrite in metallurgical samples
obtained from a mine site and confronting such results with electrochemical studies.
A new sample preparation protocol for X-ray Photoelectron Spectroscopy (XPS)
analysis, developed at the Minerals and Metals Characterisation and Separation (M
2
CS)
Research Group, was applied to pulp samples from a mine site. The plant sample consisted
of a pulp sample fed to the cleaning stage of a copper-iron bearing sulphide mineral. The
laboratory test consisted of immersing a solid electrode of pyrite into synthetic aqueous
solutions containing ion concentrations similar to that observed at plant scale. Preliminary
results showed that pyrite activation is difficult to achieve in the aqueous conditions
observed in the concentrator because the Cu/Fe ratio equals to 3 reported by many
researchers was not observed in the survey.
Instead, the Cu/Fe ratio of about 1 was observed at large scale. The latter indicates
the activation of pyrite, if applies, is driven by either sub-monolayer activation or Cu ions
weakly adsorbed at mineral surface. Further studies connecting mineralogical and XPS
analysis on is then required to assess the significance of pyrite activation in the
concentration of copper bearing ores.

Mineral Processing

MP22

THE EFFECT OF FLOCCULANTS AND THEIR DEGRADATION PRODUCTS
ON MOLYBDENITE FLOTATION

S. Castro
Department of Metallurgical Enginering, University of Concepcion,Chile

J.S. Laskowski
NB Keevil Institute of Mining Engineering, University of British Columbia,
Vancouver,Canada

ABSTRACT

Modern ore processing plants must have closed circuits in which process water is
recycled back after removal of fine particles in the solid/liquid separation unit operations.
Flotation of Cu-Mo ores includes two steps: a bulk flotation where molybdenite is
recovered together with Cu and Fe sulfides; and a subsequent selective flotation step where
molybdenite is separated from depressed copper sulfides. Flocculants are usually employed
in Cu-Mo concentrate thickeners preceding the selective molybdenite flotation plant.
However, the floatability of molybdenite, similarly to other naturally hydrophobic minerals,
is highly sensitive to the effect of both natural and synthetic polymers. In this work
flotation testing demostrate that conventional flocculants of the polyacrilamide type (PAM)
are strong depressants for molybdenite flotation. Additionally, shear degraded
polyacrylamides, in spite of loosing flocculation ability, are still able to depress
molybdenite flotation.

Also polyethylene oxide (PEO) have been studied in this project. The results show
that its ability to flocculate is pH dependent. In slightly acidic pH PEO and PAM showed
similar flocculation efficiencies on molybdenite suspensions. In alkaline pH, the
flocculating and depressing effects of PEO increased. In the case of PAM, a simultaneous
loss of flocculating and depressing efficiency was observed in alkaline pH. The proper use
and selection of flocculants for better molybdenite recovery is discussed.

Mineral Processing

MP23

TWO DIMENSIONAL STOCKPILES PHENOMENOLOGICAL MODELATION

G. Maturana
Instituto de Innovacin en Minera y Metalurgia IM2

ABSTRACT

To avoid intermittent flows in the comminution process, the stockpiles emerged as a
suitable solution to the required operational continuity in the process of comminution.
However, this causes a loss of traceability of ore characteristics inside the stockpile, mainly
due to phenomenas like segregation, stratification, avalanches and inverted cones among
others. These phenomenas are generally depending on the geometry, form to feed and
extraction, particle size distribution, moisture and others.

Currently, there are operating methods to track the mineral maintaining a constant
feed and extraction, one of them the method called "Mass Flow", which not being the most
accurate gives some approximation to reality. Moreover, when extraction is generated from
the stockpile and there is not feed, there is a regime known as "Funnel Flow", generating
inverted cones and thus losing all mineral traceability.

In order to have a wider knowledge of the effects presented above, a
phenomenological study was developed in two dimensions, the movement of ore was based
on the geometry of Codelco Norte Divisions stockpile A-2, and the extraction was
modeled by the Kinematic Model" and feeding by the Segregation Model. This allowed
a comparison between the experimentally mineral movements with those delivered by the
model. Coupling feeding models allowed the extraction of mineral predicted traceability
within the stockpile, independent of the operation sequence.

Mineral Processing

MP24

ADVANTAGES AND DISADVANTAGES OF BROWNFIELD PROJECTS

Fernando Pino
Senior Process and Commissioning Engineer
Jacobs Engineering, Chile

ABSTRACT

Projects are classified as Greenfield or Brownfield, the latter corresponding to those
dealing with expansion, modification and/or optimization of existing operations. Usual
thinking is that Brownfield Projects are easier to define and develop than Greenfield or new
Projects; however, evidence shows that rather the opposite is true.

Advantages of Brownfield Projects are the available improved knowledge of ore
characteristics, metallurgical processing, unit operations, equipment performance and
personnel know how. However, there are serious hurdles to overcome, such as:
coordination between the EPCM Company, the Owner Project Manager and the Operations
Manager; building additional facilities within a running operation under acceptable safety
conditions; need to maintain production level during construction; connections or tie-ins
of new facilities to the existing ones; possible modifications required due to technological
evolution or changes in the ore nature; in this paper, some general recommendations are
drawn from the analysis of selected typical cases, comprising tie-in identification, design,
engineering, coordination and implementation; and planning the execution of modifications
during normal and extraordinary plant detentions. Additionally, cases are analyzed for
which innovations can have important effects on commissioning and start up schedule for
both project types.

Mineral Processing

MP26

FROTHER ROLES CHARACTERIZATION IN A LABORATORY
FLOTATION CELL

C.O. Gomez, P. and J. Alvarez
Universidad of Concepcin
Departamento de Ingeniera Metalrgica
Edmundo Larenas
Concepcin, Chile

ABSTRACT

Frothers play two major roles in flotation: preservation of the formation bubble size
and stabilization of the froth. Many tests have been proposed to characterize one of these
two functions and to classify frother strength based on the results obtained. A technique to
characterize these two roles simultaneously, using a laboratory flotation column, was
developed and successfully used to screen and select a replacement candidate for a
particular concentrator.

The test requires column steady state operation maintaining a constant froth height,
which entails large volumes of plant water. A technique based on batch testing around a
laboratory mechanical cell not only would demand less water, but also would make
possible on-site testing. This communication presents the development results of a batch
test to characterize frother roles in a laboratory mechanical cell, which is done through the
determination of the critical coalescence concentration and the water overflow curve.
Frothers tested follows the same classification sequence previously obtained in the column
tests.

Mineral Processing

MP28

SAG MILL DISCHARGE SECTION OPTIMIZATION STUDIES AND REDESIGN

DG Meadows, Luis Vergara, Thomas McQuillan, Horacio Marin

ABSTRACT

The SAG mill is the primary work horse on the majority of comminution circuits
throughout the globe. With declining head grades the need for higher throughput circuits
has become prevalent particularly in Latin America. This paper describes the recent design
knowledge and practical experience gained in both the areas of pulp lifters and integrated
trommel design. The importance of system efficiency in terms of pulp removal is described
together with the need for enhanced slurry distribution onto the trommel screen itself.

Redesign starts with the replacement of the original OEM discharge mill linings,
generally made of Cr-Mo steel alloy castings, by liners made from a steel-rubber-ceramic
composite that acts by using each material property for specific work and application. Thus,
very hard ceramic takes care of wear resistance, the rubber matrix underneath helps absorb
impact loads and steel gives structural support, offering a more efficient solution for the
service required workloads in terms of resistance/weight ratio and endurance.

The unique and complete discharge process from the mill grates to the pebble
collection chute at the end of the trommel was studied in depth. The flow of pulp through
the SAG mill, discharge trunnion and trommel was modeled in detail using modern
techniques such as SPH/CFD and DEM. This enabled the integral design of the pulp lifters,
trunnion section, trommel and trommel panels to be optimized and then finely tuned for
maximum throughput of fresh ore.

The final result with an optimized discharge performance allows a more efficient
energy usage and or a better ore processing mill capability that enhances its performance
and so may pay back significant investment costs. Practical data relating to the influence on
circuit operating times and availability are also described.

Mineral Processing

MP29

INSTALLATION OF INTERNAL LAUNDERS ON 130 m FLOTATION CELLS
AT MINERA LOS PELAMBRES

F.D. Henrquez and L. Maldonado
Minera Los Pelambres
Santiago, Chile

ABSTRACT

In the last decades flotation equipment has shown a significant increase in size. At the
present moment, most of the concentrators plants operating in Chile have been fully
equipped with 130250 m mechanical cells and the new projects are considering the 300
m cell on its flotation circuits. This dramatic increase in size poses new challenges in terms
to develop better approaches to optimize the operations.

Originally, Minera Los Pelambres rougher Cu Mo flotation stage was equipped
with 130 m in volume WEMCO cells with no internal launders on it. This paper describes
the metallurgical comparison between two parallel flotation lines, one of them with recently
internal launders installed on the three first cells. For this purpose, a six month sampling
campaign was developed in order to obtain the metallurgical parameters of concentrate
grade and recovery.

The analyzed data demonstrated an improvement in the Cu and Mo recovery of about
0,11% due the effects of internal launders on cells stabilization and increase on the
available concentrate discharge perimeter. This result led to extend the installation of these
devises on the other three lines remaining on the three firs cells.

Mineral Processing

MP30

CONCENTRATION OF COPPER OXIDE MINERAL WITH HYDROXAMATE

H. Nematollahi, F. Kiani and M. Asgari-Mehrabadi
kian mine pars co.

ABSTRACT
Takhate-Gonbad porphyry copper mine is located at the 80 km northeast of Sirjan,
Kerman Province, south-east of Iran. The main mineralization zones of Takhate-Gonbad
mine include: leached, oxide, mixed and hypogene. The main purpose of this study is
beneficiation of oxide zone minerals by flotation. The flotation tests are carried out on
samples obtained from 4 boreholes.
The average grade of these samples are from 0.33 to 0.86% Total Cu. The host rock
of these boreholes are different. They are: micro-granodiorite, silicified rocks, tuff and
metamorphic rocks and calcite tuff. Regarding presence of both sulphide (i.e. chalcopyrite,
covellite) and oxide (i.e. cuprite, malachite) minerals, flotation tests are carried out in
different conditions, using different reagents.
Based on these tests, the best results are obtained at pH=10.2 with 25 g/t of PAX
and 500 g/t of octyl-hydroxamate. Under this circumstance, the grano-diorite sample is
concentrated with 83.8 % of recovery (the highest one) and the silicified sample is
concentrated with 35.0 % of recovery (the lowest one). Base on obtained results, all 4
boreholes was mixed together and flotation tests were done. The results show that it is
possible to reach concentrate with copper contents15.51% in cleaner stages and 62.9%
copper recovery in rougher stage.

Mineral Processing

MP31

GRINDING CHEMISTRY THE APPLICATION OF GRINDING MEDIA TO
IMPROVE METALLURGICAL RESPONSE OF COPPER ORES

Christopher J Greet and Jessica Kinal

ABSTRACT

Numerous studies completed by academia and at industrial scale have consistently
demonstrated that grinding with an electrochemically inert grinding media has significant
benefits when processing copper ores.

This paper provides a summary of pulp chemical and flotation response data for a
variety of copper ores classified by geological type prepared using forged steel and high
chrome grinding media.

The results intend to show that the mineralogical character of the ore has a
profound impact on the pulp chemistry and this effects the flotation behaviour of the
sulphide minerals. Further, the choice of high chrome grinding media, to better control
the chemical environment during grinding, is driven by the mineralogy of the system
under consideration.
Mineral Processing

MP32
AMIRA P260 SILVER JUBILEE 25 YEARS OF BENEFITS TO MINERALS
FLOTATION

Zanin, Massimiliano and Skinner, William.
The Wark, University of South Australia. Mawson Lakes Campus, 5095 Mawson Lakes, SA,
Australia.

ABSTRACT
The AMIRA International P260 series of flotation projects was initiated in 1988 at
the University of South Australia, and was sponsored by 17 companies. The major focus of
P260 has been all aspects of base metal sulphide flotation, expanding to gold, and more
recently to phosphate and other value ores. A key feature of the research has been a deep
understanding of pulp and surface chemistry under processing conditions, as well as the
mechanisms underpinning the sub-processes of bubble-particle collision, attachment and
detachment in flotation.
Research comprises a combination of physical chemistry and engineering, aiming at
optimum value recovery and selectivity. Copper flotation in a variety of ore types and
deposits (Cu/Pb/Zn, Cu/Au, Cu/Mo, etc.) has been a constant theme in the project,
encompassing research for operations on four continents. Now in its 25
th
year, AMIRA
P260 was recently evaluated by an independent consultant, RMDSTEM, as having returned
over $1 billion to industry over the project life. This represents a 22:1 return on investment
to the sector. In this paper, we present some case studies of Cu flotation research in the
P260 project, together with highlights of research tools and knowledge development
contributed to industry.

Mineral Processing

MP33
NASH IN THE OPTIMIZATION OF COPPER FLOTATION
CONCENTRATOR CUAJONE

J. Dvila, R. Llerena, N. Benavides and C. Curo.
SOUTHERN COPPER SOUTHERN PER
Cuajone Mining Camp
Moquegua, Per

ABSTRACT

Since early 2011, the type of rock ore that reached Cuajone Concentrator Plant
showed high contents of basaltic andesite, andesite Intrusive (% IA +% BA) and surface
oxide ores.

This type of mineral affected the low recovery of Cu, low tonnage of treatment, and
high consumption of sparkling lime. In addition to operating flotation problems, low
stability in the area of foaming Rougher flotation stage.

To improve the recovery of copper, sulphidation was considered, which involves the
addition of reagents to provide ionS
2-
and SH
-
. The role of these ions is to modify
completely the phisycal chemical nature of its surface structure, allowing the adsorption of
collectors on it, and its subsequent flotation. In our case we use the sodium hydrosulphide
(NaSH) as an agent to enable the affected species in the flotation of copper sulphides,
andesites and oxidized surface.

Cuajone Concentrator Plant started its trial period in 2011. With no technical
background in the industry on the conditions, dosages and addition points of NaSH, it was
experimented in different parts of the flotation. And, from September 2011, it has been
determined that the dosage of 15% concentration in the head Rougher flotation at pH 10,
improved copper recovery, reducing the consumption of frother and milk of lime, is also
achievement stabilize flotation.

The average copper recovery improved 2.3%, consumption of Cal and frother
declined by 21% and 28% respectively.

Mineral Processing

MP34

A REVIEW OF BENEFICIATION SCHEME FOR COPPER-ARSENIC ORE
DEPOSITS

Vishal Gupta
FLSmidth Salt Lake City Inc.

Ken Baxter
SNC Lavalin Group
Perth, Australia

ABSTRACT

Arsenic is an undesirable element that causes serious toxicological and
environmental problems in smelting of arsenic-containing minerals such as enargite,
tennantite etc. Serious financial penalties are imposed by smelters to treat copper ores
containing higher than 0.2 wt % arsenic. Although hydrometallurgy or pyrometallurgy
processes offers some solution to recover valuable copper minerals, arsenic fixation in the
stable form remain the key problem. It would be more economical and environmentally
beneficial to remove arsenic at an early stage by pre-concentration such as flotation.
Published results showed some success in separating arsenic rich mineral such as enargite
from chalcopyrite by different strategies employed in flotation such as selective chemical
agent, pulp potential, and in combination with slurry pH. Most of these studies have been a
matter of academic interest, and no successful flotation schemes have been practiced in the
plant.
This work reviews the key findings of the arsenic removal means such as flotation
tried by the researchers and engineers, and the difficulty present there in to scale-up the
process. An overall process concept is presented where flotation forms a key unit operation
in the treatment of arsenic ores, and some of the issues with differential flotation can be
minimized through an approach which provides a mechanism to successfully treat these
ores.

Mineral Processing

MP35

PREVENTING COPPER LOSS PRODUCTION AND FLOW PROBLEMS
BY MEASURING THE MATERIALS FLOW PROPERTIES

O. Angulo and F. Cabrejos
Jenike and Johanson Chile S.A.

ABSTRACT

Hundreds of millions of tons of copper-containing products in particulate forms
(such as ROM, crushed, agglomerated or leached ore, concentrate, or tailings), having
different characteristics (like particle size distribution, shape and density, moisture content,
chemical, mineralogical and lithological composition), are daily handled, stored and
conveyed in the world through different equipment at the different stages of the copper
minerallurgical processes. In these processes, operators commonly face problems such as
loss of production, flow blockages in the equipment, segregation, equipment wear,
uncontrolled discharge and occasionally unexpected plant shutdowns. Due to the huge
investments involved in world class projects, the mining industry is particularly sensitive to
them.

The purpose of this paper is to provide a cost effective solution to flow problems in
the mining industry, by highlighting a well proven and scientific method used to ensure
controlled and reliable flow of bulk solids, based on Jenikes flow of solids technology and
laboratory testing [1]. Knowledge of the material flow properties allows designing new
installations or modifying existing defective equipment, and preventing production
stoppages due to the formation of chute pluggages, cohesive arches and/or ratholes in
silos, which are the most common causes of flow problems in the copper mining industry.

Mineral Processing

MP36

THERMODYNAMIC CONSTANTS OF MINERALS OF THE OXIDATION ZONE
OF COPPER ANTLERITE AND PSEUDOMALACHITE

N.S. Bekturganov
SC National scientific-technological holding Parasat
18 Republic Ave.
Astana, Kazakhstan 010000

M.R. Bissengaliyeva, D.B. Gogol and Sh.T. Taimassova
The Institute of problems of complex development of mineral resources
5 Ippodromnaya Street
Karaganda, Kazakhstan 100019

ABSTRACT

Minerals of the oxidation zone of copper deposits belong to the most difficult for
enrichment. To transfer them into the easily floatable sulfide components it is necessary to
have new technologies and methods of enrichment associated with solving of a number of
theoretical issues to which the chemical enrichment refers. Optimization and intensification
of the technology process for the purpose of more complete and complex utilization of raw
materials require certain knowledge of thermodynamic properties of the oxidized minerals
since the thermodynamic analysis and a preliminary simulation of the process are necessary
for creation and choice of ore processing schemes. A basic sulfate of copper antlerite and a
basic phosphate of copper pseudomalachite relate to these minerals along with malachite,
azurite, atacamite, chrysocolla, brochantite, etc.

This paper generalizes the results of experimental studies of thermodynamic
properties of antlerite and pseudomalachite obtained by a number of the calorimetric
methods (low-temperature adiabatic calorimetry, the Tian-Calvet high-temperature melt
solution calorimetry). This resulted in obtaining such fundamental thermodynamic
constants as the heat capacity, entropy, the change of enthalpy, the enthalpy of formation
and the Gibbs energy of formation used in simulation of technological processes of
processing of the oxidized and mixed copper ores.

Mineral Processing

MP38

RECENT DEVELOPMENTS IN FLOTATION COLUMN
INSTRUMENTATION AND CONTROL

R. del Villar, J. Bouchard
Department of Mining, Materials and Metallurgical Engineering

A. Desbiens, . Poulin
Department of Electrical and Computer Engineering
LOOP (Laboratoire dobservation et doptimisation des procds)
Universit Laval
Qubec (QC), Canada

ABSTRACT

For over two decades, the Process Observation and Optimisation Laboratory
(LOOP) has been working in developing and/or improving specific sensors for flotation
columns and their use for process control. Numerous papers have already been published
for the Mineral Processing industrial and scientific community in peer-reviewed journals
and conference proceedings, e.g. for the Copper Conference series. This paper summarizes
the latest completed milestones by the group, since the last Copper conference held in Chile
in 2003, emphasizing on results presented in North America and Europe since Copper
2010.

On the instrumentation side, developments encompass a more accurate method for
measuring electrical conductivity for flotation column sensors, a device for estimating the
bias rate, a better procedure for evaluating bubble size from images taken by bubble
viewers, and a method for on line estimation of frother concentration. In terms of process
control advances, the discussion will focus on results for bubble size control in a two-phase
system, and the application of a 3x3 multivariable predictive control to a pilot flotation
column running in parallel to industrial columns in a Qubec concentrator. Current
investigations on bubble size distribution modeling and control, as well as matching bubble
size to particle size will be discussed.

Mineral Processing

MP39

METALLURGICAL OPTIMIZATION OF A HIGH DISSEMINATION
AND HIGH HARDNESS COPPER ORE

Ral Jara Iturre
Empresa Minera Altos de Punitaqui
Miguel Aguirre 280 - Oficinas 47-48. Ovalle

Luis Tello Muoz, Cristian Gonzalez Bravo, Hector Guinel Figueroa
Empresa Minera Altos de Punitaqui
Miguel Aguirre 280 - Oficinas 47-48. Ovalle

ABSTRACT

Minera Altos de Punitaqui owns a concentrator plant near Punitaqui City, 12 km
south from Ovalle City located in northern Chiles Fourth Region. This Concentrator plant
processes about 3,500 DMT/day and produces 43,000 DMT/year of concentrate with 28%
copper content and some silver content.
In early 2012, the plants copper recovery was approximately 77%. According to
mining standards, this is a low recovery rate, although earlier mineralogical and
metallurgical studies indicated that the maximum possible recovery wouldnt be higher
than 80% due to the high value dissemination in the feed ore.
The plant superintendence and its technical team developed a work plan resulting in
systematic enhancements to the flotation process; the operational variability decreased and
relevant conditions were modified, including the flotation circuit and process variables; to
end up that year with a steady state recovery of 80 82% with a quality of more than 27%
copper, 2% higher than the 2011 average.
In 2013 without any investment in flotation cells the flotation capacity has been
increased from 3,100 DMT/day to 3,500 DMT/day with higher copper recovery. This
comes with the bonus alternative of using the idle capacity to process other third party
minerals adding further profitability to the Altos de Punitaqui site.
This paper describes both the optimization strategy applied and the improvement
results, underlining the virtuous triangle made up by a well-organized operation, the
metallurgical laboratory support and the support received from the industrial process
analysis, modelling and simulation.

Mineral Processing

MP40

MARINE TAILINGS PLACEMENT: EXPERIENCES AND LESSONS FROM THE
ASIA PACIFIC REGION

D. Gwyther
Picton Group Pty Ltd
30 Malpas Drive
Wallington Vic3222, Australia
dg@pictongroup.com.au

J. Waworuntu
P.T. Newmont Nusa Tenggara,
Jalan Sriwijaya 258 Mataram, Indonesia
Jorina.waworuntu@nnt.co.id

ABSTRACT

This presentation looks at some of the advancements in operating and monitoring
that have accompanied the implementation of deep sea tailings placement (DSTP) in the
Asia Pacific region over the past 20 years. It describes the guidelines and criteria that have
been developed to ensure that DSTP systems are properly assessed and located prior to
approval and throughout operation and closure.
In considering the potential applicability of these experiences to countries such as
Chile, substantial research will clearly be required to establish equivalent criteria to achieve
the same objectives and environmental safeguards in the Chilean socio-political context.
However, just as important for gaining acceptability will be the acknowledgement by
governments and all sectors of the community of the existence of the dilemma now or at
some time into the future that if the currently accepted land storage methods reach their
physical or safety limits, alternative storage methods will need to be considered. DSTP
cannot be a solution without broad community acknowledgement that a dilemma about
future mine tailings management needs to be faced. It is the role of governments, informed
by scientific study, to evaluate the best solution for future tailings management for the
country in each case.

Mineral Processing

MP41

MODELLING BUBBLE HYDRODYNAMICS IN FLOTATION

C.O. Gomez and J.A. Finch
McGill University
3610 University Street
Montreal, Canada H3A 2B2
cesar.gomez@mcgill.ca

M. Maldonado
Departamento de Ingeniera Metalrgica
Universidad de Santiago de Chile
Avenida Libertador Bernardo OHiggins 3363
Santiago, Chile

ABSTRACT

Three parameters are generally used to describe gas dispersion in a flotation
machine: superficial gas (air) velocity, gas holdup and bubble size. Techniques and sensors
to measure local values of these parameters, including industrial flotation units, have been
developed.

A model relating these variables, which was developed based on a drift-flux
analysis of bubble hydrodynamics, has been available for many years. The model has been
mainly used to predict one variable (typically bubble size) from measurements of the other
two. Gas dispersion measurements in laboratory and industrial units have demonstrated
that in many cases significant differences between measurement and model prediction exist.

A reliable model to predict properties of bubble populations would help in the
selection and operation of flotation equipment. This work takes laboratory air-water data
sets to establish the adequacy of the equations in the drift-flux model. The results
demonstrated that ignoring the effect of frother on bubble terminal and swarm velocities is
the reason for the poor model prediction.

Mineral Processing

MP42

PRIMARY CRITERIA FOR PRESSURE COPPER LEACHING PROCESS
SELECTION

G. Debernardi, R. Souyris and M. Gianetti
DESSAU CHILE INGENIERA
Ricardo Lyon 222, Piso 10, Providencia
Santiago, Chile
gianfranco.debernardi@dessau.cl
raul.souyris@dessau.cl

J. Menacho
De Re Metallica Ingeniera
Av. del Valle 601, oficina 31, Huechuraba
Santiago, Chile
jorgemenacho@drm.cl

ABSTRACT
Several hydrometallurgical processes for high and moderate pressure leaching of
copper sulfides have been developed in the past years, such as the Total Pressure Oxidation,
Sepon, Platsol, Mt. Gordon, AAC/UBC, Dynatec, CESL, Activox and MT-DEW-SX
processes. Nowadays, several are under industrial scale application, or well tested at pilot
scale level.
The basics and current status of these processes is briefly reviewed, with special
consideration on their applicability to the leaching of different copper ores, depending on
its sulfide mineralogy and occurrence of impurities such as arsenic and the presence of
other valuable metals. A comparison of the general conditions in the autoclave leaching for
each process is presented, and a decision tree is proposed for a simple choice of the best
technology for a given application from a process point of view, before proceeding to
perform feasibility study.

Mineral Processing

MP45
MODELLING BUBBLES GOING THROUGH FLOTATION CELLS
Jorge M. Menacho and Juan Rodrguez
De Re Metallica Consultant, Av. Del Valle 601, Oficina 31, Huechuraba, Santiago,
Chile, (562)-738-4493, drm@drm.cl

ABSTRACT
A new phenomenological approach is presented in this paper, in which bubble
dynamics is described from the bubble generator, going through the slurry phase, where
they move within a turbulent circulating field subjected to simultaneous rupture and
coalescence phenomena, both controlled by the frother HLB and dosage. Size growth
simultaneously occurs due to lower pressure as bubbles move up. After a time bubbles
arrive to a compaction zone where porosity is reduced becoming a continuous bed. Then
the bubble bed enter the froth phase moving upward in plug flow condition and
capillary drainage occurs getting bubbles even closer and promoting further
coalescence, such that in the final froth zone bubbles are nearly impervious to washing
water.
Equations representing the above-described physical model are presented and
several examples of performance are given.
Mineral Processing

MP48
REMOTE SOLUTIONS TO IMPROVE PROCESS RESULTS AT
CONCENTRATOR PLANTS
Jorge M. Menacho
Chile, (562)-738-4493, drm@drm.cl

ABSTRACT
A new approach to improve operational managing at concentrator plants is described in
this paper. It combines robust process models connected to intelligent algorithms
specially designed for specific goals, all settled into a powerful communication platform
which assure maximum usability through remote applications.
This approach combines expert knowledge and modern cloud computing technology to
produce efficient tools for monitoring, optimization and control of critical operational
issues.
Specific examples are given showing potentiality of these tools, directed toward
increasing of productivity and efficiency, reducing water and energy consumption and
improving communities and environment friendship.

Pyrometallurgy

SYMPOSIUM: 03 PYROMETALLURGY

PY01 James Edwards COMING OF AGE - 21 YEARS COMERCIAL OPERATION OF
COPPER ISASMELT IM AT MONT ISA
PY02 Kim Fagerlund SMELTING - INTEGRATED, SUSTAINABLE PLANT SOLUTION
PY03 Dean Gregurek WEAR PHENOMENA OF BASIC BRICK LININGS IN COPPER
INDUSTRY
PY04 Dean Gregurek CORROSION TESTING METHODS FOR NEWLY DEVELOPED
REFRACTORY PRODUCTS
PY05 N. Brogden ELECTROMAGNETIC LEVEL PROFILE MEASUREMENT SYSTEM
TESTED BY AGELLIS GROUP AB ON KENNECOTT COPPER
FLASH SMELTERS IS DESIGNED TO ENHANCE PROCESS
CONTROL DECISION MAKING AND IMPROVE OPERATOR
SAFETY
PY06 Klaus Gamweger FIELD REPORTS OF THE NEW INNOVATIVE GAS PURGING
SYSTEM FOR STATIONARY AND TILTING COPPER ANODE
FURNACES
PY07 G. Alvear SMELTING OF KAZAKHSTAN CONCENTRATES AT UST-
KAMENOGORSK USING A COPPER ISASMELT FURNACE
PY08 Angelika Ressler DESTRUCTIVE AND NONDESTRUCTIVE TESTING METHODS
FOR THE CHARACTERIZATION OF MGOCR2O3-BASED
REFRACTORY BRICKS
PY09 Chiharu Tokoro SULFULIZATION AND SLOW-COOLING FOR MOLYBDENUM
RECOVERY FROM COPPER SMELTING SLAG
PY10 Gavin Swayn DESIGN AND COMMISSIONING OF THE OUTOTEC AUSMELT
TSL COPPER SMELTER AT DNMC
PY11 Cristian Martinez General Maintenance of Electric Furnace
PY12 G. Alvear XSTRATA TECHNOLOGY`S APPROACH FOR THE PROCESSING
OF COPPER BEARING MATERIALS
PY13 G. Richter CALETONES SMELTER; ENVIRONMENTAL AND
COMPETITIVENESS CHALLENGES
PY14 Maximo Leon ON THE INTERACTION BETWEEN REVERTS MEAN PARTICLE
SIZE AND FLASH FURNACE REACTION SHAFT HEIGHT: A
SENSITIVITY ANALYSIS
PY15 Taufiq Hidayat A THERMODYNAMIC OPTIMIZATION OF THE "CU2O"-
CONTAINING SLAG SYSTEM AND ITS APPLICATIONS IN HIGH-
TEMPERATURE COPPER MAKING PROCESSES
PY16 Carl Justav Berg OPTIMUM DRYING SOLUTION FOR COPPER CONCENTRATE
PY17 Per G. Brnnstrm ENVIRONMENTAL IMPROVEMENTS FOR PS CONVERTERS WITH
OUTOTEC'S CONVERTER HOOD TECHNOLOGY FOR PRIMARY
AND SECONDARY GAS CAPTURE
PY18 G. Richter INCREASE AVAILABILITY SMELTER PLANT
PY19 G. Richter INCREASE SULFUR CAPTURE - OPERATIONAL MANAGEMENT
PY20 G. Richter INSTALLATION OF DILUTED OPXYGEN COMBUSTION
TECHNOLOGY IN A COPPER ANODE REFINING FURNACE AT
CODELCO EL TENIENTE PLANT

Pyrometallurgy

PY21 Boajun Zhao FEATURES OF THE BOTTOM BLOWN OXYGEN COPPER
SMELTING TECHNOLOGY
PY22 Baojun Zhao VISCOSITY MEASUREMENTS FOR COPPER SMELTING SLAGS
PY24 Alejandro Molina AVA (ANLISIS VA VISIN ARTIFICIAL)} SYSTEM
PY25 Alejandro Molina THE SYSTEM FOR OPERATIONAL CONTROL OF EMISSIONS
(SCOE+)
PY26 F. Jimenez SPECIATION OF COPPER IN FLASH, CONVERTER AND SLAG
CLEANING FURNACE SLAGS
PY27 Milorad ?irkovi? SYNERGY OF ENERGY RESOURCES OF COPPER
PYROMETALLURGY IN RTB BOR-SERBIA
PY28 S. Pietrzyk VISCOSITY OF COPPER SLAGS FROM THE PROCESS OF
DECOPPERING IN AN ELECTRIC FURNACE
PY29 J. Font OPTIMAL CONFIGURATION OF VOLTAGE AND CURRENT
INTENSITY IN AN ELECTRIC FURNACE FOR SLAG CLEANING
PY30 B. T. Chambers SULPHATION ROASTING OF ENARGITE CONCENTRATE
PY31 A. Warczok COPPER RECOVERY FROM THE SMELTING SLAG IN A
ELECTRIC FURNACE
PY33 Peter Bjrklund RECENT EXPRIENCES FROM IMPLEMENTING DYNAMIC
PROCESS CONTROL AND MONITORING IN THE FLASH
SMELTING PROCESS
PY34 S. B. Breyner THERMAL SHOCK RESISTANT ALUMINA-CHROMIA
REFRACTORY MATERIALS FOR THE COPPER INDUSTRY
PY35 Zhi Sun, Taufiq
Hidayat, Peter C.
Hayes, Evgueni Jak
LIQUIDUS TEMPERATURES, MAJOR AND MINOR ELEMENTS
EQUILIBRIUM PARTITIONING IN COPPER SMELTING SLAG /
MATTE /GAS SYSTEMS
PY36 Zhi Sun, Masanori
Suzuki, Peter
Hayes, Evgueni Jak
QUASI-CHEMICAL VISCOSITY MODEL FOR COPPER-
CONTAINING MULTI-COMPONENT LIQUID SLAGS
PY37 Czernecki Jozef MEANS OF REMOVING LEAD AND ARSENIC DURING THE
COPPER PRODUCTION CYCLE IN UPGRADED TECHNOLOGY OF
KGHM POLSKA MIED? SA
PY38 Zhou Jun FLASH SMELTING AND FLASH CONVERTING PROCESS AND
COMMISSIONING AT JINGUAN COPPER
PY39 Vaajamo Lina AN EXTENSIVE SLAG DATABASE: LEAD-ING THE WAY
PY40 Ata Fallah-
Mehrjardi
INVESTIGATION OF THE BATH-DEPOSIT INTERFACE OF
FREEZE-LININGS IN COPPER SLAGS
PY41 Sergio Carrasco ADVANCED PILOT PLANT ROASTING TESTS GIVE NECESSARY
KNOWLEDGE FOR DESIGN OF A LARGE ROASTER PLANT AT
MMH
PY42 Evgueni Jak INTEGRATED EXPERIMENTAL AND MODELLING RESEARCH ON
COPPER SLAGS PHYSICO-CHEMICAL PROPERTIES IN SUPPORT
OF OPTIMISATION OF COPPER MAKING PROCESSES
PY43 E. Jak CALCIUM FERRITE SLAG PHASE CHEMISTRY CONTROL USED
IN CONTINUOUS FLASH CONVERTING
PY44 Katsunori
Yamaguchi
DISTRIBUTION RATIOS OF PLATINUM AND PALLADIUM
BETWEEN IRON OXIDE SLAGS AND MOLTEN COPPER AT 1573 K

Pyrometallurgy

PY45 Hiromichi Inada IMPROVEMENT OF CIRCULATED WATER COOLING SYSTEM
FOR COPPER SLAG GRANULATION AND EFFECTIVE USE OF
BLEEDING-OFF WATER
PY46 S. Sasai DEVELOPMENT OF SIDE-BLOWING OXY-FUEL CONCENTRATE
BURNER IN FLASH SMELTING PROCESS AT SUMITOMO TOYO
SMELTER
PY47 Jun-Ichi STUDY ON LIQUIDUS TEMPERATURE AND VISCOSITY OF
COPPER SMELTING SLAG
PY50 Masanori Yoshida THE ESTABLISHMENT OF AN OPTIMUM OPERATION AFTER THE
INTRODUCTION OF THE O-SR PROCESS AT ONAHAMA
SMELTER & REFINERY
PY51 R. Knig HIGH EFFICIENT SLAG CLEANING - LATEST RESULTS FROM
PILOT SCALE OPERATION
PY52 N. Cardona OPTIMIZING CONVERTER AISLE OPERATION AT ATLANTIC
COPPER SMELTER, HUELVA, SPAIN
PY53 Javad Khosravi APPLICATION OF EXERGY ANALYSIS IN COPPER SMELTING
PRODUCTION
PY54 Baojun Zhao PHASE EQUILIBRIA STUDIES FOR COPPER SMELTIMG/
CONVERTING SLAGS
PY55 Ata Fallah-
Mehrjardi
INVESTIGATION OF FREEZE-LINING FORMED IN AN
INDUSTRIAL COPPER CONVERTING CALCIUM FERRITE SLAGS
PY56 V.R. Parra-Sanchez CHEMICAL COMPOSITION AND DUST GENERATION OF COPPER
CONCENTRATE PARTICLES OXIDIZED UNDER SUSPENSION-
SMELTING CONDITIONS
PY57 V.R. Parra-Sanchez EVOLUTION OF SIZE DISTRIBUTION OF COPPER CONCENTRATE
PARTICLES OXIDIZED UNDER SUSPENSION-SMELTING
CONDITIONS
PY59 I. Wilkomirsky CONTINUOUS CONVERTING OF COPPER MATTE IN A MOLETEN
- LAYER REACTOR
PY60 I. Wilkomirsky PHYSICO - CHEMISTRY OF NEUTRAL ROASTING OF HIGH
ARSENIC COPPER CONCENTRATES
PY61 I. Wilkomirsky RECOVERY OF COPPER, MOLYBDENUM, ZINC AND IRON
(HEMATITE) FROM COPPER SMELTER SLAGS
PY63 Mark Coleman REFINEMENT OF FLASH FURNACE AND CODELCO TENIENTE
REACTOR MATERIAL FEED SYSTEMS TO UTILISE CALCINED
CONCENTRATES
PY64 Xiaohong Hao DEVELOPMENT AND APPLICATION OF OXYGEN BOTTOM-
BLOWING CU SMELTING TECHNOLOGY
PY65 Bing Li DEVELOPMENT OF THE CONTINUOUS BOTTOM-BLOWING
MATTE CONVERTING PROCESS
PY66 Mike Santaluce AN INTEGRATED LIFECYCLE APPROACH TO FURNACE
REBUILDS
PY67 P.J. Mackey COPPER SMELTING TECHNOLOGIES IN 2013 AND BEYOND
PY68 Alfredo Martinez USE OF WASTE HEAT BOILERS TO SAVE RESOURCES
PY69 Antoine Allanore DIRECT SULFIDES ELECTROLYSIS: A SUSTAINABLE PROCESS
FOR COPPER RECOVERY?
PY70 L. Scheunis THE EFFECT OF IN SITU PHASE FORMATION ON THE
INFILTRATION BEHAVIOR AND CHEMICAL DEGRADATION OF

Pyrometallurgy

MAGNESIA-CHROMITE BRICKS IN CONTACT WITH A
SYNTHETIC NON-FERROUS SLAG
PY71 Marcin Kacperski OPTIMIZATION OF TECHNOLOGY FOR CONCENTRATE
SMELTING IN FLASH FURNACE WITH CHARGE CHANGES
PY73 Patricio Hernandez
N.
MECHANICAL SYSTEM FOR REVERTS CHARGING INTO PEIRCE-
SMITH CONVERTERS
PY74 Alberto Fernandez EMISSIONS REDUCTION AND PROCESS IMPROVEMENTS
ACHIEVED WITH THE NEW ANODE FURNACE OFF-GAS SYSTEM
AT ASARCO HAYDEN
PY75 Matt Russell TECHNOLOGY DEVELOPMENTS FOR SMELTER OFF-GAS HEAT
RECOVERY
PY76 A.J.Rigby THE USE OF CHROME-ALUMINA REFRACTORIES IN THE HIGH
WEAR AREAS OF ANODE REFINING VESSLS
PY77 L. Voisin IMPURITY BEHAVIOUR DURING THE CONTINUOUS
CONVERTING OF COPPER MATTE IN A PACKED BED REACTOR
PY78 L. Voisin - J. Diaz OXIDATION KINETIC OF COPPER MATTE DURING THE
CONTINUOUS CONVERTING PROCESS IN A PACKED BED
REACTOR
PY79 L. Voisin - F.
Mansilla
KINETIC AND MODELING OF CONTINUOUS COPPER REFINING
IN A PACKED BED REACTOR DURING THE REDUCTION STAGE
PY80 L. Voisin - G.
Damm
PHASE RELATIONS AND MINOR ELEMENT DISTRIBUTION IN
CU-FE-PB-AS SYSTEM SATURATED WITH CARBON AT 1473 K
PY81 L. Voisin - K.
Mhlenbrock
CU-FE-PB-SB SYSTEM SATURATED WITH CARBON AT 1473 K
PY82 L. Voisin - E.
Marambio
THERMO-FLUID-DYNAMICS MODELING FOR CONTINUOUS
CONVERTING PROCESS OF COPPER MATTE IN PACKED BED
REACTOR
PY83 L. Voisin CHARACTERIZATION AND FROTH FLOTATION OF SMELTING
FURNACE COPPER SLAG
PY85 Chang-Buhm Kim MAXIMIZATION OF HEAT RECOVERY BY PRODUCING LOW
PRESSURE STEAM
PY86 Jonkion Font COPPER DISSOLUTION IN THE FEOX-SIO2 BASE SLAG OF THE
FLASH SMELTING FURNACE AND THE TENIENTE CONVERTER
AT THE CHUQUICAMATA SMELTER
PY87 Kozhakhmetov S IMPROVEMENTS IN THE VANYUKOV SMELTING TECHNOLOGY
PY89 Yan Jie LATEST DEVELOPMENT OF OXYGEN BOTTOM-BLOWING
COPPER SMELTING TECHNOLOGY
PY90 Li Feng DEVELOPMENT OF COPPER/GOLD SULFIDE CONCENTRATES
PYROMETALLURGICAL PROCESS
PY91 Zhixiang Cui INDUSTRIAL TEST DEVELOPMENT OF CONTINUOUS BOTTOM
BLOWN OXYGEN COPPER SMELTING PROCESS
PY92 Zhixiang Cui NEW DEVELOPMENT OF BOTTOM BLOWN OXYGEN SMELTING
TECHNOLOGY IN DONGYING FANGYUAN NONFERROUS
METALS CO. LTD
PY95 L. A. Campos DESIGN OF A HEAT RECOVERY COOLING CHAMBER SYSTEM
FOR COPPER SMELTERS

Pyrometallurgy

PY96 L.B. Tsymbulov COMPARATIVE ANALYSIS OF PYROMETALLURGICAL
METHODS FOR PROCESSING OF SULFIDE COPPER
CONCENTRATION FROM UDOCAN DEPOSIT
PY97 L.B. Tsymbulov OPTIMAL SLAG COMPOSITION FOR PROCESSING OF COPPER
NICKEL MATTES AND CONCENTRATES IN A VANIUKOV TWO-
ZONE CONVERTER THAT PRODUCES BLISTER COPPER
PY98 P.Coursol ARSENIC REMOVAL FROM BLISTER COPPER USING MOLTEN
SODIUM AND CALCIUM SULPHATES
PY99 M. Rosales ON THE POSSIBILITY OF USING HIGH OXYGEN ENRICHMENT IN
TENIENTE CONVERTERS
PY101 G. Wastavino COPPER CONTENT IN FLASH FURNACE SLAG CHUQUICAMATA
SMELTER, USING OLIVINE-TYPE SLAG
PY103 Enrique Herrera CONTROLLING SO3 FORMATION IN THE OFF-GASES PROCESS
FROM THE ISASMELTTM FURNACE AT SOUTHERN PERU ILO
SMELTER
PY104 Stefan Konetschnik SERVICE LIVE INCREASE OF TSL LANCES USING IONIC LIQUID
COOLING TECHNOLOGY
PY105 Arsenio (Jun)
Enriquez
AN UPDATE ON KENNECOTT UTAH COPPER'S USE OF
PRAXAIR'S COHERENT JET TECHNOLOGY IN ANODE REFINING
- DEVELOPMENTS SINCE 2010
PY106 Alessandro Navarra AUTOMATIC SCHEDULING OF ALTONORTE OPERATIONS
USING GREEDY ALGORITHMS
PY134 Gert Erasmus A NOVEL METHOD FOR QUANTIFYING SMELTER SO2 FUGITIVE
EMISSIONS USING AN OPEN PATH FOURIER TRANSFORMS
INFRARED (FTIR) ANALYSER
PY135 Thomas Zabev -
Pascal Coursol
OBSERVATIONS ON THE REDUCTIVE PYRO DE-
ARSENIFICATION OF ENARGITE
PY136 Y. Prevost FORTY YEARS OF OPERATION OF THE NORANDA REACTOR
PROCESS
PY137 A.Warczok PHENOMENOLOGY OF COPPER MATTE CONTINUOUS
CONVERTING IN A PACKED BED
PY138 L. Diaz A MASS TRANSFER MODEL FOR MOLTEN COPPER
DEOXIDATION
PY139 M. Gous DUST EXPLOSIONS AT THE CHAGRES SMELTER DUE TO
SPONTANEOUS SELF-HEATING OF DRIED COPPER
CONCENTRATES
PY140 Chunlin Chen THERMODYNAMICS DATABASE OF SULPHIDE SMELTING
SYSTEM AND ITS APPLICATIONS TO RECYCLING CU-PB-FE-S
MATERIALS
PY141 Evelien De Wilde CHARACTERIZATION METHODOLOGY FOR CU-DROPLET
LOSSES IN SLAGS
PY143 Bhavin Desai CONTROL STRATEGY FOR REDUCING COPPER LOSS FROM
MITSUBISHI PROCESS
PY144 M. U. Jastrzebski IN PURSUIT OF IMPROVED FLASH-SMELTING BURNER
PERFORMANCE
PY145 Songlin Zhou APPLICATION OF ROTATION-SUSPENSION SMELTING PROCESS
AND PULSE CYCLONE BURNER IN XIANGGUANG COPPER

Pyrometallurgy

PY146 Afshin Sadri APPLICATION OF SPECIALIZED NON-DESTRUCTIVE TESTING
(NDT) FOR OPERATING COPPER PROCESS VESSELS
PY147 G. Richter DEVELOPMENT PLAN CALETONES SMELTER
PY148 J.P. Kapusta, Robert
G.H. Lee
THE SAVARD-LEE SHROUDED INJECTOR: A REVIEW OF ITS
ADOPTION AND ADAPTATION FROM FERROUS TO NON-
FERROUS PYROMETALLURGY
PY149 A P Campbell, M
Reed
DEBOTTLENECKING AND OPTIMISATION OF COPPER
SMELTERS LEVERAGING SIMULATION
PY150 Armando Olavarra
C
POTRERILLOS SMELTER CURRENT AND FUTURE CHALLENGES
PY151 Claudio Queirolo /
Fernando Rojas
CHUQUICAMATA SMELTER DEVELOPMENT PROJECTS

Pyrometallurgy

PY01
COMING OF AGE - 21 YEARS COMMERCIAL OPERATION OF COPPER
ISASMELT AT MOUNT ISA

JS Edwards
Principal Metallurgist, Xstrata Technology, Level 10, 160 Ann St, Brisbane, Queensland,
Australia, 4000
P Telford
General Manager, Mount Isa Mines, Mount Isa, Queensland, Australia, 4825
L Yunus
Senior Metallurgist, Mount Isa Mines, Mount Isa, Queensland, Australia, 4825

ABSTRACT
Development of a new smelting technology, such as ISASMELT, requires a
significant investment of time as well as resources and capital. In the case of the copper
ISASMELT process developed in Mount Isa the commissioning of the commercial
furnace in 1992 was the culmination of 14 years of bench, pilot and demonstration scale
testwork. The demonstration plant was operated from 1987 to 1992, initially at a feed rate
of 12 t/h of concentrate increasing to a maximum of 50 t/h during trials performed to reduce
the scale-up factor between demonstration plant and commercial plant.
The commercial scale copper ISASMELT furnace in Mount Isa was
commissioned in August 1992 with a capacity rated at 180 000 tonnes per year of copper
anode. In 2013 the copper ISASMELT has been operating for 21 years which is a
Coming of Age birthday in Australia. After two major smelter upgrades in 21 years the
original furnace is still in service and routinely treats in excess of 1 000 000 tonnes per
annum of copper containing feed and has a demonstrated campaign life, using uncooled
refractory, approaching 4 years.

Pyrometallurgy

PY02

OUTOTEC SMELTING INTEGRATED, SUSTAINABLE PLANT SOLUTIONS

Fagerlund, K

ABSTRACT
Outotec has a very unique and exceptional combination of different types of
smelting process technologies together with the state-of-art products and continuous
development in our research laboratories and pilot-plants. Worlds leading smelting
technologies are all now within the Outotec family: Outotec Flash Smelting, Kennecott-
Outotec Flash Converting, Direct Blister Flash Smelting, Ausmelt TSL, Kaldo, Troff,
Electric Furnace, Fire-refining and Anode Casting. Outotec is not only able to evaluate the
available various complex raw materials but also to provide the best available solution for
the specific project. This paper will provide examples how to cross-utilize and apply know-
how, expertise from different technologies and products in an innovative way to provide
sustainable solutions for copper industry.
In addition, social responsibility and increasing governmental regulatory
requirements brings new demands to the copper producers, thus environmental approvals
for the new and existing smelting plants have become increasingly more difficult to
acquire.
This paper will provide an examples how to combine overall process knowledge
together with modern tools to enable reliable and effective data for decision making,
especially while discussing with different authorities, stake-holders and investors. Selection
of best-available-technologies with proven references can ensure the long operational life-
time of the smelters. Also, modernization and upgrade investments of the operational plants
can be better justified by taking into consideration not only the economical but also
environmental aspects. Examples will be provided where safety, campaign life, furnace
integrity all contribute into the plant life-cycle, where Outotec new cooling solutions can
provide considerable improvements and can be flexibly applied in the operating plants and
also in wide variety of different applications.

Pyrometallurgy

PY03

WEAR PHENOMENA OF BASIC BRICK LININGS IN THE COPPER INDUSTRY

D. Gregurek, C. Majcenovic
RHI AG; TC Leoben; Magnesitstrasse 2; Leoben, A-8700, Austria

A. Spanring, M. Kirschen
RHI AG; Wienerbergerstrasse 9, Vienna, A-1100, Austria

ABSTRACT

In the non ferrous metals industry particulary in the copper smelting furnaces the
refractory lining made of magnesia-chromite bricks is exposed to several stresses rather
complex in their interaction. These can be classified as chemical, thermal and mechanical
stresses occurring as a single wear factor or in combination.

The chemical factors include corrosion caused by acidic slag and gaseous SO
2

diffusion, redox effects and in particular cases hydration. In most of the non-ferrous
metallurgical processes the chemo-thermal load by Fe-silicatic slags of fayalithic type is a
common wear mechanism of the magnesia-chromite bricks. Nevertheless the extraordinary
massive SiO
2
-supply caused by changes in the processing and the uncontrolled addition of
silica sand results in a severe formation of forsterite respectively in a volume expansion due
to forsterite bursting. Increased temperature level respectively changes in the temperature
during the furnace operation as well as the copper metal infiltration into the brick
microstructure are further wear factors on thermal side. The hot erosion is the dominant
mechanical factor. Therefore understanding of wear mechanisms through post mortem
investigation and praxis field trials are highly important to ensure product
recommendation for industrial application.

Pyrometallurgy

PY04

CORROSION TESTING METHODS FOR NEWLY DEVELOPED REFRACTORY
PRODUCTS

D. Gregurek, A. Ressler, V. Reiter,
RHI AG, TC Leoben, Magnesitstrasse 2, Leoben, A-8700, Austria

A. Franzkowiak, A. Spanring
RHI AG, Wienerbergerstrasse 9, Vienna, A-1100, Austria

ABSTRACT

The processing routes in the base metals industry, especially copper smelting,
converting and fire-refining, have recently undergone significant changes in terms of slag
chemistry, temperatures, redox and more frequently deviating raw material compositions
(blended low-grade fractions) in the primary smelter feed. All these parameters
significantly influence the performance of already well-approved refractory linings.
Decreased brick lifetimes associated with process changes - also confirmed by the results of
post mortem studies - were a clear signal for RHI AG to focus on the development of high
grade refractory bricks for chemically stressed areas. In order to determine the most
suitable refractory grades and to improve the performance in specific furnace areas, special
test methods were selected.

The practical test facilities, including an induction furnace, rotary kiln and cup test,
at RHIs Technology Center use process slags, for example of a fayalithic and Ca-ferritic
type, and enable the best possible understanding of brick wear on a pilot scale. A complete
mineralogical investigation including thermo-chemical calculations with FactSage were
performed to determine the highest influencing wear parameters. Optimized and engineered
Pyrometallurgy

lining solutions for the copper industry can be provided based on the acquired knowledge
from test results in combination with praxis trials.
Pyrometallurgy

PY05

ELECTROMAGNETIC LEVEL PROFILE MEASUREMENT SYSTEM TESTED
BY AGELLIS GROUP AB ON KENNECOTT COPPER FLASH SMELTERS IS
DESIGNED TO ENHANCE PROCESS CONTROL DECISION MAKING AND
IMPROVE OPERATOR SAFETY.

N. Brogden, JP. Nilsson, P. Bloemer, A. Lyons
AGELLIS Group AB, Tellusgatan 15, 224 57 Lund, Sweden

R. Kaur, David Krippner,
KUC, Magna Plant, Salt lake City, Utah, USA

ABSTRACT

Reliable and accurate furnace level information for blister, matte and slag during
smelting processes is invaluable for decision making and process optimization, while
obtaining such information safely is a necessity.

Agellis Group AB had previously identified inherent problems with gauging levels
accurately in furnaces. We had successfully installed our EMLI ELP systems on
Submerged Arc and other electric furnaces in order to solve measurement problems.
In Flash Furnaces the problems appeared to be the same, with sounding bars operated from
the furnace roof area being used to take measurements. As a result operators can be at risk
and the results are often inaccurate. It was therefore decided to test the ELP system on a
flash smelter.

This paper shows how the Agellis EMLI-ELP system was successfully trialled at
Kennecott Utah Copper (KUC) on both their Flash Smelting (FSF) and Flash Converting
(FCF) furnaces. The results were used to compare the accuracy and reliability of
Kennecotts current measuring methods with that of the Agellis system.

Finally the paper will discuss the potential production/safety improvements,
maintenance savings and data integration attainable through application of the Agellis
EMLI- ELP measurement system.

Pyrometallurgy

PY06

FIELD REPORTS OF THE NEW INNOVATIVE GAS PURGING SYSTEM FOR
STATIONARY AND TILTING COPPER ANODE FURNACES

Klaus Gamweger

ABSTRACT
The use of gas purging plugs in the copper industry is a widely used practice. They
provide substantial improvements especially in anode refining furnaces, where savings in
process time and energy are obtained as well as refractory wear and buildups inside the
furnace are minimized. The newly developed system enables purging plugs to be
implemented in both stationary and tilting furnaces is in operation in vessels on three
continents.
An additional advantage in these furnaces above all other benefits is the
significantly improved melting rate. This innovative and patented gas purging system
consists of a purging plug cooling device and a slidable, cooled piping system. It provides
compensation for any thermal expansion in the furnace lining and minimizes the risk of
undesirable copper infiltration.

PY07

SMELTING OF KAZAKHSTAN CONCENTRATES AT UST-KAMENOGORSK
USING A COPPER ISASMELT FURNACE

G.R.F. Alvear F.
1
, A.S. Burrows
2
and A.T. Tynybaev
3

1
Xstrata Technology;
Level 10, 700 West Pender St. Vancouver, Canada
2
Xstrata Technology;
Level 10, 160 Ann St.; Brisbane, QLD 4000, Australia
3
Kazzinc Ltd;
1 Promyshlennaya St., 070002 Ust-Kamenogorsk, Republic of Kazakhstan

ABSTRACT

In July 2011 a new Copper ISASMELT Furnace was commissioned at the Ust-
Kamenogorsk Metallurgical Complex, in Ust-Kamenogorsk, Kazakhstan. It was part of a
greenfields smelter project, situated inside an existing metallurgical complex. The entire
copper stream was new, from feed blending through to cathode strapping. Within 14
months it was sustainably achieving its design production capacity.

For the project to be brought to successful fruition, numerous challenges had to be
met: new technology had to be brought into the Republic of Kazakhstan and the local
operating team had to become competent to operate it; the complex polymetallic
concentrates of the East Kazakhstan region had to be smelted without compromising the
production rate or product quality; and the copper production stream had to be integrated
into the overall metallurgical complex to derive greatest benefit from the polymetallic
nature of the raw materials.


This paper describes how the Copper ISASMELT Furnace fitted into this
strategy, and how the coordinated actions of Kazzinc and Xstrata Technology personnel
brought this project to fruition.

Pyrometallurgy

PY08
DESTRUCTIVE AND NONDESTRUCTIVE TESTING METHODS FOR THE
CHARACTERIZATION OF MGO-CR
2
O
3
-BASED REFRACTORY BRICKS

A. Ressler, C. Manhart and R. Neuboeck
RHI AG
Technology Center Leoben
Magnesitstrasse 2
A-8700 Leoben, Austria
Angelika.ressler@rhi-ag.com

A. Franzkowiak
RHI AG
Wienerbergstrasse 9
A-1100 Vienna, Austria

ABSTRACT

In the nonferrous metal industry and particularly in the copper production
magnesia-chromite refractory bricks are widely applied since decades. Being characterized
by high refractoriness and good resistance to slag corrosion these bricks are used in
chemically high stressed areas.
While the frequently determined physical properties (e.g. density, open porosity,
cold crushing strength measured at room temperature) are adequate for quality
management and selection purposes, but they are insufficient for conclusions about the
behavior of the brick after installation at application temperature (from 1200C up to
1750C). Especially the characterization at operation conditions support the understanding
of main wear mechanisms. This paper provides information concerning investigated
properties, which have a high impact on the lining performance, such as thermal shock
resistance, modulus of elasticity and hot modulus of rupture.
The results of destructive and non destructive measurement methods are compared
for specific magnesia and magnesia-chromite brick qualities. The correlation of all tested
properties at room and different application temperatures enhance the decisions for lining
concepts in different applications for our customers in the copper and other nonferrous
metals industry.
Pyrometallurgy

PY09

SULFULIZATION AND SLOW-COOLING FOR MOLYBDENUM RECOVERY
FROM COPPER SMELTING SLAG

CHIHARU TOKORO

Waseda University, Tokyo, Japan,

tokoro@waseda.jp

SHUNSUKE SUDO
Waseda University, Tokyo, Japan, s-sudo@fuji.waseda.jp

TAKAHIKO OKURA
The University of Tokyo, Tokyo, Japan, okura@iis.u-tokyo.ac.jp

ABSTRACT

Sulfurization and slow-cooling process was investigated for selective recovery of
molybdenum (Mo) from the copper smelting slag. To get slag samples containing 0.2 to
4.0 % of Mo, MoO
3
reagent was added to a water cooled slag and heated at 1300 C for 1
hour in Ar atmosphere. After cooled and ground under 125 m, sample was mixed with
FeS
2
(pyrite) to be 2 or 5 of S/Mo molar ratio. This mixture was heated at 1300 C for 1
hour in Ar atmosphere and slowly cooled at up to 18 C/min.

XRD patterns of the slow cooled slag containing 2.0 or 4.0 wt.% of Mo showed
Mo was sulfurized as MoS
2
crystal. XANES spectra at Mo K edge showed 95.83 % of Mo
was sulfurized as MoS
2
when S/Mo molar ratio was 5 and Mo content in slag was 4.0 wt.%.
According to the observation using SEM-EDS, maximum particle diameter of MoS
2
was
150 m which is enough grain size for several physical separations. 16.7 wt.% of Mo
concentrate was obtained by flotation after ground under 125 m with PAX and MIBC at
pH 6.6.

Pyrometallurgy

PY10

DESIGN AND COMMISSIONING OF THE OUTOTEC
AUSMELT TSL COPPER

SMELTER AT DNMC

LIU Chuanzhuan, WAN Jun, CHEN Baizhi
Daye Non-Ferrous Metallurgical Company, Peoples Republic of China

Gavin Swayn, Jacob Wood, Alexander Glinin
Outotec, Level 2, 2 Brandon Park Drive, Wheelers Hill, Victoria, Australia

ABSTRACT

The largest commercial copper smelter using Outotec
Ausmelt TSL Technology has

been successfully commissioned and put into operation at Daye Non-Ferrous Metallurgical
Company Ltd operations in Huangshi City, Hubei Province, China. The plant was
commissioned from November 2010 to January 2011 after three years of design and
construction works.

The process treats low grade copper sulphide concentrates to produce a matte
containing 55% copper and a low copper bearing slag. The molten matte and slag flow
continuously from the TSL furnace via an underflow weir to a specifically designed electric
settling furnace for matte/slag separation. The paper provides details of the start-up and
increase in production to 200kt/a contained copper capacity processing rates in line with
oxygen availability, achieved in the first 3 to 6 months of operation.

Pyrometallurgy

PY11

GENERAL MAINTENANCE OF ELECTRIC CLEANING FURNACE SLAG

C. Herrera, C. Martnez, B. Medel, M. Lara G., W. Daz, M. Correa.
Hernn Videla Lira Smelter
Empresa Nacional de Minera
Copiap, Chile

ABSTRACT

The Hernn Videla Lira Smelter operates an electric slag cleaning furnaceto treat
the slag of the Teniente Converter. This furnace was supplied by DEMAG and was
commissioned in September 2001, with a treatment capacity of 800 t/d of liquid slag and
150 t/d of reverts, with a copper content in the end slag of maximum 0,85%. The furnace
dimensions are 10 meters of outer diameter and 5,2 meters high. Its electric power reaches
11 MVA.

Since its last general maintenance (GM), 4 years ago, a new GM was scheduled to be
performed since January the 8
th
2013, which mainly includes the replacement of the walls
refractory lining, the floor skewback and refractory dome. Additionally, there placement of
the open circuit water distribution system, the cooling rings of the slippers of the electrodes
N1 and N2, and a full service of 22 of the 24 hydraulic heads of the electrodes
displacement system.

The dome refractory and cooling rings replacements were works scheduled for the first
time since the commissioning of the furnace.

The detailed programming and efficient coordination of the activities involved, allowed a
repair time of 29 days, 1 day less than considered in the original program. The activities
carried out during the GM were recorded in an audio visual file which will be presented at
this Conference.

Pyrometallurgy

PY12

XSTRATA TECHNOLOGYS APPROACH FOR THE PROCESSING OF
COPPER BEARING MATERIALS

G.R.F. Alvear F.
Xstrata Technology;
Level 10, 700 West Pender St. Vancouver, Canada

S. Nikolic A. S. Burrows, M. Hourn
Xstrata Technology;
Level 10, 160 Ann.; Brisbane, QLD 4000, Australia

J. C. Salas M.
Xstrata Technology;
Alcntara 200, Of. 1202, Las Condes, Santiago, Chile

ABSTRACT

The processing of copper bearing materials is becoming more challenging due to the
increase in their mineralogical and compositional complexity.

Smelting of polymetallic concentrates is becoming more common and this trend has
led to the requirement that smelters modify their operating strategies to remain cost
competitive, whilst meeting ever more stringent environmental regulations. In addition,
when considering the processing of secondary materials, a key aspect in the recycling of
electronic scrap is the diverse range of elements that may require recovery.

The increased complexity of these primary and secondary raw materials requires the
use ofadvanced technologies to maximise the recovery of the targeted metals whilst
maintaining sustainable operating practices.

Xstrata has developed at its operations a number of processes, including
ISASMELT the Albion Process, and IsaKidd technologies that, both individually and
when combined, provide a competitive solution for the sustainable production of copper
Pyrometallurgy

PY13

CALETONES SMELTER: ENVIRONMENTAL AND COMPETITIVENESS
CHALLENGES

G. Richter P., J. Bobadilla M.

and F. Hernndez A.

Caletones Smelter - Codelco-Chile - Division El Teniente

ABSTRACT
In the nineties decade the environmental variable started to impact in a sensible way
the Caletones Smelter business due to the necessity to commit the introduced standards and
the Decontamination Plan agreed in 1998 with the governmental authorities.

During that period several technical and management modifications were
introduced in the smelter, being the most noticeable the construction of the sulfuric acid
plants 1 and 2 in 1995 and 1999 respectively, and the adoption of a new operation
philosophy of progressive subordination of the copper production to the environmental
control. The operation paradigm change implemented in an almost centenary smelter has
been a complex process of continuous improvement not exempt of difficulties.

However the net result had been favorable, noticed that Caletones Smelter is
accomplishing the environmental standards currently in force in Chile and attaining also
competitive results that permitted to successfully overcome recent periods of depressed and
volatile treatment charges.

Most recently in 2011, as result of several operational improvements introduced in
the gas handling and treatment systems, SO
2
capture that until 2010 was less than 88%, was
increased to 94%, ensuring the environmental results attained.

Pyrometallurgy

Even though the human en financial efforts done in the recent past, the
environmental performance achieved is not being enough to fulfill the most strict emission
standards that the governmental authorities are designing to be applied to the Chilean
copper smelters.

This paper describes the actions that allow the present environmental results and the
proposal of improvement that Caletones Smelter is developing to accomplish the future
environmental standards and maintain it as a sustainable smelter.
Pyrometallurgy

PY14

ON THE INTERACTION BETWEEN REVERTS MEAN PARTICLE SIZE AND
FLASH FURNACE REACTION SHAFT HEIGHT: A SENSITIVITY ANALYSIS

Maximo Leon, Javier Larrondo, Tom Gonzales

ABSTRACT

The dimensions of a Flash Furnace (FF) are critical in determining the
characteristics of its cooling system. In particular, the thermal loads on cooling blocks
located at the base of the Reaction Shaft (RS) are strongly dependent on the heat generated
by the reactions taking place inside the furnace. In the typical FF process, low sulfur feed-
materials are added to reduce the temperatures that arise from these reactions.

The current paper provides a sensitivity analysis of the size of the RS for several
mean particle sizes of reverts. The objective is to develop a correlation between the
minimum Reaction Shaft size and revert particle size. Computational Fluid Dynamics
(CFD) is used to compare the heat absorbed by reverts with that absorbed by the cooling
system. The indicated minimum size is determined with the design parameters of the
cooling system.

In general, a non linear interaction between the size of the furnace and the mean
particle size of reverts has been found. However, a more precise indication of a
recommended FF size needs to be studied in detail within a range of FF shaft sizes.
Pyrometallurgy

PY15
A THERMODYNAMIC OPTIMIZATION OF THE Cu
2
O-CONTAINING SLAG
SYSTEM AND ITS APPLICATIONS IN HIGH-TEMPERATURE COPPER
MAKING PROCESSES

Taufiq Hidayat, Evgueni Jak
PYROSEARCH, the University of Queensland, Brisbane, Queensland, Australia

Denis Shishin, Sergei A. Decterov
Centre de Recherche en Calcul Thermochimique (CRCT), cole Polytechnique, Montral,
Qubec, Canada

ABSTRACT
Improvements to industrial copper production can be made through informed
decisions on the selection of slag compositions, fluxing strategies, and operating conditions
for a given feed and product requirement. This can be facilitated through thermodynamic
modelling in which phase equilibria, partitioning of major and minor elements between
phases, activities, vapour pressure, and other thermodynamic properties of the relevant
systems can be accurately predicted over a wide range of process conditions. The Al-Ca-
Cu-Fe-Mg-Si-O-S system is of importance for copper smelting, converting, and slag-
cleaning processes. New experimental data of the systems for various compositions and
conditions relevant to copper production process have been generated and improvement of
the existing chemical thermodynamic FactSage
TM
database for the cuprous oxide-
containing system has been carried out as part of the overall integrated research program on
complex copper-containing slag-matte-metal-solids system. All cuprous oxide-containing
binaries, ternaries, and multi-components systems are optimized simultaneously to obtain one
self-consistent set of model parameters for Gibbs energies of stoichiometric phases, solid
solutions, and liquid solution as functions of temperature and composition. Details of the
recent optimization of the thermodynamic database and examples of industrial application
of the database for the high-temperature copper making processes are presented.
Pyrometallurgy

PY16

OPTIMUM DRYING SOLUTION FOR COPPER CONCENTRATE

Mr. Jyri Talja, Dr. Shaolong Chen, Mr. Hannu Mansikkaviita, Dr. Carl-Gustav Berg
Kumera Corporation
Kumerankatu 2
11100 Riihimki, Finland

ABSTRACT

Non-ferrous metal concentrates contain typically 7-12 % water when received at the
smelter. Removal of this water prior to smelting is always economically feasible because
unnecessary heating of vapour can thus be eliminated resulting in major savings and reduc-
tion in CO
2
emission.

Energy efficiency of drying can be significantly increased by selection of modern
drying technology. Consequently, CO
2
emission, SO
2
emission and NO
x
emission will be
all eliminated.

Replacement of conventional devices with indirect steam dryers brings, in addition
to significant reduction in emission, additional savings due to improved energy efficiency.
Direct energy savings count for 900-1,300 MJ/t
H2O
, which depending on the concentrate
feed rate, its moisture content and price of energy is worth 1-3 MEUR every year. Further-
more, other operational expenses can also be cut by another 1-3 MEUR resulting in com-
bined 2-6 MEUR direct savings annually in operational expenses. Furthermore, availability
can exceed 99 %.

Sustainability is the key issue today in process industry. Kumera Steam Dryer is al-
ready recognized as a symbol of the energy saving and emission-free equipment with very
high availability for non-ferrous metallurgical industry world-wide. Latest improvements of
the Kumera steam dryer are discussed in greater detail.
Pyrometallurgy

PY17

ENVIRONMENTAL IMPROVEMENTS FOR PS CONVERTERS WITH
OUTOTECS CONVERTER HOOD TECHNOLOGY FOR PRIMARY AND
SECONDARY GAS CAPTURE

Per G. Brnnstrm & Lennart M. Hedlund
Outotec

ABSTRACT

The paper describes the improvements that Outotec has made on the design on
converter hoods in order to improve operational performance and environmental situation
in the converter aisle.

Most smelters have changed their primary smelting technology. Reverberatory
furnaces have been replaced by more environmentally friendly and energy-efficient
furnaces like Outotec FSF or TSL. When the environmental performance has been
improved for the primary smelting furnace, the focus turns toward the acid plant (if single
absorption) and later the converter aisle.

Outotec`s Converter Hood Technology assures that processing of copper matte will
be done more sustainable and environmentally acceptable. Sulphur and dust capture above
95 percent is no problem to reach with Outotec`s water cooled primary converter hoods.
Outotec`s converter hoods for primary gas capture are designed for low false air inlet and
high production.

After changing the primary hoods, the next step in the environmental efforts, is
implementation of a secondary gas system to collect fugitive gas and dust. Fugitive gas
comes from rolling the PS-converter in and out, ladles handling etc. With Outotec`s
knowhow and technology the converter aisle will become a more environmentally friendly
unit with high production.
Pyrometallurgy

PY18
INCREASE AVAILABILITY SMELTER PLANT

G. Richter P.
General Manager - Codelco-Chile
J. Berrios O.
Maintenance Superintendent - Codelco-Chile

ABSTRACT

Caletones Smelter has a nominal capacity of 1.4 Mton smelting copper concentrate, for
this purpose, would have a significant asset, namely:

Three Concentrate Drying Plants
Two Smelting Reactors, Teniente Converters
Four Peirce Smith Converters
Four Slag Cleaning Furnaces
Five Anode Refining Furnace
Two Casting Wheels
Two Acid Plant
Two Effluent Treatment Plants
Two Oxygen Plant

In order to increase the use of smelter complex, intensive work is done in the main
equipment.

This work consisted of defining operating models, use of materials and different
maintenance strategies, the results to date are:

Pyrometallurgy

Bases Present
Smelting Reactors: 1.5 years 3 years
Acid Plants: 1 year 2 years
Slag Cleaning Furnaces: 7 months 2 years

This paper describes the actions, which allowed achieving these results and
increasing the smelting capacity of concentrate.

Pyrometallurgy

PY19
INCREASE SULFUR CAPTURE OPERATIONAL MANAGEMENT

G. Richter P.
J. Bobadilla M.
Operation Superintendent - Codelco-Chile

ABSTRACT

Caletones Smelter has a nominal melting capacity of 1,4 Mt/y copper concentrated,
the concentrate is fed entirely from the mining complex of mine pant of El Teniente
Division.

Until 2010 sulfur capture reached 85%, re presenting a sulfur dioxide (SO
2
)
emission of 130 kt/y. This low capture put at risk the future fulfillment of sulfur emission
limits voluntarily committed environmental authorities, commitment established the
following schedule
:
Year 2011 2012 2013 2014
Sulfur dioxide emission (SO
2
)
(kt/y) 140 130 120 100

In order to meet the timetable for reducing emissions in 2011, modifications were
made to the scheme operating and maintenance and modifications to the gas handling
system. Changes made it possible to increase the capture of sulfur to 92.9% in 2011 and
94% by 2012, sulfur dioxide emissions were around 60 kt/y.

Pyrometallurgy

This paper describes the actions that allowed these results and anticipate achieving
compliance contracted emission reduction.
Pyrometallurgy

PY20

INSTALLATION OF DILUTED OXYGEN COMBUSTION TECHNOLOGY IN A
COPPER ANODE REFINING FURNACE AT CODELCO EL TENIENTE PLANT

G. Richter P., C. Carrasco O., F. Condore R.

Codelco Chile Divisin El Teniente
A. Tasca

White Martins Gases Industriais Ltda
F. Kaiser

Praxair Chile Ltda.

ABSTRACT

The combustion system in #2 Anode Refining furnace at CODELCO (Corporacin
Nacional del Cobre) El Tenientes plant in Chile was retrofitted to an advanced oxy-fuel
technology called DOC (Dilute Oxygen Combustion). Praxair DOC technology uses
separate high momentum fuel and oxygen jets to generate strong in-furnace gas
recirculation.

This technique produces low peak temperature flame, substantially improves
temperature uniformity, generates ultra low NOx emission rates and reduces carbon
emissions. DOC technology has been developed and commercially demonstrated in several
types of industrial melting and heating furnaces meeting the industry needs for increased
productivity and lower operating costs with minimal capital expense and low maintenance.
This paper presents the results achieved regarding fuel savings, and reduction in operating
cost.

Pyrometallurgy

PY21

FEATURES OF THE BOTTOM BLOWN OXYGEN COPPER SMELTING
TECHNOLOGY

Baojun Zhao
School of Chemical Engineering, The University of Queensland, Brisbane, Australia

Zhixiang Cui, Zhi Wang
Dongying Fangyuan Nonferrous Metals Co., Ltd, Dongying City, China
Email: baojun@uq.edu.au

ABSTRACT
The first commercial scale bottom blown oxygen copper smelting furnace has been
installed and operated at Dongying Fangyuan Nonferrous Metals Co., Ltd. for 4 years. This
is the first modern copper smelting technology developed in China with the advantages of
1) high oxygen enrichment, which results in high productivity, low off-gas volume and
negative pressure inside the furnace;
2) high Fe/SiO
2
ratio in the slag, which not only reduce the direct cost of the flux (SiO
2
)
but also reduce the slag volume and therefore the heat loss associated with the slag and
workload of the slag cleaning;
3) high grade matte (over 70 wt% Cu) and low Cu content (2-3 wt%) in the smelting slag
which significantly increase the direct recovery of the smelting process;
4) autothermal operation. When normal concentrate is treated in the bottom blown oxygen
furnace no extra fuel is required due to a) low temperature operation (1160-1180
o
C); b)
high Fe/SiO
2
ratio results in low slag volume for less heat loss; c) high concentration
oxygen reduces the heat loss associated with the off-gas; d) high heat efficiency as a
result of submerge combustion.

Pyrometallurgy

The details of these advantages and their influences on the operations are discussed.

PY22

VISCOSITY MEASUREMENTS FOR COPPER SMELTING SLAGS

Baojun Zhao
School of Chemical Engineering, University of Queensland, Brisbane, Australia

ABSTRACT
Phase equilibria of silicate slags relevant to the copper smelting/converting
operations have been systemically investigated in the temperature range 1.200 to 1.300
o
C
and oxygen partial pressures between 10
-5
and 10
-9
atm. The experimental procedures
include high temperature equilibration, quenching and accurate measurements of phase
compositions using electron probe X-ray microanalysis (EPMA). The effects of CaO,
Al
2
O
3
, MgO and PO
2
on the phase equilibria of the fayalite slags have been systematically
investigated.

It was found that spinel and silica are major primary phases in the composition
range related to copper smelting/converting slags. In addition, olivine, diopside and
pyroxene also appear at certain conditions. The presence ofup to 20 wt% CaO, and up to 10
wt% MgO and Al
2
O
3
in the slag increases the spinel liquidus and decreases the silica
liquidus. Liquidus temperatures in silica primary phase field are not sensitive to PO
2
;
Liquidus temperatures in spinel primary phase field increase significantly with increasing
PO
2
.
Pyrometallurgy

PY24

AVA (ANLISIS VA VISIN ARTIFICIAL)} SYSTEM

Alejandro Molina Olave
E-MAS Ingeniera S.A.

ABSTRACT

We present an artificial vision system to analyze the concentration of copper in the
white metal or matte, that is based on the measurement of some color tones of a sample
obtained from the liquid discharge of the copper concentrates melting furnace .
Empirically we have obtained a mathematical relationship that allows relating the color
intensity of a sample of white metal with its concentration of copper, which is the base of
the patent no. 47.109 Integrated system for the determination of copper in a sample of
white metal and associated method.
This technology strengthens the eyesight of the operators to determine the quality of
the product by some distinguishing and quantifiable physical characteristic. Here, we
propose to capture an image of the sample using a diffuse lighting system for further
digital processing with an algorithm that quantifies and correlates the color intensity with
the copper composition. This method requires no sample preparation room (avoiding the
production of contaminant, noise, dust and solids waste that usually take place in this
facilities) after the analisys, .
This technological innovation analyzes quickly, with precision and accuracy matte
grade and allows the operator to opportunely correct the input variables for control.

Pyrometallurgy

PY25

THE SYSTEM FOR OPERATIONAL CONTROL OF EMISSIONS (SCOE+)

Alejandro Molina Olave
E-MAS Ingeniera S.A.

ABSTRACT
The System for Operational Control of Emissions (SCOE+) uses mathematical
modeling of mass and energy balances, thermodynamic equilibrium and empirical
correlations to simulate steady state all daily unit operations of a copper concentrate smelter
in stationary state. SCOE+ integrates in its simulations all the reactions that take part during
the following processes: drying, smelting, conversion and refining, flotation , and acid
plant, and allows to configure any particular foundry.
The interface user-server is friendly and just requires a basic knowledge of
managing windows and pop-up menus. The user configures each unit operation and also
stablishes its own strategy for handling with the recycle material. The result report includes
the following outputs: flows of supplies and products, overall balances, particular mass
balances (for copper, sulfur, arsenic, etc.), flows of emissions of contaminants and
performance indicators (KPI). These outputs can be exported and integrated with other
applications/softwares, allowing to look for optimal points of production in a sustainable
way.
SCOE+ is an innovative solution that gives daily support on the analysis of
operations, evaluation of strategies for the mitigation of polutants, and it also stands as a
help to look for sustainable points of production without investments, using information
about concentrates mix, matte grade, handling of recycles and fuels..

Pyrometallurgy

PY26
SPECIATION OF COPPER IN FLASH, CONVERTER AND SLAG CLEANING
FURNACE SLAGS.

J.C. Fernndez-Caliani
Department of Geology, University of Huelva, Spain

F. Jimnez, G. Ros, J. Martnez
Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold), Huelva, Spain

ABSTRACT

Research on slags involved in smelting-converting-refining operations to produce
blister copper at the Atlantic Copper smelter, in Huelva (Spain), has been carried out by
quantitative electron microprobe analysis, X-ray diffraction and digital imaging techniques.

The results showed that mechanically entrapped matte particles are the dominant
copper losses in the slags. The largest proportion of Cu-bearing particles is present in the
magnetite-rich converter slags, due to the negative effect of viscosity on coalescence and
precipitation of copper matte during conversion.

The mechanical entrapment of copper matte by slags from both the flash and
electric furnaces resulted in copper losses mostly occurring as tiny particles with a
stoichiometric composition similar to that of bornite. The Cu-bearing particle distribution
has been analysed and the effect on settling time in the slag cleaning furnace calculated.

Pyrometallurgy

PY27

SYNERGY OF ENERGY RESOURCES OF COPPER PYROMETALLURGY IN
RTB BOR-SERBIA

Milorad IRKOVI,

Vlastimir TRUJI, Mile BUGARIN

Mining and Metallurgy Institute Bor, Zeleni bulevar 35, Bor, Serbia
E-mail: milorad.cirkovic@irmbor.co.rs

MILANE MITOVSKI
RTB-BOR Group, Djordja Vajferta 20, Bor, Serbia

Aleksandra MITOVSKI
University of Belgrade, Tehnical Faculty, Bor, Serbia

ABSTRACT
Copper production is a big consumer of energy consisting of almost all fossil fuels,
including also electricity. This work presents a comparison of the specific energy
consumption of many metallurgical copper producers in the world, with the installed
different technological processes, in relation to the production of copper in RTB Bor
(Serbia). An important place is dedicated to the quantitative participation of energy fuels in
the production of copper. In addition to this, an analysis of cost structure for energy fuels
was shown in the production process of copper. This work particularly emphasizes the
aspect of use the secondary (waste) heat energy as a prerequisite to improve the energy
efficiency and economy of pyrometallurgical copper production. Using the waste heat of
pyrometallurgical process, m the protection of workin and life environment is improved
Selection and development of new metallurgical processes in order to achieve the
best economic effects is achieved selecting the optimum technology, on one side, and
selection of energy system with the best performances with the full utilization the
secondary heat energy of the process. Concretization of this aspect also relates to the
modernization of the Copper Smelter in RTB Bor installing the new technology for
smelting of copper concentrates.

Pyrometallurgy

PY28

VISCOSITY OF COPPER SLAGS FROM THE PROCESS OF DECOPPERING
IN AN ELECTRIC FURNACE

S. Pietrzyk, J. Kowalczyk, W. Mroz
AGH-University of Science and Technology, Faculty of Non-ferrous Metals,
Department of Physical Chemistry and Metallurgy of Non-ferrous Metals, Krakow, Poland

ABSTRACT

One of the stages of copper production process based on direct-to-blister flash
furnace is decoppering of a slag containing considerable amounts of copper (12-15 wt%).
At the GLOGOW Copper Smelter this stage is performed under reducing conditions in an
electric slag-cleaning furnace with the addition of coke and limestone. During the
implementation of a process, there are changes of the viscosity of the slag subjected to
decoppering.

In this work, viscosity of the industrial flash smelting slags with different degree of
reduction and variable contents of the oxides were investigated in the temperature range
from 1200 to -1350
0
C. The viscosity was measured by the rotating cylinder method.
The increase of CaO and Cu
2
O contents leads to decrease in the viscosity as long as the
slags remain fully liquid. However, upon reaching the liquidus temperature, a sharp inverse
in viscosity is observed. This is clearly illustrated by change in the slope of the viscosity
logarithm vs the temperature. The activation energy above the critical temperature have
been determined.

Pyrometallurgy

PY29

OPTIMAL CONFIGURATION OF VOLTAGE AND CURRENT INTENSITY IN
AN ELECTRIC FURNACE FOR SLAG CLEANING

J. Font and V. Montenegro
Instituto De Innovacion En Mineria Y Metalurgia
Ahumada 357, Piso 7.
Santiago, Chile

A.Warczok
Universidad De Chile
Departamento Ingenieria deMinas
Av. Tupper 2069
Santiago, Chile
awarczok@bell.net
A. Moyano
Codelco Norte
Calama, Chile

ABSTRACT
The three phases, rounded electric furnace is the most typical unit used for a slag
cleaning. The configuration voltage/current depends on the slag electric conductivity, the
depth of electrodes immersion in the slag and the properties of the transformer,
Based on analysis of industrial parameters of the electric furnace in CODELCO
NORTE Smelter the optimal voltage/current intensity has been determined for various
criteria, such as unitary energy consumption, unitary coke and electrode consumptions, and
copper recovery.
CFD and heat transfer modeling allowed for determination of a slag motion and its
impact on the rate of magnetite reduction, coalescence of copper matte inclusions for
various depth of electrodes immersion and voltage.
The increase of the electrodes immersion in a slag did not result in the increase of
the slag motion, leading to the increase of cod and the decrease of energy efficiency.
Pyrometallurgy

PY30

SULPHATION ROASTING OF AN ENARGITE CONCENTRATE

B. Chambers, C. Pickles and J. Peacey

Robert M. Buchan Department of Mining
Queens University
Kingston, Ontario
Canada K7L 3N6
John.Peacey@queensu.ca

ABSTRACT

Due to the increasing difficulty of finding conventional copper and gold ore bodies, the
processing of complex ores, such as those containing enargite, is being explored. A
sulphation roast, weak-acid leach, electrowinning process flowsheet was studied as a
possible new treatment method for copper concentrates containing significant amounts of
enargite. The sulphation roasting of an enargite concentrate was investigated in the
laboratory in order to determine the behaviour of arsenic as a function of roasting
conditions. Diagnostic leaching tests were then used to estimate the probable arsenic,
copper and iron phases in the resulting calcine. Based on the estimated heat and mass
balances, the economics of a sulphation roast-leach-electrowinning process was compared
to that for the conventional partial dearsenizing roast and sale of calcine to copper smelters.

Pyrometallurgy

PY31
COPPER RECOVERY FROM THE SMELTING SLAG IN AN ELECTRIC
FURNACE

A.Warczok
Av. Tupper 2069
Santiago, Chile
awarczok@bell.net

J. Font, V. Montenegro and C.Pizarro
Instituto De Innovacion En Mineria Y Metalurgia
Ahumada 357, Piso 7.
Santiago, Chile

A. Moyano
Codelco Norte
Calama, Chile

ABSTRACT
The mechanisms of a slag reduction and removal of copper matte inclusions in an
electric furnace for slag cleaning have been analyzed and discussed on the basis of CFD
modeling, rate of magnetite reduction controlled by its transfer in the slag, and gravitational
coalescence of copper matte and metallic copper inclusions. The results were confronted
with the results of slag cleaning in CODELCO NORTE Smelter.
Slag properties, particularly its viscosity and related temperature, were analyzed on
the background of matte inclusions size distribution, and their settling and gravitational
coalescence.
The recycling of highly oxidized slags from matte converting into Teniente
Converter as a smelting unit was pointed out as one of the important factor affecting the
decrease of copper recovery.
Pyrometallurgy

PY33

RECENT EXPERIENCES FROM IMPLEMENTING DYNAMIC PROCESS
CONTROL AND MONITORING IN THE FLASH SMELTING PROCESS

Peter Bjrklund, Tiina Ranki, Elli Miettinen
Outotec Oyj, Espoo, Finland

ABSTRACT
This paper will discuss recent advances and challenges in implementing control and
monitoring of the Flash Smelting process and possibilities to utilize these in improving not
only the process itself but also the safety and work environment for the smelter personnel.
To achieve these targets Outotec has developed advanced Expert Systems integrated with
the Automation system and these were successfully started up in the Paranapanema Smelter
in 2012.
As raw-materials become more complex operating tools need to follow this trend.
The Outotec Process Advisor is a predictive dynamic online process control model for
calculating the optimal operating parameters in real time taking into account all relevant
raw-material elements and the actual furnace situation. Together with the Outotec Proscon
automation system, these form a complete platform for smelter operation.
A rising trend is also the need to focus on plant safety in a smelter. The highest risk
rankings are often related to close proximity of molten metal. Through accurate and user-
friendly individual element heat flux monitoring these risks can be caught and reacted on in
time and the furnace integrity improved, meaning a safer plant and a longer campaign life.
The Outotec Sentinel system provides such a complete monitoring system.

Pyrometallurgy

PY34

THERMAL SHOCK RESISTANT ALUMINA-CHROMIA REFRACTORY
MATERIALS FOR THE COPPER INDUSTRY.

S. B. Breyner, K. Santowski
RHI AG, TC Leoben, Magnesitstrasse 2, Leoben, A-8700, Austria

T. Prietl
RHI AG, Wienerbergstrasse 9, Vienna, A-1100, Austria

ASBTRACT

Conventional alumina-chromia materials are characterized by a high resistance to
acidic slags due to the formation of a Al
2
O
3
-Cr
2
O
3
solid solution during brick firing.
Typical application areas for such products are glass tanks, waste incinerators or copper
smelting furnaces. In other areas, where not only corrosion by chemothermal load but also
thermal shock is predominating, these products suffer from discontinuous spalling and
exhibit poor refractory service life.

Research and development efforts were therefore shifted in favour of increased
thermal shock resistance of shaped alumina-chromia products. Laboratory slag testing and
physical testing indicated that the material properties are on a sufficiently high level to
conduct field experiments at customers. First test results in a tyuere zone of a Peirce-Smith
converter demonstrated that the material properties of the new alumina-chromia products
meet both the corrosion and thermal shock resistance required for this application. This was
particularly evident from the fact that the postmortem sample had a residual thickness of
47% after a standard operation cycle of 11 weeks.
Pyrometallurgy

PY35

LIQUIDUS TEMPERATURES, MAJOR AND MINOR ELEMENTS
EQUILIBRIUM PARTITIONING IN COPPER SMELTING SLAG / MATTE /GAS
SYSTEMS

Zhi Sun, Evgueni Jak
PYROSEARCH, The University of Queensland, Brisbane, QLD, 4072, Australia

ABSTRACT

Phase-equilibria data make it possible to identify the likely outcomes of reactions
and the limits to reactor performance. Although repeated studies have been carried out
over the past several decades, significant gaps and uncertainties still remain for the copper
slag/matte/gas systems so that the description of liquidus-temperatures, major and minor
elements equilibrium partitioning require further improvements.
Experimental procedures involving high-temperature-equilibration and quenching
followed by electron-probe X-ray microanalysis, developed at PYROSEARCH, have
resolved a number of experimental difficulties associated with high temperature phase-
equilibria determination in these systems. Systematic investigations are carried out in the
multi-component Cu-Fe-Si-S-O system with addition of impurities, such as CaO, Al
2
O
3
,
MgO, and minor elements, such as Bi, Sn, at controlled oxygen and sulphur partial
pressures and temperatures in the range of interest to copper smelting operations.
New experimental data have been obtained for the slag/matte/gas equilibria.
Tridymite/spinel liquidus, copper and sulphur solubilities in slag, Bi and Sn partitioning
between slag and matte for the range of matte grades from 20 to 70 wt.% Cu have been
measured. These data resolve previous discrepancies in values previously reported in
literature, and provide better characterisation of the complex chemistry, which is vital for
the process optimisation of copper production.

Pyrometallurgy

PY36

QUASI-CHEMICAL VISCOSITY MODEL FOR COPPER-CONTAINING MULTI-
COMPONENT LIQUID SLAGS

Zhi Sun, Evgueni Jak
PYROSEARCH, The University of Queensland, St Lucia, Brisbane, QLD 4072 Australia

Masanori Suzuki

Graduate School of Engineering, Osaka University, 2-1 Yamadaoka, Suita, 565-0871
Osaka, Japan

ABSTRACT
Slag viscosity is one of the key properties particularly important for good metal
recovery and overall productivity in pyrometallurgical copper-making processes. The
quasi-chemical viscosity (QCV) model has been developed and recently modified to allow
the viscosities of multi-component fully-liquid oxide slags to be predicted within
experimental uncertainties over wide ranges of compositions and temperatures.
This model takes into account the complex internal slag structure providing
advantages in accurate predictions of multi-component liquid slag viscosities, especially in
slags having high SiO
2
concentrations. The present research extends the QCV model to the
SiO
2
- Al
2
O
3
- CaO - MgO - FeO - Fe
2
O
3
Cu
2
O multi-component liquid slags directly
relevant to various copper smelting and converting operations by incorporating new
experimental data and new optimised thermodynamic model of copper-containing oxide
slags. Critical analysis of the available experimental viscosity measurements and their
uncertainties, as well as analysis of common trends, has enabled the model parameters to be
developed so as to give reliable viscosity predictions. Examples of the applications of the
model will be presented for conditions where the control of viscosity of the multi-
component complex slag systems is important for the copper smelting and converting
operations.
Pyrometallurgy

PY37

MEANS OF REMOVING LEAD AND ARSENIC DURING THE COPPER
PRODUCTION CYCLE IN UPGRADED TECHNOLOGY OF KGHM POLSKA
MIEDZ SA

Czernecki Jzef, Ph.D, Prof. IMN
Miczkowski Zdzisaw, Dr Eng.
Krawiec Grzegorz, MSc.Eng.
Institute of Non-ferrous Metals, Gliwice

Byszyski Leszek MSc.Eng
Gostyski Zbigniew MScEng
KGHM Polska Mied S.A. Lubin

ABSTRACT
The copper content in chalcocite-bornite concentrates produced by KGHM Polska
Mied SA is similar to that in chalcopyrite concentrates (20 - 30% by wt.). However, the
concentration of sulfur and iron is much lower, respectively by 9 - 12 and 3 - 6% by wt.
Furthermore, a characteristic of Polish concentrates is the presence of carbon (6 - 9% by
wt.) and impurities: lead (1.5 - 3.0% by wt.) and arsenic (0.05 - 0.4% by wt.).
Due to the low sulfur and iron content and the presence of organic carbon, two types
of technology were chosen for the melting of the kinds of concentrates encountered in
Poland: the shaft smelting process (Gogw I and Legnica) and the one-stage flash smelting
process (Gogw II). In both processes the organic carbon constitutes a fuel to provide the
desired temperature of the products.
The smelters in which the shaft process is used are characterized by a high degree of
elimination of Pb and As in the copper production cycle when, in the first two
pyrometallurgical operations (concentrates melting, copper matte converting) stable sulfide
phases occur.

Pyrometallurgy

A different situation occurs in the one-stage flash smelting process, where the
sulfides are oxidized quickly to the metals.
The beginning of the process of pyrometallurgy modernization by KGHM Polska
Mied SA, involving replacement of the shaft furnaces at Gogw I and Legnica with a
single flash smelting furnace, required solutions to such problems as how to remove major
contaminants such as lead and arsenic from the copper production cycle.
In this paper the behavior of lead and arsenic is presented, as well as the current
means of removing these contaminants from the copper production cycle, when there are
two technologies, i.e. the process of shaft furnace smelting and the one-stage flash smelting
process.
To deal with the situation after the upgrade, when KGHM Polish Copper SA will
operate two flash smelting furnaces for the production of copper blister directly from
concentrates, solutions are being developed to enable the elimination of Pb and As to the
degree necessary to ensure that the concentration levels of these metals in the semi-finished
products are maintained at the required level.

Pyrometallurgy

PY38

FLASH SMELTING AND FLASH CONVERTING PROCESS AND
COMMISSIONING AT JINGUAN COPPER

Zhou Jun, Sun Laisheng,
Tongling Nonferrous Metals Group Co., Ltd
Tongling, Anhui, China
244100
zhouj@jgty.net, zhouj@tlys.cn

ABSTRACT

Tongling Nonferrous Metals Group, the leading copper producer in China, started up a
green-field copper smelter and refinery in December 2012. The new copper smelter employs
Outotec flash smelting and Outotec-Kennecott flash converting process with a design
capacity of 400,000tpa primary copper. It is the third flash converting plant in the world, and
also the biggest copper smelter in terms of concentrate throughput. This paper presents
process, facilities, commissioning, operation and environment control of the new smelter.

Pyrometallurgy

PY39
AN EXTENSIVE SLAG DATABASE: LEAD-ING THE WAY

Vaajamo Iina, Taskinen Pekka, Gisby John

ABSTRACT
Industrial processes at high temperatures are complex in nature involving many
types of compounds, substances and solution phases. Due to this complexity it is sometimes
impossible to investigate a specific problem experimentally or even understand in-depth the
problem in question without input from reliable models. The MTDATA software package
from UKs national measurement institute NPL (National Physical Laboratory) and the
thermodynamic databases developed by NPL and its co-operators are used to understand
these problems faced by industry. This work gives insight into the development of a lead-
based database built as a part of NPLs extensive MTOX (metal-oxide-sulphide) database.

The database development work has required a critical literature review, new
equilibration experiments providing information of the mutual solubilities of the elements,
and optimization of interaction parameters for the lead-containing systems. A direct-to-
blister copper slag cleaning process in an electric furnace has been simulated as an
illustrative application of the MTOX database.

Pyrometallurgy

PY40

INVESTIGATION OF THE BATH-DEPOSIT INTERFACE OF FREEZE-LININGS
IN COPPER SLAGS

Ata Fallah-Mehrjardi, Peter C. Hayes, Evgueni Jak
Pyrosearch, The University Of Queensland, Brisbane,
Australia

ABSTRACT

Freeze-lining technology is actively employed to protect reactors walls from
chemically- aggressive molten slags. To date, the design of freeze-linings for
pyrometallurgical reactors has been solely based on the assumption that the interface
between the deposit and bath at steady stage is at the liquidus temperature of the
bulk liquid bath. However, there is increasing evidence that the interface temperature
between stagnant deposit and molten bath at steady state may be below the liquidus of
the bulk liquid. This finding strongly influences the way bath chemistry effects should be
taken into account in freeze-lining designs. In order to investigate fundamental
processes involved in the formation and stability of the freeze- lining deposits,
experimental laboratory studies have been undertaken in the Cu-Fe-Si-Al-O slag system
at equilibrium with metallic copper using an air-cooled cold finger probe technique; the
probe is submerged into the synthetic slag bath heated in an induction furnace and stirred
by rotation of a crucible.
The effects of bath agitation on the microstructure, morphology of phases and
formation of various layers across the freeze-lining deposit were studied at steady-state
conditions in this study. It appears that the changes in the fluid flow characteristics
strongly affect the deposit microstructures, the formation of the sealing solids layer and,
thus, the interface temperature between freeze-lining deposit and the liquid bath. The
results demonstrate that the mass transfer and crystallisation / dissolution processes in
the area adjacent to the deposit interface are crucial factors that determine the
Pyrometallurgy

microstructures and temperatures of the interface layer of the deposits. Systematic
laboratory study provides firm scientific basis to assist in the freeze-lining design that can
result in significant energy savings and therefore reduction of CO
2
emissions by
optimisation of process temperature and flux additions.
Pyrometallurgy

PY41

ADVANCED PILOT PLANT ROASTING TESTS GIVE NECESSARY
KNOWLEDGE FOR DESIGN OF A LARGE ROASTER PLANT AT MMH

Sergio Carrasco, Mr Daniel Deutsch,
Codelco-VP

Gunnar Berg, Dr ke Holmstrom, Mr Lars Hedstrom,
Outotec

ABSTRACT
The MMH roaster project has a long history and it is now about 20 years
since the initial plans of a roaster for the MMH concentrate came up.
The first contacts were made between Codelco and Outotec. (At the time
named Boliden Contech.) Outotec had the knowledge of arsenic removal from copper and
gold concentrates by fluidized bed roasting and Codelco had a new huge copper deposit,
called MMH, located in between the Calama city and the Chuquicamata copper smelter.
The arsenic bearing mineral at MMH is mainly enargite (Cu
3
AsS
4
) so is not
possible to eliminate the arsenic by selective flotation. Partial roasting is one possible
method to clean the concentrate from arsenic and thereby produce a suitable raw material
for the copper smelter.
Outotec had already before the MMH project run pilot plant tests in a
fluidized bed roaster on behalf of Codelco to remove arsenic from the arsenic rich
Chuquicamata concentrate to produce a low arsenic containing calcine. The tests were
successful and showed that the roasting process was an efficient way of separating arsenic
from the copper rich raw material before it is treated in the copper smelter.
All concentrates containing arsenic are unique and the process design of a
roaster plant must be based on relevant design data. The process data was collected during
several tests in fluidized bed pilot plants. Most tests were made in the fluidized bed pilot
plant of Outotec in Sweden and others were carried out in Chile (Concepcin University).
Pyrometallurgy

The influence on calcine quality by critical process parameters like e.g.
roasting temperature, silica bed, feed composition and the temperature of gas cleaning
equipment was studied and the outcome of the tests have had direct influence on the design
of the full scale plant at Calama.
The ability to run pilot plant tests is essential during development of the
roasting process. During the long history of roasting in Outotec, the roasting group, formed
out of former Lurgi and Boliden Contech, has to date delivered 285 fluid bed plants. The
Outotec roaster reference list includes a variety of processes and concepts: from high
trough-put circulating fluid bed rosters for ore (Newmont Gold Roaster) to small two-stage
stationary bed rosters for concentrate (Tongguan Smelting). Outotec can deliver the
complete process chain for the pyrometallurgical plant, e.g.: roaster; dust-gas separation;
calcine cooling; gas cleaning; water treatment; sulphuric acid. Outotec can also provide
required technology for many beneficiation and the hydrometallurgical processes, which
are connected to our roasters. In the MMH project, Codelco has chosen Outotec as
supplier on EPC basis for roaster, gas cleaning sulphuric acid and effluent treatment.
This presentation summarizes the pilot plants experiences made during tests
both in Sweden and in Chile and describes how important knowledge has been collected by
the cooperative work of Codelco and Outotec.

Pyrometallurgy

PY42

INTEGRATED EXPERIMENTAL AND MODELLING RESEARCH ON COPPER
SLAGS PHYSICO-CHEMICAL PROPERTIES IN SUPPORT OF OPTIMISATION
OF COPPER MAKING PROCESSES

Evgueni Jak and Peter Hayes
Pyrosearch, The University Of Queensland, Brisbane, 4072, Australia.
E.Jak@uq.edu.au

ABSTRACT

Copper smelter operations around the world are under sustained pressure to reduce
costs and increase output. Through the provision of reliable data on fundamental properties
of the chemical systems the opportunities for improvements of industrial copper production
can be identified. Experimental and modelling studies on phase equilibria,
thermodynamics and viscosities of copper slag/matte/metal/gas systems have been
combined into an integrated research program undertaken at PYROSEARCH.
Experimental phase equilibria studies involve high temperature equilibration in controlled
gas atmospheres, rapid quenching and direct measurement of compositions of equilibrium
phases with electron probe X-ray microanalysis (EPMA). Thermodynamic modelling is
undertaken using the computer package FactSage in conjunction with advanced models
used for complex solution phases. Slag viscosities are characterised through systematic
modelling supported by experiments. Progressive development of these research
methodologies has brought significant advances in characterisation of these complex
systems.

The new data and models can now be applied to assist in improvements of the
processes. The effects of changes to chemistry and process conditions within the smelting
reactor can be examined. Examples of multivariate analysis of trends in a range of
conditions relevant to a typical copper smelter operation parameters are provided. These
examples examine the potential impact of impurity elements on slag properties, fluxing
requirements, metal losses, fuel requirements and operating temperature. These
demonstrate the potential of the theoretical, laboratory and plant-based studies, to improve
smelter performance.

Pyrometallurgy

1
PY43

CALCIUM FERRITE SLAG PHASE CHEMISTRY CONTROL USED IN
CONTINUOUS FLASH CONVERTING

E. Jak,
Pyrosearch, The University of Queensland, Brisbane, Australia, e.jak@uq.edu.au

C. Nexhip

, D. P. George-Kennedy
Rio Tinto -Kennecott Utah Copper LLC, Magna, Utah, USA

ABSTRACT

Calcium ferrite slags with Cu
2
O, "Fe
2
O
3
" and CaO as major components are used in
the continuous flash copper-converting process developed at Rio Tinto -Kennecott Utah
Copper LLC (KUC). A number of other impurities including SiO
2
, S, MgO, Al
2
O
3
, As and
other are also present in the slag. Knowledge of phase equilibria in this slag system is im-
portant for optimal control of the furnace performance including melting temperatures and
deposit control.

Extensive investigations have been undertaken a) to characterise the phase chemis-
try of deposits taken from various parts of the smelter in parallel with b) comprehensive
laboratory-based liquidus and sub-liquidus phase equilibria studies in the multi-component
system using synthetic slag samples. Major findings related to the phase chemistry control
of the Ca-ferrite slags, constitution and possible mechanisms of deposits formation in the
converter, including protective freeze-lining, will be summarised. The role of major and, in
particular, minor elements including SiO
2
, S, and As will be discussed. The combination of
systematic collaborative research into the plant deposits and fundamental phase equilibria
studies provided better understanding of the melting and solidification behaviour of the
complex Ca-ferrite slags.
Pyrometallurgy

PY44

DISTRIBUTION RATIOS OF PLATINUM AND PALLADIUM BETWEEN IRON
OXIDE SLAGS AND MOLTEN COPPER AT 1573 K

Katsunori Yamaguchi
Iwate University

ABSTRACT

Copper scrap containing PGM is treated with a copper smelting process, and copper
and PGM are recovered. As a fundamental study of the oxidation process, measurement of
the distribution ratios of iron, platinum and palladium between the FeOx-CaO slag and
molten copper was carried out in the range of log pO2 between 9 and -5 at 1573 K
Distribution ratios of iron, platinum and palladium are increasing with oxygen partial
pressure. Based on the distnb~ ution ratios, the recovery of platinum and palladium is
calculated under the oxygen potential, log yo2 between `9 and -5 at 1573 K using the
FeOx-CaO slag.
Pyrometallurgy

PY45

IMPROVEMENT OF COPPER SLAG GRANULATION SYSTEM WITH CLOSED
WATER CIRCULATION AND IMPURITIES BLEED--OFF CIRCUIT

Hiromichi Inada, Hiroyuki Wakasa
Tamano Smelter & Refinery
Bibi Kyodo Smelting Co., Ltd

Tatsuya Wada
Saganoseki Smelter & Refinery
Pan Pacific Copper Co., Ltd.

ABSTRACT
In Tamano smelter, seawater had been used as the granulation measure of flash
smelting furnace slag. Since some amount of heavy metals, such as As and Pb, tended to
elute from slag to the granulation water, Tarn&no tried to reduce the heavy metals emission
via discharging seawater by converting the granulation system to the closed water
circulation. 'I_amano smelter locates at the area where the industrial water supply is not
abundant. Therefore, the indirect water cooling system was applied to minimize the
evaporation loss. To avoid the impurities condensation in the circulating water, impurities
bleed-off circuit was developed and adopted to the system. The system has started its
operation in April 2012, and achieved almost zero emission of impurities derived from slag
granulation. This paper describes the design concept of the system and its cuxTent
operational performance.
Pyrometallurgy

PY46

DEVELOPMENT OF SIDE-BLOWING OXY-FUEL CONCENTRATE BURNER IN
FLASH SMELTING PROCESS AT SUMITOMO TOYS SMELTER

S, Sasai, K. Nagai, K. Kawanaka and K. Yarnamoto
Toyo Smelter & Refme Non-ferrous Metals Division
Sumitomo MetaI Mining Co., Ltd,
DISH 145-I, FunLtya, Saijo, Ehime 793-0005
JAPAN

ABSTRACT

Sumitomo Metal Mining Toyo Smelter and Refillery has achieved concentrate
feeding rate of Flash smelting furnace up to 4,000 TPD by developing the Surnitomo type
concentrate burner, lo misc the performance of concentrate burner more, Sumitomo original
smelting process, "Side-blowillg Oxy-fuel concentrate burner in Flash Smelting process"
(S.O.F) which had been developed by using pilot plant in 1980s at Niihama Research
Laboratories, was applied to commercial plant. In S.O.F process, parts of reaction air are
blown from the side nonles of flash furnace reaction shaft.
In commercial plant, several tests had been carried out and the longest test was
continued successfully for one month without serious trouble. S.O.F process also showed
very high performance such as low dusting rate. This paper describes the details of those
technical development referring test operation results.

Pyrometallurgy

PY47

STUDY ON LIQUIDUS TEMPERATURE AND VISCOSITY OF COPPER
SMELTING SLAG

Jun`ichi TAKAHASHI
Sumitomo Metal g Co., Ltd.
Niihama Research Laboratories
Process Metallurgy Group
Manager of Pyrometallnrgy' Section

ABSTRACT:
Limited data are available on the phase chemistry of the copper smelting slag
system used in the copper smelting and slag cleaning processes. The measurement of
liquidus temperature of silicate slag systems relevant to copper smelting was carried out at
controlled oxygen partial pressures in equilibrium with metallic copper by the procedures,
which involve equilibration of mixtures, rapid quenching of resulting phases, and
measurement of phase compositions using electron probe X`ray microanalyses (EPMA),
developed at the Pyrometallurgy Research Centre (PYROSEARCH), the University of
Queensland. The measurement or viscosities was also carried out by using the rotating
cylinder viscometer techniques which developed at the Kyushu University from 1423K to
1573K at oxygen partial pressure of 10.9 atm as a function of CaO% A1203%, and Fe/SiO2
weight ratio.
The increase of CaO% decreases liquidus temperature. The increases of FeiSiO2
and A1203% increase liquidus temperature. The decreases of viscosity were obtained with
the increase of CaO% and the increase of Fe/SiO2 without relation to the liquidus
Pyrometallurgy

PY50

THE ESTABLISHMENT OF AN OPTIMUM OPERATION AFTER THE
INTRODUCTION OF THE O-SR PROCESS AT ONAHAMA SMELTER &
REFINERY

Masanori Yoshida
Manager of Production Division
Onafiama Smelter & Refinery
Onahama Smelting and Refinery

Tetsuro Sakai
Managing Director & General Manager
Onahafna Smelter & Refinery
Onahama Smelting and Refinery Co, Ltd

ABSTRACT
The "O-SR" Process, which is an innovative combination of a newly installed
Mitsubishi-Process S-furnace with the existing reverberatory furnaces (RFs) followed by
PS-converters (PSC), has been operated since December 2007. The project of the O-SR
process had aimed to increase the treatment of copper concentrates in the S-furnace while
enhancing the treatment of combustible wastes such as shredder residue (SR) and
successively corresponded the intention. The original facilities of the O-SR process have
recently modified to establish an optimum operation, as follows:
Launder between the S-furnace and RFs was redesigned to increase the availability
at S-furnace @ A new coal combustion system and a compact hot-blast stove were adopted
for RFs. The operation of PSCs including the number of working converters was cllanged
to treat high grade matte. As a results, the operation cost and carbon footprint due to the
consumption of fossil fuel have decreased dramatically.
Pyrometallurgy

PY51

HIGH EFFICIENT SLAG CLEANING LATEST RESULTS FROM PILOT
SCALE OPERATION

R. Knig, R.Degel, L. Rose (SMS Siemag),
J. Schmidl, A. Specht, H. Kadereit (Aurubis AG)

ABSTRACT

During the last 25 years sustainability has become one of the major issues for our
growing society. The fast development of the emerging countries and the still high level of
consumption in the industrialized states require the further development of existing
production processes. The future challenge for the copper industry is to treat more complex
ores on the one hand and increasing the yield by reducing the copper losses and to remain
the iron-silicate-by-product marketable on the other hand.

By applying a magnetic field to a slag crossing a DC field stirring is improved and
thereby the settling of entrained copper droplets is fostered. Based on this theoretical
background and the results of an intensive parameter study by CFD-simulation the results
were subsequently verified in a 2-4 t/h pilot plant. During 10 test trials, each one week, in
the pilot plant it was the aim to generate reliable results for an approximation of the
economic feasibility of the new process. The results confirmed that a significant reduction
of the Cu-content in the resulting iron-silicate-product depending on the incoming copper-
slag content is feasible and economical interesting. Hence, the basics for the design of an
industrial furnace were determined.
Pyrometallurgy

PY52
OPTIMIZING CONVERTER AISLE OPERATION AT ATLANTIC COPPER
SMELTER, HUELVA, SPAIN

Nubia Cardona V.
Kingston Process Metallurgy
759 Progress Avenue
Kingston, ON, Canada K7M6N6
nubia.cardona@kpm.ca

A. Martin, F. Jimnez and G.Rios
Atlantic Copper
Av. Francisco Montenegro s/n
21001, Huelva, Spain

Philip Mackey
P.J. Mackey Technology Inc.

Pascal Coursol
Barrick Gold Corp.
3700-161 Bay Street
Toronto, ON, Canada, M5J 2S1

ABSTRACT

With the aim of reducing copper losses in slag and to further optimize converters
performance, the Atlantic Copper smelter (Huelva smelter) performed a project leading to
optimisation of its converter aisle practices. This study consisted of a review of the current
converter aisle operation, a full mapping of the slag chemistry and a modeling of the
converter cycle through a new blow-by blow approach. The modelling approach and
main variables influencing overall performance, slag chemistry and copper losses are
discussed in this paper. The impact of operational practices such as blowing rate and
blowing time, oxygen enrichment, fluxing, reverts and scrap copper addition, copper slag
recirculation and slag skimming practices are discussed in the context of overall heat and
mass balance for the Peirce Smith converters. Activities performed at the plant, leading to
marked improvements in the converter aisle performance and slag quality are also
discussed.

Pyrometallurgy

PY53
APPLICATION OF EXERGY ANALYSIS IN COPPER SMELTING
PRODUCTION

Javad Khosravi
1
, Mark A. Rosen
2

1
WorleyParsons Minerals and Metals, 2645 Skymark Avenue, Mississauga, Ontario,
Canada
2
Faculty of Engineering and Applied Science, University of Ontario Institute of
Technology, Oshawa, Canada
Email of corresponding author: javad.khosravi@worleyparsons.com

ABSTRACT

Exergy analysis has received lots of attention in recent years due to its application in
the waste heat management in various industries. However, the exergy analysis still is not a
common tool for metallurgical industries to use as useful and accurate method of energy
measurement. This paper intends to briefly review the exergy concept and its applicability
in energy management of metallurgical processes. Two case studies were analyzed: exergy
analysis of a copper smelter at different matte grade production. In another study the
impacts of copper concentrate grade on exergy of copper production were analyzed.
Pyrometallurgy

PY54
PHASE EQUILIBRIA STUDIES FOR COPPER SMELTING/CONVERTING
SLAGS

Baojun Zhao
School of Chemical Engineering
The University of Queensland, Brisbane, Australia
baojun@uq.edu.au

ABSTRACT

Phase equilibria of silicate slags relevant to the copper smelting/converting operations
have been systemically investigated in the temperature range 1200 to 1300
o
C and oxygen
partial pressures between 10
-5
and 10
-9
atm. The experimental procedures include high
temperature equilibration, quenching and accurate measurements of phase compositions
using electron probe X-ray microanalysis (EPMA). The effects of CaO, Al
2
O
3
, MgO and
Po
2
on the phase equilibria of the fayalite slags have been systematically investigated.

It was found that spinel and tridymite (SiO
2
) are major primary phases in the
composition range related to copper smelting/converting slags. In addition, olivine,
diopside and pyroxene may also appear at certain conditions. The presence of up to 20 wt%
CaO, up to 10 wt% MgO and 10 wt% Al
2
O
3
in the slag increases the spinel liquidus and
decreases the tridymite liquidus. Liquidus temperatures in tridymite primary phase field are
not sensitive to Po
2
; Liquidus temperatures in spinel primary phase field increase
significantly with increasing Po
2
. Addition of the same weight of Al
2
O
3
or MgO in slag
shows the same effect on the liquidus temperatures in spinel and tridymite primary phase
fields. The trends in the effects of Al
2
O
3
or MgO on liquidus temperatura are similar for
both copper smelting and converting slags.

Pyrometallurgy

PY55
INVESTIGATION OF FREEZE-LINING FORMED IN AN INDUSTRIAL COPPER
CONVERTING CALCIUM-FERRITE SLAG.

ATA FALLAH-MEHRJARDI , PETER C. HAYES, EVGUENI JAK
PYROSEARCH, The University of Queensland, Brisbane, Australia
JANI JANSSON2, PEKKA TASKINEN2
Thermodynamics and Modelling Group, Aalto University, Finland

ABSTRACT
Pyrometallurgical coppermaking processes are operated under intensive conditions
such as high process temperatures and vigorously agitated bath to accelerate kinetics of
reactions and to achieve high smelters throughput. Slag freeze-lining reactor wall protection
is a widely used technology in coppermaking processes, such as, flash smelting and
converting reactors to mitigate and resist the effects of thermal and chemical attack by
aggressive slags. In this laboratory-based study, water-cooled probe cold finger technique
has been used to investigate the behaviour of the calcium ferrite slags in equilibrium with
metallic copper; the slag composition reflects that used in the industrial copper flash
converting furnace of Rio Tinto Kennecott Utah Copper LLC (KUC). The effects of
probe immersion times on the thickness, stability, and heat transfer characteristics of
freeze-lining deposits have been measured.
It has been shown that under steady-state conditions several different layers are
formed within the deposit starting from the cold probe surface as follows: quenched and
microcrystalline layers; closed crystalline layer with multiphase sub-liquidus material
formed without mass exchange with the bulk liquid; dense primary phase crystals sealing
layer; and the subliquidus boundary layer between stagnant deposit and the agitated liquid
bath. The microstructures of the freeze-lining obtained at steady-state thickness were
compared to sub-solidus equilibrium phase assemblages.
Pyrometallurgy

PY56

CHEMICAL COMPOSITION AND DUST GENERATION OF COPPER
CONCENTRATE PARTICLES OXIDIZED UNDER SUSPENSION-SMELTING
CONDITIONS

V.R. Parra-Snchez, M. Prez-Tello, V.M. Snchez-Corrales, A. Gmez-lvarez
Department of Chemical Engineering and Metallurgy, University of Sonora
Blvd. Luis Encinas & Rosales. Hermosillo, Mxico 83000
mperezt@iq.uson.mx

R. Parra-Figueroa, E. Balladares-Varela, E. Araneda
Dept. of Metallurgical Engineering, University of Concepcion.
Department of Metallurgical Engineering, University of Concepcin
Edmundo Larenas 285 Casilla 160-C Correo 3
Concepcin, Chile.

ABSTRACT

The chemical composition and dust formation during the oxidation of copper
concentrate particles under suspension-smelting conditions were investigated. The effects
of initial particle size and oxygen concentration in the process gas on the particle
composition, morphology, and mineralogy of the reacted particles along a laminar-flow
reactor were tested. The chemical composition of the reacted particles was determined by
atomic absorption spectroscopy.

The mineralogy was determined by X-ray diffraction and QEMSCAN techniques,
the latter of which involves scanning electron microscopy combined with energy-dispersive
X-ray spectroscopy. The experimental data indicated that the smaller the size fraction in the
feed, the higher the extent of oxidation. The QEMSCAN micrographs in general agree
with a reaction mechanism involving expansion and further fragmentation of the particles
during flight. The extent at which both phenomena occurred was dependent upon the initial
particle size and residence time of the particles in the reactor.

Pyrometallurgy

PY57

EVOLUTION OF SIZE DISTRIBUTION OF COPPER CONCENTRATE
PARTICLES OXIDIZED UNDER SUSPENSION-SMELTING CONDITIONS

V.R. Parra-Snchez, M. Prez-Tello and V.M. Snchez-Corrales
Department of Chemical Engineering and Metallurgy, University of Sonora
Blvd. Luis Encinas & Rosales. Hermosillo, Mxico 83000
mperezt@iq.uson.mx

R. Parra-Figueroa and E. Balladares-Varela
Department of Metallurgical Engineering, University of Concepcin
Edmundo Larenas 285 Casilla 160-C Correo 3
Concepcin, Chile

ABSTRACT

Experiments were conducted to investigate the effects of the initial particle size and
oxygen concentration in the process gas on the size distribution of copper concentrate
particles oxidized under suspension-smelting conditions. The size distribution was
determined by both QEMSCAN and laser diffraction techniques from samples of reacted
particles collected along the reactor length of a laminar-flow reactor.

The experimental data indicate that the change in particle size of the particle
population was strongly dependent upon the particle size of the feed material, whereas the
oxygen concentration in the process gas did not play a significant role in the range of 40-70
vol. %. Particle expansion was the predominant phenomenon in the early stages of
oxidation, whereas fragmentation started to occur at further stages of oxidation down the
reactor length. The amount of dust, i.e., particles with size smaller than 20 m, is discussed
as a function of the operating conditions tested in the experiments.
Pyrometallurgy

PY59

CONTINUOUS CONVERTING OF COPPER MATTE TO BLISTER COPPER IN A
HIGH INTENSITY MOLTEN - LAYER REACTOR.

I. Wilkomirsky, R. Parra, F. Parada & E. Balladares
Dept. Metallurgical Engineering
University of Concepcin
Edmundo Larenas 285, Concepcin, Chile
iwilkomi@udec.cl

ABSTRACT

Continuous converting of copper matte or white metal into blister copper can be
carried out in a new high - intensity molten layer reactor that operates with dry, -65 mesh
grinded matte or white metal and technical oxygen. The reactor operates at 1500-1600C
producing a blister copper with 0.5 0.8%S which can be refined in conventional form, and
a slag with less than 8% Cu. The reactor operates continuously with no fugitive emissions,
generating and off gases with over 50% SO
2
. The phenomenological model of the molten
layer reactor can predict with good agreement the results obtained in a pilot prototype
reactor.

Pyrometallurgy

PY60

PHYSICOCHEMISTRY AND KINETICS MECHANISMS OF PARTIAL
ROASTING OF HIGH ARSENIC COPPER CONCENTRATES

I. Wilkomirsky, R. Parra, F. Parada and E. Balladares
Dept. Metallurgical Engineering
Edmundo Larenas 285, Concepcin, Chile
iwilkomi@udec.cl

ABSTRACT

A physicochemical/kinetic model is being proposed to explain the formation of
bornite, chalcopyrite and magnetite during partial roasting of higharsenic copper
concentrates at 700C. The mechanism involves solid state-gas and solidgas reactions
between chalcosite, pyrrhotite and gaseous sulphur, and is thermodynamically consistent
with the experimental results obtained in pilot plant.

Pyrometallurgy

PY61

RECOVERY OF COPPER, MOLYBDENUM, ZINC AND IRON FROM COPPER
SMELTER SLAGS.

I. Wilkomirsky, R. Parra, F. Parada and E. Balladares
Dept. Metallurgica Engineering
University of Concepcin, Chile
iwilkomi@udec.cl

J. Smit, M. Acua and M. P. Merino
ECOMETALES Ltd.
Calama, Chile

ABSTRACT

A new process is being developed which permit to recover up to 98% of copper,
76% molybdenum and 98% zinc from copper smelter slags, generating a solid residue of
red hematite that can be used in paints and ceramics. The process consist of two
consecutive step: an initial total sulphation of the slag at 150-180C with sulphuric acid
followed by a thermal decomposition at 700C 750C of the sulphated slag to form copper
and zinc sulphates, copper molybdate and hematite. The acid used in the first step of
sulphation is re-synthtetical in the seconds step of thermal decomposition and recirculated
back to the sulphation step. The process is being developed at pilot scale in a plant that will
be commissioned by the end of 2013.

Pyrometallurgy

PY63
REFINEMENT OF FLASH FURNACE AND CODELCO TENIENTE REACTOR
MATERIAL FEED SYSTEMS TO UTILISE CALCINED CONCENTRATES

Mark Coleman

ABSTRACT
Clyde Process an established customer-driven solutions provider, utilising its
knowledge, expertise and technologies to transform production processes, operating in the
ferrous and non-ferrous metals industries joined the Schenck Process Group of Darmstadt
Germany bringing the Brand into their focused Process Team.

Clyde Process solutions have delivered transformed operation to many of their
global clients, enabling them to generate sustainable economic benefit and maintain
positions as leaders in their markets.

Clyde Process have been a partner of Codelco for some time and when Codelco
developed its Calcined Concentrate from the new Hales Mine they turned to Clyde to
support their operation of the Flash Furnace and the Codelco Teniente Reactor allowing the
material to be exploited. Homogeneously mixed and delivered such that the existing
furnaces could maintain their performance.

Following process trials, targets were set and Clyde contracted to supply the
transport conveying equipment to deliver the Calcined material from the roaster to the
smelter and then homogeneously mix the materials on the Flash Furnace direct to the day
bin and on line directly to the Lances on the Codelco Teniente Converter with standard
Copper Concentrate and Silica Flux.

This paper reveals the solutions delivered showing the truth of Schenck Process
Solutions claim that we make processes work

Pyrometallurgy

PY64

DEVELOPMENT AND APPLICATION OF OXYGEN BOTTOM-BLOWING CU
SMELTING TECHNOLOGY

Xiaohong Hao, Zhifang Lu, Kejian Wei, Zhenmin Zhang, Liqiong Hu and Bing Li
China ENFI Engineering Corporation
12 Fuxing Avenue
Haidian District,Beijing 100038P.R.China
haoxh@enfi.com.cn

Zhi Wen , Fuyong Su and Yue Yu
University of Science & Technology Beijing
30 Xueyuan Road
Haidian District, Beijing 100083 P.R.China
wenzhi@me.ustb.edu.cn

ABSTRACT
Oxygen Bottom-blowing Cu Smelting Technology is a modern and clean technology
featured with low capital cost, low comprehensive energy consumption, high metal and
sulfur recovery rate, low operating cost and a good operational environment. The core
equipment of this technology is the bottom-blowing smelting furnace. This paper
summarizes the development history of bottom-blowing Cu smelting technology, and the
structural features and applications of a bottom-blowing smelting furnace. It then compares
it with other bath smelting technologies, coming to the conclusion that oxygen bottom-
blowing smelting furnace could ensure higher smelting strength, longer furnace life and
higher operational efficiency and that this technology has broad development prospect.

Pyrometallurgy

PY65

DEVELOPMENT OF THE CONTINUOUS BOTTOM-BLOWING MATTE
CONVERTING PROCESS

Bing Li, Jimu Jiang, Kejian Wei, Feng Li and Xiaohong Hao
12 Fuxing Avenue
Haidian District, Beijing 100038 P.R.China
libing@enfi.com.cn

Chuanfu Zhang
Central South University (CSU)
Changsha, Hunan 410083, PR. China
Chuanfuzhang@csu.edu.cn
ABSTRACT
This Paper describes the continuous bottom-blowing matte converting process, as
well as the pilot plant test conducted for this process from May to June, 2012. The pilot
plant test shows that under three-phase conditions in the bath, sulfur in blister is 0.7%-1.0%,
and Cu in slag is 8-12%; while under two-phase conditions, sulfur in blister is 0.2%, and
Cu in slag is around 20%. During the test, oxygen lance and refractory linings are under
good conditions. Therefore, it can be concluded from the pilot plant test that continuous
bottom-blowing matte converting process has good application prospect. The first plant
adopting this process is under design now and will be put into operation in China in
October 2013.

Pyrometallurgy

PY66

AN INTEGRATED LIFECYCLE APPROACH TO FURNACE REBUILDS

Mike Santaluce
Outotec
1551 Corporate Dr
Burlington, Canada L7L 6M3
mike.santaluce@outotec.com

ABSTRACT

Outotecs Integrated, Lifecycle Solution to Furnace Rebuild Projects is designed to
provide smelters with reliable furnace rebuild project solutions and asset program lifecycle
services. The concept addresses furnace rebuilds at the project level and at the asset
program level. At the project level, this solution combines Outotecs proven Smelting
Technology with its expertise in executing furnace rebuild shutdowns to deliver a complete
furnace rebuild project solution to clients which includes design, supply, construction,
commissioning and start-up activities for the furnace. At the asset program level, it delivers
regular audits, process, operating and maintenance support to provide a solution for
lifecycle management of the furnace rebuild program, aimed at maintaining continuity
between individual rebuild projects and improving the overall performance of the furnace
over the smelter lifecycle.

The Integrated, Lifecycle Solution to Furnace Rebuild Projects offers clients a
number of benefits both at the project level and the asset management level, ultimately with
the goal of enhancing the return on investment that copper smelters extract from their
rebuild projects and from the furnace asset itself over the lifecycle of the furnace.

Pyrometallurgy

Ref: 20/10/2013 10:28 AM
PY67

COPPER SMELTING TECHNOLOGIES IN 2013 AND BEYOND

P.J. Mackey
P.J. Mackey Technology Inc., Kirkland, QC, Canada
E Mail: pjmackey@hotmail.com

ABSTRACT

Modern bath and flash smelting technologies dominate world copper smelting
today. In recent years, these technologies have been perfected achieving high unit tonnages
as a result of continuous plant improvements and development work by the technology
owners. Flash smelting is dominated today by the Outokumpu flash technology, while there
are a number of established bath smelting technologies today including: Top Lance
Smelting such the ISASMELT
TM
Process, the Noranda and El Teniente Processes and the
Mitsubishi Process.

This paper explores the development cycle of these leading processes and charts
potential future trends, including aspects such as the early role of piloting and process
perfection, energy consumption, environmental design and sustainability, along with capital
and operating costs. Included is a technical evaluation of emerging and new smelting
technologies, typified by the SKS bath smelting process. Looking beyond 2013 and based
on the technical review, the paper attempts to place into perspective the likely niche such
new technologies will have in the suite of the bath and flash technologies of the future.

Pyrometallurgy

PY68

USE OF WASTE HEAT BOILERS TO SAVE RESOURCES

Dipl.-Ing. Alfredo Martnez
Oschatz GmbH
Westendhof 10 - 12
Essen, Germany
martinez.a@oschatz.com

ABSTRACT

Pyro-metallurgical industries are constantly affected by more rigorous
environmental regulations and global lack of necessary resources, like energy and water for
their processes. Plant owners look for new ways to operate their plants in an efficient and
economical way. One possibility is the usage of waste heat boilers (WHB) to recover the
energy potential of their plants. The WHB recovers the waste heat of the process to
generate steam and cools down the gas.

The produced steam can be used for power generation to improve the energy
efficiency of the plant. By cooling down the waste gas, the requirement of additional
cooling systems like water injection is not necessary. Water consumption is reduced.

This work describes some existing furnace technologies and types of WHB which
can be installed in non-ferrous industry plants. The main objectives are to show different
possibilities to save natural resources (fuels, water, etc.) while producing electrical energy
from the steam generated by these WHB.

Furthermore, some mechanisms which improve the efficiency of the waste heat
recovery are described and an example for using the recovered heat to generate electricity is
shown.
Finally, a preview on further developments for this subject is given.

Pyrometallurgy

PY69

DIRECT SULFIDES ELECTROLYSIS:
A SUSTAINABLE PROCESS FOR COPPER RECOVERY?

Antoine Allanore
Massachusetts Institute of Technology
Department of Materials Science & Engineering
77 Massachusetts Avenue, Cambridge, MA 02139 USA
allanore@mit.edu

ABSTRACT

Environmental awareness along with restrictions on investments, are calling for the
development of new approaches for metal extraction. In particular, the notion that an
extraction process necessary involves the emission of hazardous gas or the investment in
capital-intensive post-treatments is to be revisited. Technological trends suggest that an
electricity-based technique is well suited to accommodate these modern challenges [1]. In
the case of sulfides processing, one underexplored approach is the direct electrolysis of the
sulfides [2], leading to the decomposition of the feedstock to metal and elemental sulfur,
e.g.:

Cu
2
S 2Cu + S
2
(g)
This concept, in particular if applied at a temperature above the metal melting point,
has the advantage to allow a semi-continuous single step process, as experienced for
aluminium. It also offers to decouple the metal production from the generation of sulfuric
acid. In terms of volume, the generation of S
2
is an asset as it can be conveniently disposed
or transported in solid form. This presentation first proposes to review some of the pioneer
concepts. In a second part, a discussion of the electrolyte design challenges that are
currently limiting this approach will be offered, along with new opportunities that are
arising in this field.
[1] A. Allanore, Contribution of Electricity to Materials Processing: Historical and
Current Perspectives, JOM, vol. 65, issue 2, 131, (2013)

[2] F. Habashi, The Recovery of Elemental Sulfur from Sulfide Ores, Bureau of
Mines and Geologym Bulletin 51, (1966)

Pyrometallurgy

PY70

THE EFFECT OF I N SI TU PHASE FORMATION ON THE INFILTRATION
BEHAVIOR AND CHEMICAL DEGRADATION OF MAGNESIA-CHROMITE
BRICKS IN CONTACT WITH A SYNTHETIC NON-FERROUS SLAG

L. Scheunis
1
, A. Malfliet
1
, M. Campforts
2
, P.T. Jones
1
, B. Blanpain
1

1
Dept. Metallurgy and Materials Engineering, KUL, Leuven, Belgium;
2
Umicore R&D, Olen, Belgium

ABSTRACT

To have a robust smelting process it is essential to be able to rely on a long
refractory life. In case of Cu-smelters, life times of 2 and more years can be obtained. In
these processes a fayalite slag is used. However, in processes where a PbO slag is used, the
refractory life time is often lower. A major difference between both slags lies in the
infiltration behavior of the slag; PbO slags can infiltrate the porous lining much deeper,
attacking a larger part of the lining. In order to mitigate this, the possibility of preventing
deep infiltration by sealing off the pores with in-situ formed phases is investigated for a
synthetic non-ferrous PbO-SiO
2
-MgO slag. The results indicate the formation of forsterite
(Mg
2
SiO
4
) throughout the refractory sample by the reaction between the silica present in
the infiltrated liquid and the MgO from the refractory sample. This phase grows with time,
eventually sealing off the pores near the interface with the bath but is unable to prevent
complete infiltration of the refractory. However, once the forsterite seals off the pores, it
prevents contact between the bath and the interior of the brick, ceasing the chemical
corrosion inside the brick.

Pyrometallurgy

PY71

OPTIMIZATION OF TECHNOLOGY FOR CONCENTRATE SMELTING IN
FLASH FURNACE WITH CHARGE CHANGES

Marcin Kacperski, Zbigniew Gostyski, Tomasz Gbka, Piotr Poks.
KGHM PM, Poland

ABSTRACT
Copper Smelter Glogow (HMG) is a part of mining and metallurgical concern
KGHM PM SA. There are two primary smelters and copper refineries in HMG. The flash
furnace was built 1978 and the process of concentrates blend melting began. Due to the
characteristics of the Polish concentrates (low sulfur content, high organic carbon and lead)
technology of the direct smelting to blister copper was applied. Year by year the technology
was improved both technically and in case cost effectiveness. Recently, lead and organic
carbon content in concentrates increased and forced a change in approach to the
technological process parameters and verification its important parameters. The
presentation / paper describes the technical and technological changes in flash furnace
smelting.

Pyrometallurgy

PY73

MECHANICAL SYSTEM FOR REVERTS CHARGING INTO PEIRCE-SMITH
CONVERTERS

Patricio Hernndez Norambuena
1

Christian Guibout Cid
2

1
Ingeniero de Desarrollo Senior, Divisin Ventanas, Codelco Chile
2
Ingeniero Jefe de Fundicin, Divisin Ventanas, Codelco Chile

ABSTRACT
This system aims to feed reverts during the blowing step of the PSC converting
process at the Ventanas Smelter, thus avoiding direct addition through the converter mouth,
thereby reducing the emission of gases to the atmosphere. This mechanized system which
replaces the normal feeding procedure by tilting the converter and adding reverts through
the gas mouth is part of the Investment Plan that Codelco Ventanas Division is developing
to improve industrial processes in order to reduce gaseous and particulate matter emissions
to the atmosphere.

This system is made up with several auxiliary equipment and control systems,
which allows, in addition to reducing emissions to the atmosphere, to adequately control
the temperature of the conversion process during the blowing operation, as well as to obtain
a more stable flow of gas to the acid plant and not to expose the operator to hazardous work
conditions.

This paper shows in some detail how the system is structured describing its
mechanical and process control components. It also outlines the way the system works and
the results obtained to date.

Pyrometallurgy

PY74

EMISSIONS REDUCTION AND PROCESS IMPROVEMENTS ACHIEVED WITH
THE NEW ANODE FURNACE OFF-GAS SYSTEM AT ASARCO HAYDEN

Alberto Fernandez, Steve Gasser, Kevin McPeak, and Joe Wilhelm
ASARCO Hayden Operations, Hayden, Arizona USA

Mark Rowsell, Matt Russell, and Paykan Safe
GCT, LLC, Irving, Texas USA

ABSTRACT

The ASARCO smelter in Hayden, Arizona operates three anode furnaces to fire-
refine blister copper for casting to anodes. The furnaces use natural gas with steam for
reduction and natural gas burners for temperature control. Previously, anode furnace off-
gas discharged directly to the building with no gas collection, and burner gas consumption
was high.

ASARCO engaged GCT, LLC to provide preliminary and detail engineering and
EPCM services for a new off-gas system to reduce anode furnace emissions. The baghouse-
based system was installed and successfully started up in February 2012. Following startup
of the new off-gas system, ASARCO and GCT worked together to optimize the tuyere and
burner practices in order to improve reduction efficiency and processing time, to reduce gas
consumption and soot formation, and to optimize the off-gas system operation. The process
improvements resulted in significantly reduced natural gas consumption and improved gas
capture performance of the new hoods.

This paper outlines the challenges faced in designing the new off-gas system and
the process improvements and energy savings achieved through the collaborative
optimization effort.

Pyrometallurgy

PY75

TECHNOLOGY DEVELOPMENTS FOR SMELTER OFF-GAS HEAT
RECOVERY

Matt Russell and Paykan Safe
GCT, LLC, Irving, Texas USA

ABSTRACT

Smelter processes generate a significant amount of heat, of which a large percentage
is released with the process off-gas. Therefore off-gas heat recovery is critical to
minimizing energy consumption and reducing operating costs. Metallurgical process off-
gas presents major challenges for heat recovery due to high dust loading, corrosive gases,
and thermal cycling in batch processes. Waste heat boilers have been used for many years
for heat recovery on continuous smelting and converting processes. However, heat recovery
technologies have not been widely adopted on batch processes such as Peirce-Smith
converting and other lower temperature applications.

The design and development of novel heat recovery technologies to smelter
processes can provide produce significant reductions in energy consumption, greenhouse
gas emissions, and operating cost. This paper outlines the challenges faced in recovering
heat in smelter processes and presents recent technology developments for heat recovery
for batch processes and lower temperature applications, including a recent successful
installation of Organic Rankine Cycle (ORC) technology for heat recovery to power
generation on a steel reheat furnace.

Pyrometallurgy

PY76

THE USE OF CHROME-ALUMINA REFRACTORIES IN THE HIGH WEAR
AREAS OF ANODE REFINING VESSLS

A.J.Rigby Harbison-Walker Refractories, Pittsburgh, U.S.A.

ABSTRACT
Refractory lining designs based on products containing direct-bonded or rebonded
fused grain magnesia-chrome have been the industry-wide standard for anode refining
vessels in all primary copper smelters. These linings are usually zoned with the denser
rebonded fused grain material at the severe wear areas at the tuyeres, tapholes, skimming
ports and charges mouths. This zoning aids to improve the lining performance in these
areas but commonly the vessels must be taken out of service every 4-6 months for
maintenance. It has been shown in the past that wear mechanisms leading to severe joint
penetration at the skimming ports and significant spalling of the brick in the tuyere areas
are a result of copper oxide penetration and reaction.
Early trials of alumina-chrome monolithics and bricks containing 30% chromic oxide
have shown remarkable resistance to copper oxide slags. Chemical analysis and
microscopical examination of laboratory test samples and refractory products recovered
from the field illustrate that the matrix of the refractory rich in chromic reacts oxide with
the penetrating copper oxide slag to form a refractory reaction layer that prevents further
ingress of the slag.
This paper will summarize the actual results realized in the anode refining vessels
and develop an over-arching vision of the potential future benefits generally which could
very well accrue additionally in the primary smelting and converting production units

Pyrometallurgy

PY77

IMPURITY BEHAVIOUR DURING THE CONTINUOUS CONVERTING OF
COPPER MATTE IN A PACKED BED REACTOR

L. Voisin and J. Diaz
AMTC-DIMin, University of Chile
Advanced Mining Technology Center-Department of Mining Engineering
Av. Tupper 2007-2069,
Santiago Chile 837-0451
lvoisin@ing.uchile.cl

ABSTRACT
The Chilean mining is facing high and rising levels of arsenic and antimony
contents in copper sulphide ores and therefore their smelters have had to treat complex
concentrates rich in these impurities under stricter environmental regulations.
Concerning the study of the continuous converting of copper matte to Blister in a
packed bed reactor, the distribution of detrimental impurities of As, Sb, Pb and Zn were
investigated by experimental tests at laboratory scale at 1523K in relation to four variables;
matte grade, blast flow rate, oxygen enrichment into the blast and packed bed height.
The results indicated that the removal of impurities towards the slag and gas phases
is strongly dependent on oxygen enrichment and packed bed height. An increase of the
latter, contributes to prolong the residence time of the impurities improving contact with the
blast, while higher oxygen enrichment enhanced their oxidation and subsequent slagging
and volatilization. Compared to the conventional processes, As and Sb removals were
similar, whereas those for Pb and Zn were higher.

The study corresponds to the first reference of impurity behaviour in a packed bed
reactor and indicate a concrete and promising use of this novel technology as a replacement
to the traditional ones.
Pyrometallurgy

PY78

OXIDATION KINETIC OF COPPER MATTE DURING THE CONTINUOUS
CONVERTING PROCESS IN A PACKED BED REACTOR

J. Diaz and L. Voisin
Av. Tupper 2007-2069,

ABSTRACT
The increasingly stringent environmental requirements against the emission of
impurities and fugitive gases and the higher energy costs during the converting of copper
matte have encouraged the development of continuous and cheaper processes.

Thus, a new continuous converting process has been developed based on the
oxidation of copper matte with a countercurrent oxygen-enriched air blast into a packed bed
reactor. In this study, the oxidation kinetic of copper matte was investigated by
experimental tests at laboratory scale in relation to four variables; matte grade, blast flow
rate, oxygen enrichment into the blast and packed bed height.

Copper matte oxidation, in terms of desulfurization, follows a first order kinetic,
where the sulfur content into the Blister copper, [S], depends on the oxygen enrichment,
%O2, and the packed bed height [H]:

10.9H) ) 2.18Hln(%O (
0
2
e [S] [S]

Pyrometallurgy

A high oxidation kinetic was observed due to the increasing reaction area produced
by the higher dispersion of copper matte within the reactor, reporting a minimum
standardized desulfurization rate of 5.67x10-3 [mol/g/min], which corresponds to 4 times
of that in the conventional processes, besides, it was determined that the kinetic of the
reaction was controlled by the diffusion of the oxygen contained into the blast.

Pyrometallurgy

PY79

KINETIC AND MODELING OF CONTINUOUS COPPER REFINING IN A
PACKED BED REACTOR DURING THE REDUCTION STAGE

F. Mansilla and L. Voisin
Av. Tupper 2007-2069,

ABSTRACT
A novel technology was proposed by the Department of Mining Engineering of
University of Chile which consists in two cylindrical packed bed furnaces in cascade for
refining molten blister copper. The first furnace, containing a refractory packed bed has the
function of removing the sulfur until 25 [ppm] as SO2 using a countercurrent airflow, while
the second one, containing a coal or coke packed bed reduces the oxygen to around 1500
[ppm] as CO, CO2 and H2O(g). This technology is characterized by increasing the kinetics
of refining, decreasing the amount of fugitive combustion gas emissions and as a result
reduces both investment and operating costs compared with the traditional anodic furnace.
The purpose of the present work was to model this technology at a laboratory scale during
the reduction stage in order to obtain optimum parameters for future industrial furnace
designs.
The experimental tests were carried out in a laboratory scale electric furnace at
1473 K and the oxygen content in anodic copper was measured with a LECO analyzer.
Results allow visualizing the copper flow and oxygen concentration inside the crucible and
mainly confirm that is possible to achieve an anodic copper with oxygen values below 1500
[ppm].

Pyrometallurgy

PY80

Cu-Fe-Pb-As SYSTEM SATURATED WITH CARBON AT 1473 K

G. Damm and L. Voisin
Av. Tupper 2007-2069,

ABSTRACT

In order to develop a new pyrometallurgical process for eliminating detrimental
arsenic and recovering precious elements of silver, gold and platinum from arsenic-rich
copper-lead scraps the phase relations in the Cu-Fe-Pb-As system saturated with carbon and
the distribution of minor elements between the condensed phases generated during the
equilibrium at high temperature were studied. The investigation was carried out by
performing a series of laboratory scale experiments into an electrical furnace at 1473 K
follows by a quenching method on the final stage.

The samples obtained from the experiments were analyzed by using Inductively
Couple Plasma, ICP and Carbon Infrared Spectrometry, CIS techniques. The results were
discussed on the basis of the activity coefficient of arsenic and distribution parameters for
precious metals in the miscibility gap where three equilibrated alloy phases of lead-rich,
copper-rich and iron-rich coexist. It is expected that by using this phase separation
technique it might be feasible both, to recover some precious elements into the copper-rich
or lead-rich alloy phases and eliminate iron and arsenic into the iron-rich alloy phase,
which can be discarded as a harmless and smaller deposit.

Pyrometallurgy

PY81

Cu-Fe-Pb-Sb SYSTEM SATURATED WITH CARBON AT 1473 K

K. Mhlenbrock and L. Voisin
Av. Tupper 2007-2069,

ABSTRACT

In order to develop a new pyrometallurgical process for eliminating detrimental
antimony and recovering precious elements of silver, gold and platinum from arsenic-rich
copper-lead scraps the phase relations in the Cu-Fe-Pb-Sb system saturated with carbon and
the distribution of minor elements between the condensed phases generated during the
equilibrium at high temperature were studied. The investigation was carried out by
performing a series of laboratory scale experiments into an electrical furnace at 1473 K
follows by a quenching method on the final stage.

The samples obtained from the experiments were analyzed by using Inductively
Couple Plasma, ICP and Carbon Infrared Spectrometry, CIS techniques. The results were
discussed and compared with those obtained in a previous work related the Cu-Fe-Pb-As-C
system on the basis of the activity coefficient of antimony and distribution parameters for
precious metals in the miscibility gap where three equilibrated alloy phases of lead-rich,
copper-rich and iron-rich coexist. It is expected that by using this phase separation
technique it might be feasible both, to recover some precious elements into the copper-rich
or lead-rich alloy phases and eliminate iron and antimony into the iron-rich alloy phase,
which can be discarded as a harmless and smaller deposit.

Pyrometallurgy

PY82

THERMO-FLUID-DYNAMICS MODELING FOR CONTINUOUS CONVERTING
PROCESS OF COPPER MATTE IN PACKED BED REACTOR

E. Marambio and L. Voisin
Av. Tupper 2007-2069,

ABSTRACT

The conversion of copper matte to Blister, is a traditional and essential stage during
the production process of metallic copper from sulfide concentrates, however, higher
energy costs and environmental standards are becoming increasingly stringent regarding
fugitive gas emissions and impurities disposal, thereby, the development of continuous
processes with lower operational costs have been considered. Thus, the pyrometallurgical
group of University of Chile, ENAMI and Buildtek S.A. have been investigating and
developing a continuous process based on the oxidation of copper matte with a
countercurrent oxygen-enriched air blast into a packed bed reactor. This study considered
the elaboration of the Computational Thermo Fluid Dynamics, CTFD modeling based on
experimental laboratory scale results and the adjustment of transport phenomena equations
related to heat, mass and momentum behavior.

The modeling considers parameters such as oxygen concentration in copper, packed
bed height, diameter of the spherical refractory packed bed, etc., and will be developed and
simulated by using the software COMSOL Multiphysics. It is expected that the modeling
will be able to describe and predict the behavior at a laboratory scale of the proposed novel
technology of continuous converting in packed bed reactor providing the base for the
replacement of the traditional Peirce-Smith Converter.

Pyrometallurgy

PY83

CHARACTERIZATION AND FROTH FLOTATION OF
SMELTING FURNACE COPPER SLAG

L. Voisin, W. Kracht and G. Jeldres
Av. Tupper 2007-2069,

ABSTRACT
During the first stage of the pyrometallurgical production of molten copper a
smelting slag, contains from one to eight percent of both chemical and in trap copper
depending mainly on matte grade, is generated. In Chile, the treatment of this phase to
recover copper is widely performed in an electric or a fuel fired slag-cleaning furnace,
however higher energy costs and environmental problems related to the fugitive gas
emissions and the disposal of complex treated slag have increased, thereby, the study of
froth flotation for smelting complex copper slag with high content of impurities of arsenic
and antimony have been considered. The study considered to stages, the first one related to
the characterization of smelting slag, provided by four of the seven copper smelters located
in Chile, using optical microscopy, XRD, XRF, XPS and ICP techniques, and the second
stage concerning to investigate by experimental test the optimal froth flotation reagents and
conditions to maximize the recovery of copper. The results were compared with the
traditional treatment methods and will be generate a technical-economic assessment which
allows Chilean copper smelters to make the best decision regarding to the treatment of
smelting furnace copper slag.
Pyrometallurgy

PY85

MAXIMIZATION OF HEAT RECOVERY BY PRODUCING LOW PRESSURE
STEAM

Chang-Buhm Kim, Kyoung-Soo Jung, Hyung-Taek Chung
LS-Nikko Copper Inc.
148, Sanam-ro, Onsan-eup, Ulju-gun
Ulsan, 689-892, Korea
cbkim@lsnikko.com

ABSTRACT

All companies are facing global warming issues now. Copper business also cannot be
free from CO2 emission. Before taking into new and renewable energy, LS-Nikko is trying
to maximize waste heat recovery. By installing HRS system and new Waste Heat Boiler,
we have succeeded to reduce CO2 emission about 65,000 tons per year since 2004. From
2011, low pressure steam is generated in flash drum at Sulfuric acid No.1. It heats up
combustion air for flash smelting furnace and anode furnaces. At Plant No.2, modified HRS
preheater can warm up feed water to the waste heat boilers in both acid plant and smelter.
As the result, the CO2 emission has been decreased by 15,000 t/y additionally.

Pyrometallurgy

PY86

COPPER DISSOLUTION IN THE FEO
X
-SIO
2
BASE SLAG OF THE FLASH
SMELTING FURNACE AND THE TENIENTE CONVERTER AT THE
CHUQUICAMATA SMELTER

J. Font, A. Moyano
Codelco Chile, Chuquicamata Smelter & Division
Av. Once Norte 1291, Villa Extica Calama, Chile
jfont@codelco.cl

K. Itagaki
Emeritus Professor, Tohoku University
Sendai, Japan

ABSTRACT
It is well known that at a given matte grade the solubility of copper in the slag is
independent of pSO
2
in both smelting units of the Chuquicamata smelter, namely the Flash
Smelting Furnace (FSF) and the Teniente Converter (TC), and depend mainly on the
oxygen potential or matte grade. The metallic forms of copper content in the same slags
depend indirectly on the oxygen potential by affecting the slags chemical compositions
which influence the slags viscosities. For instance, in the FeO
X
-SiO
2
slag saturated with
SiO
2
which is the base slag for both smelting units, the Fe
3
O
4
content in the FSF slag has
lower values than that of the TC slag, and this difference affects directly the total copper
content in the FeO
X
-SiO
2
base slag.

Thus, as an update contribution to the understanding of oxygen-blowing of copper matte
smelting, the copper solubility between the FeO
X
-SiO
2
base slag and the Cu
2
S-FeS matte
will be discussed in the Flash Smelting Furnace and the Teniente Converter.
Pyrometallurgy

PY87

IMPROVEMENT TECHNOLOGY OF VANYUKOV SMELTING

Kozhakhmetov S., Kvyatkovskiy S., Abisheva Z.,
Bekenov M.,KamirdinovG., Semenova A.
Center of Earth Sciences, Metallurgy and Ore Beneficiation,
Almaty, Republic of Kazakhstan; kvyatkovskiy55@mail.ru

ABSTRACT
Today pyrometallurgy is the most widely applied industrial practice of copper
recovery in Kazakhstan. More than one half copper in Kasakhstan is produced by
Vanyukov smelting. Ores occurred in Kazakhstandiffer for their varied compositions.
Moreover, high contents of zinc, lead and arsenic sulfides while low contents of iron sulfide
in copper concentrates shall be noted. Reduced concentrations of iron sulfides lead to
shifting heat balance of autogenous smelting process that requires increased extent of
desulfuration which, in its turn, results in changed slag compositions,altered mechanical
propertiesand increased copper losses. One of the ways to solve this problem could be
using additional fuel; other way is increasing oxygen content in blowing gas mix.
We managed to enhance matte and slag removingthrough supply of additional fuel by
special designed burners, oxygen-enriched blowing to 95%, decreasedmagnetite content in
slag and so on.

Pyrometallurgy

PY89

LATEST DEVELOPMENT OF OXYGEN BOTTOM-BLOWING COPPER
SMELTING TECHNOLOGY

Yan Jie
NO. 12 Fuxing Avenue, Haidian Disctrict,
Beijing, China 100038
yanj@enfi.com.cn

ABSTRACT

The Oxygen Bottom-blowing Copper Smelting Technology is a new copper smelting
process developed by China ENFI Engineering Corporation. This paper describes the
characteristics of this technology, summarizes production of the oxygen bottom-blown
smelting furnace, analyzes problems occurring in the production and proposes
countermeasures for coping with these problems. The paper also discusses the future
development orientation of the oxygen bottom-blowing copper smelting technology. By
continuous exploring, development and improvement, advantages and potentiality of the
technology will be brought into full play.
Pyrometallurgy

PY90

DEVELOPMENT OF COPPER/GOLD SULFIDE CONCENTRATES
PYROMETALLURGICAL PROCESS

Li Feng
NO. 12 Fuxing Avenue, Haidian Disctrict,
Beijing, China 100038
lif@enfi.com.cn

ABSTRACT

This paper introduces the development orientation of Matte Making for Au/Ag
Recovery technology, with the reference to the status-quo of technologies adopted in gold
smelters. It focuses on the characteristics of the different processes for copper smelting and
converting which involves Matte makting for Au/Ag Recovery, describes in particular
the development of Continuous Bottom-blowing Cu Smelting Technology, coming to the
conclusion that copper continuous smelting technology has become the trend for Greenfield
or Brownfield copper/gold smelters.

Pyrometallurgy

PY91

INDUSTRIAL TEST DEVELOPMENT OF CONTINUOUS BOTTOM BLOWN
OXYGEN COPPER SMELTING PROCESS

Zhixiang Cui, Zhi Wang, Juntao Zheng, Ruimin Li
Dongying Fangyuan Nonferrous Metals Co., Ltd,
No 99 of Liuyanghe Road, Economic Developments Zone,
Dongying City, Shandong Province, China
wangzhi7612126@sohu.com

ABSTRACT

The paper describes the continuous bottom blown oxygen Copper smelting process.
Based on this process, tests were carried out processing both cool and steamed high grade
matte with different processes to research the effects of different devices, slag type,
blowing intensity, oxygen level and blowing smelting end to the indexes of converting
blister; also the lances arrangement and life and the refractory lining validity was
researched. The series of tests empowered us to develop the continuous Copper smelting
process and devices and finally realized producing anode Copper directly with continuous
converting reactor.

Pyrometallurgy

PY92

NEW DEVELOPMENT OF BOTTOM BLOWN OXYGEN SMELTING
TECHNOLOGY IN DONGYING FANGYUAN
NONFERROUS METALS CO. LTD

Zhixiang Cui, Zhi Wang, Ruimin Li
Dongying Fangyuan Nonferrous Metals Co., Ltd,
No 99 of Liuyanghe Road, Economic Developments Zone,
Dongying City, Shandong Province, China
wangzhi7612126@sohu.com

ABSTRACT

Bottom blown oxygen smelting process was successfully industrialized in
Dongying Fangyuan Nonferrous Metals Co., Ltd. in 2008. By continuous technical
innovation and process upgrade during the last 4 years, new breakthroughs have been
achieved one after another and the energy consumption has been lower and lower.
Even though, we can guarantee sound smelting effect, i.e. the matte concentration is
over 73% while the copper content in slag is 2-3%. Meanwhile we have developed a
series of new technologies respecting to it including processing high impurity anode
plate, processing the fume dust in heavy metals smelting, waste acid processing
technology and comprehensive recovery technology of the value elements.
Environmental copper smelting and low-carbon production have been finally realized.

Pyrometallurgy

PY95

DESIGN OF A HEAT RECOVERY COOLING CHAMBER SYSTEM FOR
COPPER SMELTERS

L.A. Campos, D.E. Wimmer and F.J. Gonzlez
Coprim Ingeniera S.A., Chile

ABSTRACT
According to growing need to reduce operating costs and minimize the use of
limited resources as water, Coprim has designed a heat recovery cooling chamber, which
seeks reuse or replace the existing radiative or evaporative cooling chambers and transform
them into equipment that is capable of capturing and transferring the absorbed heat, without
altering the foot-print of these.
The design is based on the modification of existing cooling chambers inserting into
them a heat exchanger composed internally by cooled panels with thermal oil which
operates in a closed circuit. It is pumped from a storage tank to a power generating plant.
The chamber considers a refrigerated pre-chamber, located with the purpose of decrease the
dust burden incoming into the heat transfer zone (panels). Panels are located parallel to
each other inside the chamber, where the flow of metallurgical gas is cooled. The thermal
oil flows counter-flow with the gas flow, increasing the heat transfer efficiency. The design
allows an easy maintenance and replacement of panels.
The metallurgical gas has thermal energy which can be transformed into electric
power with at least 15% of efficiency. This design minimize the investment level and
implementation time.

Pyrometallurgy

PY96

COMPARATIVE ANALYSIS OF PYROMETALLURGICAL METHODS
FOR PROCESSING OF SULFIDE COPPER CONCENTRATION
FROM UDOCAN DEPOSIT

L.B. Tsymbulov, A.B. Portov, I.V. Tereshchenko and L.Sh. Tsemekhman
LLC Gipronickel Institute, OJSC MMC Norilsk Nickel
11 Grazhdansky Prospect, Saint-Petersburg, 195220, Russia
Lbcym@nickel.spb.ru

D.A. Lapshin
LLC Baikalskaya Mining Company
28 Rublevskoe Highway, Moscow, 121609, Russia

ABSTARCT

In the nearest future development of Udokan deposit on of the world largest
deposits of complex oxide-sulfide copper ores, located in the Chita oblast of Russia - will
be started. The characteristic feature of copper sulfide concentrates, produced after ore
concentration, has low Fe content in the concentrate (3-4 wt.%) with high grade of silicon
oxide (35-45 wt.%). In this work two methods of pyrometallurgical processing are studied:
- smelting with blister copper production in a two-zone Vaniukovs furnace;
- concentrate roasting in a fluidized bed furnace followed by cinder reduction
smelting in a direct current furnace.

There are presented results of laboratory scale and enhanced laboratory
investigations. Comparative analysis of the proposed technological flow-sheets are
performed, their merits and demerits are discussed.

Pyrometallurgy

PY97

OPTIMAL SLAG COMPOSITION FOR PROCESSING OF COPPER NICKEL
MATTES AND CONCENTRATES IN A VANIUKOV TWO-ZONE CONVERTER
THAT PRODUCES BLISTER COPPER

L.B. Tsymbulov and S.P. Pigarev
LLC Gipronickel Institute, OJSC MMC Norilsk Nickel
11 Grazhdansky Prospect, Saint-Petersburg, 195220, Russia
Lbcym@nickel.spb.ru

F. Kongoli, I. McBow
FLOGEN Technologies Inc.
1255 Laird Blvd., Ste.388
Mont-Royal, Quebec Canada H3P 2T1

E.N. Selivanov, V.M. Chumarev
Institute of Metallurgy UrO RAN
101 Amundsena Street, Ekaterinburg, 620016, Russia

ABSTARCT

The Gipronickel Institute in cooperation with the Canadian company Flogen
Technologies Inc. and the Ural Institute of Metallurgy has developed a new technology for
processing of copper nickel mattes and concentrates in a Vaniukov two-zone converter that
produces blister copper. The slags formed in this process lies within a multi-component
Cu
2
O-NiO-FeO
x
-SiO
2
-CaO-Al
2
O
3
system. One of the most important technological tasks in
a new pyrometallurgical process development is the optimal slag composition choice. The
work presents the optimal slag composition for this process based on the study of their
structure and characteristic features.

Pyrometallurgy

PY98

ARSENIC REMOVAL FROM BLISTER COPPER USING MOLTEN SODIUM
AND CALCIUM SULPHATES

P.Coursol and N.Stubina
Barrick Gold Corporation
161 Bay Street suite 3700
Toronto, Ontario, Canada, M5J 2S1
pcoursol@barrick.com

P.J.Mackey
Mackey Technology Inc.,
Kirkland, QC, Canada, H9J 1P7

M. Zamalloa
Koniambo Nickel SA,
New Caledonia

ABSTRACT

New mineral deposits found nowadays are generally of lower grade and of
increasing complexity compared to those seen in earlier times. In the case of copper,
arsenic is one important impurity element often associated with the newer, complex copper
ores. Some 10 years ago, the present authors were involved in the development of a novel
technology using molten calcium/sodium sulfate salts for the removal of arsenic from
blister copper. Using appropriate flux proportions, more than 90% arsenic elimination
could be obtained while both minimizing slag production and the copper level in the
refining slag. In light of renewed interest in the treatment of copper concentrates containing
arsenic, this paper re-examines this process.

Advanced thermodynamic models are used to generate process maps showing the
impact of slag composition and oxygen content in copper on the equilibrium level of
arsenic in the fire-refined copper. The modeling results are also compared with available
published data showing that the process operates under conditions having extremely rapid
reaction kinetics. Finally, limitations for utilizing this type of salt in modern smelters
including the refining furnace heat balance, reagent cost and availability are discussed.
With increasing arsenic content in copper concentrates and with stricter environmental
regulations in the copper industry, this process is considered to be superior to conventional
fire refining practices using soda for arsenic removal.
Pyrometallurgy

PY99

ON THE POSSIBILITY OF USING HIGH OXYGEN ENRICHMENT IN
TENIENTE CONVERTERS

M. Rosales-Vera, O. Saavedra, H. Jara, R. Fuentes
Instituto De Innovacion En Mineria Y Metalurgia- Im2

A. Moyano, J. Font, R. Mackay
Codelco Chile

ABSTRACT

The increasing competitivity and specific capacity of the Teniente Converter
Reactor is a strategic issue for the future competitivity of the Codelco-Chile smelters.
Due to this, several conceptual studies were developed to phenomenologically
establish the factors governing and limitating the reactor smelting capacity.
The use of high levels of oxygen enrichment in the air flow through tuyeres in the
Teniente Converter, historically was associated with refactary wear in the tuyeres line. In
this paper we analyze theoretically, the possibility of using air blast with high levels of
oxygen enrichment. The paper shows that high levels of oxygen enrichment not necessarily
implies damage to the refractory and tuyeres line and with a good control of the bath
temperature in the reactor, the oxygen enrichment can be increased over the usual levels.

Pyrometallurgy

PY101

COPPER LOSSES CONTROL IN FLASH SMELTING SLAG AT
CHUQUICAMATA SMELTER

G. Wastavino, C. Pizarro
instituto de innovacion en mineria y metalurgia- im2

A.Moyano, J. Font
codelco norte

ABSTRACT
In order to accomplish the concentrate composition changes which are being
feeding to the smelting unit, specially the Flash furnace, the Chuquicamata Smelter has
during 2010 carried out a campaign of industrial tests to process this eventually new
concentrates, which are featured by its low calorific value (low pyrite content) and high
level of gangue material.

The aim of the industrial test was to evaluate the use of a fayalite-type slag shifting
slightly to the olivine-type slag. The traditional use of the fayalite-type slag to treat this
type of concentrates normally generates a sharp increase in the slag viscosity which
increases the copper losses, allow foaming phenomena and other kinds of operational
nature problems.

The slight addition of limestone flux along the silica flux increases the CaO content
in the slag in the range of 2.5 to 5%, changing the physical properties of the slag and allows
the efficiently smelting of this kind of concentrates, which is featured mainly by its low
pyrite content of 18% against the traditional levels of 27% (FeS2) and by its high gangue
material content of 14% against the standard value of 9%. Thus, the industrial tests results
shows an average copper content in the slag of less than 1.5% for a CaO content of 2.5%.
Additionally, for a CaO content of about 3%, the slag showed a significant decrement in the
distribution of the arsenic toward the matte phase, and also lower copper losses at the matte
grade of 62% Cu. Therefore, for treating concentrates with low pyrite content and high
gangue levels, the use of this olivine type of slag has been evaluated to be an interesting
operational option.

Pyrometallurgy

PY103

CONTROLLING SO
3
FORMATION IN THE OFF-GASES PROCESS FROM THE
ISASMELT
TM
FURNACE AT SOUTHERN PERU ILO SMELTER

Enrique Herrera and Leopoldo Mariscal
southern peru
Fundicin Ilo, Punta Tablones S/N
Ilo, Peru
eherrera@southernperu.com.pe / lmariscal@southernperu.com.pe

ABSTRACT

The Ilo Copper Smelter operates from 2007 mainly with an ISASMELT
TM
furnace as
a single smelting unit (1,200,000 tpy of copper concentrates), four PS converters (two
blowing), and two acid plants.

Excessive sulfur trioxide (SO
3
) concentration in the off-gas process of the smelting
furnace generates corrosion problems in the subsequent gas line and affects the weak acid
treatment of the acid plants. This paper describes the modifications and improvements
carried out at the controlling SO
3
formation.

Pyrometallurgy

PY104

SERVICE LIVE INCREASE OF TSL LANCES, USING IONIC LIQUID COOLING
TECHNOLOGY

Stefan Konetschnik, Andreas Filzwieser and Iris Filzwieser
METTOP GmbH, Peter-Tunner-Strasse 4, 8700 Leoben, Austria

ABSTRACT

TSL reactors are state-of-the-art vessels for the primary and secondary nonferrous
industry. Although the efficiency of smelting and metallurgical reactions is excellent in
these furnaces, the uptime is rather low due to the necessity of replacing the consumed
lance tip regularly.

Basic of the presented approach is a modified and cooled lance tip. The cooling
intensity is set in order to form a so called freeze lining, much more distinctive than in the
case of conventional lances. However, a water cooled lance would result in an
insurmountable safety risk as a leakage and breakthrough cannot be completely excluded.

A combination with METTOPs Ionic Liquid Cooling Technology (ILTEC) leads
to a revolutionary solution for the metallurgical industry: The possibility of cooling TSL
lance tips without the risk of introducing water below bath level. The cooling medium will
not react with liquid metal or slag it decomposes above a certain temperature under
formation of gaseous components.
Pyrometallurgy

PY105

AN UPDATE ON KENNECOTT UTAH COPPERS USE OF PRAXAIRS
COHERENT JET TECHNOLOGY IN ANODE REFINING DEVELOPMENTS
SINCE 2010

Arsenio (Jun) Enriquez, Colin Nexhip, David Krippner, Kyle Wright, Rio Tinto
Kennecott Utah Copper LLC
12000 West 2100 South
Magna, UT, USA

Adrian Deneys, Yi Ma, Steve Manley
Praxair, Inc.
2430 Camino Ramon
San Ramon, CA, USA

ABSTRACT
Rio Tinto through its subsidiary Kennecott Utah Copper (KUC) installed Praxairs
Coherent Jet (CoJet) system in 2007 to increase scrap melting in one Anode Furnace.
Based on positive results, the CoJet system was further integrated in both Anode Furnaces
early 2013 with the installation of a diverter valve system. A temperature measurement
system is under development to provide better copper temperature control to maintain
furnace integrity. Two additional developments on lance and jet performance were also
investigated. Further research and development initiatives using the CoJet technology in the
Flash Smelting process for cleaning slag are also underway. This paper discusses the
attributes of the CoJet system in the Anode Furnace process and other future developments.
Pyrometallurgy

PY106

AUTOMATIC SCHEDULING OF ALTONORTE OPERATIONS
USING GREEDY ALGORITHMS

Alessandro Navarra
Universidad Catlica del Norte
0610 Angamos, Antofagasta, Chile
anavarra@ucn.cl

Oscar Mendoza
Altonorte Smelter, Xstrata Copper
Panamericana Norte Km 1348, Antofagasta, Chile
omendoza@xstratacopper.com

ABSTRACT
Algorithms have been implemented at the Altonorte Smelter (Northern Chile), to
automatically schedule daily production. The resulting schedules respect all of the
operational constraints, including maintenance plans and furnace productivity, as well as
the availability of converters, offgas treatment, fire refining and casting. The algorithms
are classified formally as greedy, following the terminology from computer science.
Schedule automation is the first step toward advanced optimization techniques.

Pyrometallurgy

Copper 2013
Novel Methodology for Quantifying Fugitive SO2 Emissions 1 of 1
PY134

A NOVEL METHOD FOR QUANTIFYING SMELTER SO
2
FUGITIVE
EMISSIONS USING AN OPEN PATH FOURIER TRANSFORMS INFRARED
(FTIR) ANALYSER

Gert Erasmus, Arne Weissenberger
Hatch (Pty) Limited
Johannesburg, South Africa

ABSTRACT

Hatch developed a novel in-situ sampling method for measuring SO
2
fugitive
emissions from uncontrolled buoyant plumes of varying sizes, concentrations and
flowrates. The test procedure uses an Open Path Fourier Transforms Infrared (FTIR)
analyser which is able to count SO
2
molecules along its reflected beam path, which
therefore allows calculation of average SO
2
concentration across the emission plumes.
Continuous plume videography was used in conjunction to record gas volumetric
flow with time. The data was correlated to develop actual continuous SO
2
fugitive
emission mass flowrates for specific smelter events and operations. As a result,
quantitative emission factors were developed for furnace and converter operations which
Hatch now applies to predict fugitive emissions generated at similar smelting facilities.

Pyrometallurgy

PY135

OBSERVATIONS ON THE REDUCTIVE PYRO DE-ARSENIFICATION OF
ENARGITE.

Thomas Zabev
Process Research ORTECH

Gus Van Weert
Oretome Limited

Pascal Coursol
Barrick Gold

ABSTRACT

This paper discusses the removal of sulphur and arsenic directly from enargite
bearing concentrates by pyro-decomposition in a variety of gaseous atmospheres, including
vacuum, to yield a low volume of disposable arsenic/ sulphur mixture. Experimental results
are presented for various process routes.
Treatment in a N2 gas flushed reactor of a 4:1 enargite/ metallic iron charge at 700
0
C consistently transformed enargite into bornite and chalcopyrite with less than 0.1% As
in the product.

Pyrometallurgy

PY136

FORTY YEARS OF OPERATION OF THE NORANDA REACTOR PROCESS

Y. Prvost, C. Levac
Xstrata Copper, Horne Smelter, Rouyn-Noranda, Qubec, Canada
prevosty@xstratacopper.ca

ABSTRACT

The Noranda Continuous Smelting Process at Xstratas Horne Smelter was
commissioned in March 1973. Since then, it has evolved to follow the trends of feed
complexity, material recycling and international competition.

Process control was improved, new auxiliary equipments were tested, and blowing
enrichment was increased. This paper presents an overview of the main Noranda Reactor
improvements that have occurred since its commissioning and the effect they had on the
capacity and control of the vessel.

Pyrometallurgy

PY137

PHENOMENOLOGY OF COPPER MATTE CONTINUOUS CONVERTING IN A
PACKED BED

A.Warczok, G. Riveros and L. Voisin
Departamento Ingenieria de Minas
Av. Tupper 2069
Santiago, Chile
awarczok@bell.net

ABSTRACT

The new technology of continuous copper converting, developed by Universidad de
Chile with ENAMI, generates a series of questions about the mechanisms of a liquid copper
matte oxidation, formation of the slag, affecting the rate and efficiency of converting
process.

The CFD, mass and heat transfer modeling together with detailed analysis of
phenomena taking place at the copper matte/gas , matte/slag , slag/gas and blister
copper/gas interfaces allowed for determination of key factors affecting the rate of
oxidation. The process requires specific self-melting fluxes being able to infiltrate the
porosity of ceramic, packed bed and dissolve iron oxides as the product of oxidation,
forming the slag, which properties permit for the flow inside the bed, separation from
blister copper and continuous tapping out.

It was found that the rate of sulphides oxidation is controlled by mass transfer and
formation of iron oxide film separating sulphides and oxygen containing gas phase.
Therefore, slag formation affects the rate of iron sulphide oxidation
Pyrometallurgy

PY138

A MASS TRANSFER MODEL FOR MOLTEN COPPER DEOXIDATION

L. Daz, F. Reyes and A. Ingalls
Depto. de Ingeniera Qumica Metalrgica
Facultad de Qumica, Edificio D, UNAM
Circuito de la Investigacin Cientfica s/n
Mxico,04510 D.F., Mxico

A. Almaraz and G. Plascencia
CIITEC IPN
Cerrada Cecati s/n
Mxico, 02250 D.F.,Mxico
g.plascencia@utoronto.ca

ABSTRACT
The final refining step in copper making is fire refining. Fire refining consists of
several stages, but the most important are oxidation and reduction. These operations results
from the interaction between an injected gas and the melt. In this paper, we present a mass
transfer model that represents the reduction stage.
It has been found that two mechanisms control the deoxidation of copper: i)
Transport of the reducing gas from the gas bubbles towards the melt/bubble interface and
ii) Transport of dissolved oxygen from the melt towards the melt/bubble interface. The
former occurs in the early stages of deoxidation, while the latter controls towards the end of
the reduction of copper. Fluid flow of the gases in the refining furnace has a strong effect
on the dissolved oxygen transport.
Pyrometallurgy

PY139

DUST EXPLOSIONS AT THE CHAGRES SMELTER DUE TO SPONTANEOUS
SELF-HEATING OF DRIED COPPER CONCENTRATES

M. Gous, B. Martinich and P.A. Reyes
ANGLO AMERICAN SUR
Chagres Smelter
Av. Pedro de Valdivia 291
Santiago, Chile CP 7500524
mia.gous@angloamerican.com

R.A. Parra
Metallurgical Department
Edmundo Larenas 285
Concepcin, Chile

ABSTRACT

During the latter part of 2012 and the early months of 2013, the Chagres Copper
Smelter has experienced several incidents, varying in intensity, of self-heating of the dried
concentrate feed in the flash furnace feed bin. These events lead to small fires in the feed
transport, air circulation and concentrate storage systems and in the worst cases, dust
explosion incidents within the dry concentrate feed bin.

Self-heating is a term that defines spontaneous heating of sulphide concentrates under
certain moisture and oxygen conditions. No external heat source is required. These types
of events are not uncommon to copper smelters, although it was the first series of events of
this magnitude experienced at Chagres in more than 50 years of operation.

An investigation was launched to identify which of the concentrate characteristics had
substantially changed to activate the self-heating reaction and special conditions that can
promote explosions. This investigation has allowed the identification of the required
remedial actions to ensure safe, continued high performance operation of the smelter.
Pyrometallurgy

PY140
APPLICATION OF MPE MODEL TO DIRECT-TO-BLISTER FLASH SMELTING
AND DEPORTMENT OF MINOR ELEMENTS

Chunlin Chen, Ling Zhang
CSIRO Process Science & Engineering

Sharif Jahanshahi
CSIRO Minerals Down Under Flagship
Box 312, Clayton South, Victoria, 3169, Australia
Chunlin.Chen@csiro.au

ABSTRACT

Copper losses in slag vary from process to process during pyrometallurgical
production of copper, depending on the slag chemistry and operating conditions. Minimize
copper losses is one of major focuses in considering the optimal operating condition for
copper smelting/converting processes. At the same time, the deportment of minor elements
between various phases during copper smelting is of great interest by the smelters. This
interest is driven by the gradual depletion of high-grade ore with low levels of minor
elements such as arsenic, the requirements to manage the emission of toxic elements to the
biosphere, and a growing need to produce high-purity saleable products.

The Multi-Phase Equilibrium (MPE) is a thermodynamic package developed by
CSIRO for simulating reactions between phases in multi-component and multi-phase
systems. Over the years the capability of the MPE model has been extended to cover the
behavior of a large number of elements in high temperature system. The sulphide smelting
module of the MPE, which covers the minor elements such as As, Bi, Sb, Pb, Se, Te, Sn,
Co and Zn, is capable of modeling the deportment of major and minor elements between
various phases during the smelting of complex ores/concentrates.

In the present paper validation of the MPE model and databases against published
experimental data on multi-component and multiphase systems are presented. Results
obtained from application of the model in predicting the copper losses in slag, direct
recovery of copper to blister in direct-to-blister smelting process, as well as the arsenic
deportment between matte, slag and gas phases of various commercial copper smelting
processes will be presented. These results should allow process metallurgists in developing
practices for improved management of copper losses and minor elements during smelting
of feed materials.
Pyrometallurgy

PY141

CHARACTERIZATION METHODOLOGY FOR CU-DROPLET LOSSES IN
SLAGS

Evelien De Wilde, Stephanie Vervynckt, Mieke Campforts, Kim Vanmeensel, Nele
Moelans, Kim Verbeken

ABSTRACT

In order to have an efficient Cu-smelting process, metal losses in the slag need to be
minimized. A major cause of metal losses is the entrainment of metal droplets in the slag.
One important factor for mechanically entrained metal droplets in slags is their attachment
to solid spinel particles, which are also present in the slag phase. Consequently, these
particles hinder the settling of the metal droplets. In order to improve phase separation it is
important to identify the fundamental mechanisms governing this attachment.

Two complementary methodologies have been developed to study the tendency of
metal droplets to attach to solid particles. In one methodology, the interaction between Cu-
alloys and spinel particles is studied by high temperature contact angle measurements. In
the other, the entrainment is studied using a simplified synthetic PbO based slag (PbO-
CaO-SiO2-Cu2O-FeO-ZnO) containing solid spinel particles.
Pyrometallurgy

PY143

CONTROL STRATEGY FOR REDUCING COPPER LOSS FROM MITSUBISHI
PROCESS

Bhavin Desai and Biswajit Basu
Aditya Birla Science & Technology Company Ltd.
Plot No. 1 & 1-A/1, MIDC Taloja, Taluka Panvel, Dist. Raigad 410208
Maharashtra, India
bhavin.desai@adityabirla.com

Dilip Gaur, Kaushik Vakil and Anil Singh
Hindalco Birla Copper
Po: Dahej, District Bharuch 392130
Gujarat, India.

ABSTRACT

The Mitsubishi process at Hindalco Birla Copper has been in operation now for
more than 5 years and this mature process has attained a high level of performance. Owing
to the degradation in concentrate grade, the copper loss from the discarded slag was above
the upper specification limit. From an industry perspective there is an ongoing need to
adequately describe the phase chemistry of slag systems in order to optimize process
performance and thus minimize copper loss.

The selection of the optimum process conditions in this work has been greatly
assisted by the use of a chemical thermodynamic model of the system. A new control
strategy with respect to the determination of optimum slag chemistry and temperature has
been developed to minimize the copper loss to below the upper specification limit
consistently. The strategy is based on thermodynamic modeling using phase diagram
concept and concentrate mineralogy. A new control strategy comprises determining the slag
liquidus and slag viscosity from the known operating parameters such as slag chemistry,
temperature and oxygen potential, and providing a safe operating window with respect to
the slag chemistry and the temperature. The new strategy along with improved plant
practice has resulted in copper loss in slag to below upper specification limit.

Pyrometallurgy

PY144
IN PURSUIT OF IMPROVED FLASH-SMELTING BURNER PERFORMANCE

M. U. Jastrzebski, A. Lamoureux, T. Gonzales, R. Veenstra
Hatch
2800 Speakman Dr.
Mississauga, Canada L5K 2R7
mjastrzebski@hatch.ca

ABSTRACT

Inefficient combustion has been shown to be the principal cause of a number of
operational problems in Outokumpu flash smelting. A considerable volume of
computational fluid dynamics (CFD) and physical study results have been published on
particular problems; however, more general investigations of the behavior of the flash
smelting process have been rare. A review of a number of modeling studies and plant-
driven practical burner improvement studies published to date has identified important
parameters that affect performance.
These have been further investigated using a burner geometry independent CFD
model of the flash-smelting process taking place in a hypothetical reaction shaft. The study
confirms that high oxygen enrichment and velocity control are strong levers in controlling
dust rates and combustion efficiency, while burner diameter and combustion gas / feed
injection angle are aspects of design with a strong impact on performance.

Pyrometallurgy

PY145

APPLICATION OF ROTATION-SUSPENSION SMELTING PROCESS AND
PULSE CYCLONE BURNER IN XIANGGUANG COPPER

Songlin Zhou
Vice President
Xiangguang Copper Co., Ltd
No.1 Xiangguang Road
Shifo Town, Yanggu County, 252327, China

ABSTRACT

This paper introduces the principle of rotation-suspension copper smelting process,
feature of pulse cyclone burner and their production application. Professor Songlin Zhou of
Xiangguang Copper puts forward a reaction mechanism of particle collision for smelting
intensification and develops rotation-suspension copper smelting process and pulse cyclone
burner on the basis of this mechanism, and has successfully applied to smelting and
converting furnaces in Xiangguang Copper.

Four years practice indicates: pulse cyclone burner has some advantages-big
production capacity, complete reaction, stable furnace running, high availability, low flue
dust, high thermal load, less wear of reaction shaft wall and etc. Thanks to these
advantages, maximum feed volume is 400t/h, availability rate is 98%, flue dust rate is 4%
and thermal load is 3000 MJ/m
3
.h.

Pyrometallurgy

PY146

APPLICATION OF SPECIALIZED NON-DESTRUCTIVE TESTING
(NDT) FOR OPERATING COPPER PROCESS VESSELS

Afshin Sadri, Wai Lai Ying and Pawel Gebski

ABSTRACT

Monitoring refractory condition in process vessels allows plant owners and
operators to proactively identify problem areas in the linings. Short and long term
maintenance planning can then be implemented to prolong vessel campaign life and
minimize the possibility of catastrophic failures such as molten metal run-outs. The
refractory lining of copper process vessels such as flash and slag cleaning furnaces,
reactors, converters, and absorption acid towers is known to ultimately fail, resulting in a
shorter campaign life. Refractory wear, refractory hydration, refractory lining failure, and
hearth lifting are well known failure mechanisms of process vessels.

In this paper specialized Non-Destructive Testing (NDT) techniques available for
monitoring operating copper process vessels will be discussed. We will demonstrate how
the application of such techniques has been used to identify deterioration, ultimately
allowing plant owners and operators to prolong the service life of process vessels through
proactive maintenance planning and action.

Pyrometallurgy

PY147
DEVELOPMENT PLAN CALETONES SMELTER

G. Richter P.
C. Carrasco O.
Smelter Engineering Superintendent - Codelco-Chile

ABSTRACT

With the aim of improving the environmental standards and competitiveness of
Caletones Smelters, been conceptualized in a development plan that considers increase
melting concentrate capacity from 1,4 Mt to 1,75 Mt, and increase sulfur and arsenic
capture.

This Plan includes three phases; The 1
er
Optimization to 1,45 Mt/y, 2
do
Increase sulfur
and arsenic capture, and 3
er
Increase melting concentrate capacity to 1,75 Mt/y. Major
projects to be implemented are:

New casting wheel Twin M-16
Increase conversion white metal
Replacement slag cleaning process for flotation plant
Reduction emission actual acid plant
New smelting reactor
New hood reactors and handling gas modification
New acid plant

The main results are projected:
Pyrometallurgy

Caletones Smelter Scenarios
Indicators Units Base Optimization Development
Smelter Capacities Kta 1.400 1.450 1.750
Sulfur / Arsenic Capture % 94 / 91 96,5 / 96 96,5 / 96
Metallurgical Recovery % 97,6 98,1 98,1
Operation Cost US$c/lb 27,0 26,0 22,9
Productivities t/h-y 612 612 754

This paper summarizes the projects to be undertaken, constructive and interference.
Pyrometallurgy

PY148

THE SAVARD-LEE SHROUDED INJECTOR: A REVIEW OF ITS ADOPTION
AND ADAPTATION FROM FERROUS TO NON-FERROUS
PYROMETALLURGY

J.P. Kapusta
BBA Inc.
630, Ren-Lvesque Blvd. West, Suite 1900
Montral, Qubec, Canada H3B 4V5
Joel.Kapusta@bba.ca

Robert G.H. Lee
Air Liquide Canada (Retired)
Calgary, Alberta, Canada

ABSTRACT

Pyrometallurgical processes for iron and base metals present major similarities since
they occur at high temperatures and in molten state. Pyrometallurgists, therefore, have long
believed that some technologies from ferrous metallurgy could be beneficially adapted (and
transferred) to non-ferrous metallurgy, and vice versa. The Savard-Lee shrouded injector is
one such technology. Developed for steelmaking, the concept has inspired non-ferrous
pyrometallurgists for decades and is now receiving renewed interest in light of recent
commercial successes in high intensity smelting, particularly in Asia. This paper provides a
review of key non-ferrous pyrometallurgical processes that have innovatively adapted and
implemented the shrouded injector concept. Such processes include bath smelting of lead
and copper (QSL, SKS), bath converting of copper and nickel (Hoboken and SMC with
ALSI Technology, SKS), copper pyro-refining (O
2
/N
2
/H
2
injectors) and lead-silver
cupellation (BBOC). The authors highlight how the injector was adapted from its original
steel refining design for oxygen bottom metallurgy (OBM) into new designs for non-
ferrous applications. The authors also offer their views on the future of bath smelting and
converting with high oxygen submerged injection, especially at times when energy
conservation and efficiency, lower quality concentrate, and environmental footprint
awareness are at the forefront of the industry preoccupations.
Pyrometallurgy

PY149

DEBOTTLENECKING AND OPTIMISATION OF COPPER SMELTERS
LEVERAGING SIMULATION

A P Campbell
WorleyParsons
PO Box 7637
Cloisters Square Perth WA 6850 Australia
andrew.campbell@worleyparsons.com

M Reed
WorleyParsons
Level 12 115 Grenfell Street
Adelaide SA 5000 Australia
michael.meed@WorleyParsons.com

A E M Warner

WorleyParsons
2645 Skymark Avenue
Mississauga, Ontario, L4W 4H2 Canada
tony.warner@WorleyParsons.com

ABSTRACT
WorleyParsons has used Discrete Event Simulation (DES) methods in conjunction
with more traditional process models to assess the performance of copper smelting
operations. The DES model allows for a more complete and realistic picture of an operation
to be developed based on the plant capacities and accounting for breakdowns and
shutdowns. This paper outlines methods used to identify the opportunities to de-constrain
existing operations and demonstrate that other constraints will not impact the overall
improvement to the production. Examples of aisle and typical smelting operations are
covered.

Pyrometallurgy

PY150

POTRERILLOS SMELTER CURRENT AND FUTURE CHALLENGES

Armando Olavarra C.

ABSTRACT

Owned by Codelcos Salvador Division, Potrerillos Smelter is a metallurgical
complex dating back to the XIX century, and that started up with the mining of rich copper
oxide veins.

Under the property of the Copper Mining Company, a smelter, a concentration
plant, a leaching plant and mine infrastructure were built in 1927.
Much later, Potrerillos Smelter became part of Codelco Chiles Salvador Division,
envisioning a Smelter Refinery complex to process own and third party copper
concentrates for today and the future.

Today, Potrerillos major challenges are tackled by the recovery of high safety
standards, operational excellence and environmentally sustainable operations. This is a
current transformation that will be presented with its main guidelines in this paper.

Pyrometallurgy

PY151
CHUQUICAMATA SMELTER DEVELOPMENT PROJECTS
Claudio Queirolo
Copper Smelter and Refinery Manager
Fernando Rojas
Smelter Projects Director
ABSTRACT

Chuquicamata Smelter has a capacity to process 1.450.000 t/y of copper concentrates. It has two
smelter reactors, one Flash Furnace and one Teniente Converter, an Electric Slag Cleaning Furnace, four
Peirce Smith Converters, six Anodes Furnaces, three casting Wheels, in addition to two Oxygen Plants
and three Sulfuric Acid Plants. In the near future Chuquicamata Smelter faces important challenges.

To improve its metallurgical efficiency will replace the Electric Slag Cleaning Furnace by a
Flotation Plant which is under construction and will enter into operation during year 2014.

Since year 2014 it will start processing copper calcines proceeding from a roaster furnace of the new
Ministro Hales, Codelco Division. These calcines will be processed in the Flash Furnace and in the
Teniente Converter.

Since now on until year 2018 will develop all the projects required to attain a 95 % of sulphur
fixation starting from its actual 90 %. The main project to be developed is a significant improvement of
the Capture and Processing of its Metallurgical Gases. This means new Converters Hoods,
improvements of the gas cooling, cleaning and handling system, additional capacity for the Acid Plants,
besides Double Absorption and Contact and an capacity increase of it Effluents Treatment Plant.

Hydrometallurgy

SYMPOSIUM: 04 HYDROMETALLURGY

HY01 Kathy Sole GLOBAL SURVEY OF COPPER SOLVENT
EXTRACTION, OPERATIONS AND PRACTICES
HY02 Jason Morgan - Nick Ostberg
- Roman Sheinman - Leonis
Braginsky - Yuri Kokotov -
Mark Vancas
HOMOGENOUS TURBULENT MIXING FOR
REDUCING ENTRAINMENT IN COPPER SX
HY03 Jacklyn Steeples CONCENTRATED ACID ADDITION INTO WASH
STAGES - CASE STUDY AT FREEPORT-MCMORAN
COPPER & GOLD MORENCI OPERATIONS
HY04 Janne Karonen HIGH RECOVERY OF COPPER. GOLD AND SILVER
FROM COPPER CONCENTRATES WITH
HYDROMETALLURGICAL PROCESSING
TECHNOLOGIES OF OUTOTEC
HY05 Wayne R. Hopkins BUILDING COST EFFECTIVE SX/EW PLANTS
HY06 Boris Y. Calienes PLUGGING OF DRIP EMITTERS IN FREEPORT-
MCMORAN COPPER LEACHING OPERATIONS:
CAUSES, CHARACTERIZATION, AND PREVENTION
HY07 K.R. Barnard EFFECT OF TEMPERATURE AND AIR SPARGING ON
SELECTED CHEMICAL AND PHYSICAL
PROPERTIES OF THE ACORGA M5640 / SHELLSOL
2046 ORGANIC SYSTEM
HY08 K.R. Barnard IMPROVING SOLVENT EXTRACTION
TECHNOLOGY
HY09 Hidetoshi Sasaoka NOVEL FERRIC LEACHING PROCESS TO RECOVER
COPPER FROM CONVERTER DUST
HY10 A. Robles-Vega EVALUATION OF A HYDROMETALLURGICAL
ROUTE FOR TREATMENT OF A SILVER -RICH SLAG
GENERATED AT MDC`S PRECIOUS METAL PLANT
HY12 Michael L. Free - Baoping
Zhang
COPPER EXTRACTION AND RECOVERY FROM
CHALCOPYIRITE IN CHLORIDE MEDIA
HY13 Michael L. Free COPPER ORE AGGLOMERATION EVALUATION,
CHARACTERIZATION, AND MODELING
HY14 Atsushi Shibayama INVESTIGATION OF TENNANTITE/TETRAHEDRITE
TREATMENT PROCESS BY ALKALINE LEACHING
AND PRECIPITATION
HY15 Massimo Maccagni IMPROVING PRIMARY COPPER PRODUCTION BY
COUPLING PYROMETALLURGY AND
HYDROMETALLURGY
HY16 Mauro Torres B CUPRO MEX EXTRACTANTS AS EQUIVALENT
ALTERNATIVES FOR COPPER RECOVERY
HY17 J.A. Brown PROCESSING OF GOLD FIELDS' ARCTIC PLATINUM
PROJECT ORES FOR RECOVERY OF CU-NI-CO-PT-
PD-AU
HY18 Keith Mayhew TECK'S CESL COPPER PROCESS: A COMMERCIAL
READY CONCENTRATE LEACHING ALTERNATIVE
HY19 Mayu Tincopa RELEVANCE OF HYDRO-GEOMECHANICAL-
GEOCHEMICAL PROCESSES IN THE DESIGN AND
MANAGEMENT OF COPPER HEAP LEACH PADS

Hydrometallurgy

HY20 M.J. Collins PILOT PLANT PRESSURE OXIDATION OF COPPER
CONCENTRATE
HY21 Jochen Petersen AMMONIA LEACHING OF CHALCOPYRITE IN LOW
GRADE ORES - A FRESH PERSPECTIVE
HY22 L.S. Quiroz-Castillo EFFECT OF SULFURIC ACID CONCENTRATION ON
THE EXTRACTIONS OF ARSENIC AND COPPER IN
CATALYZED LEACHING CONDITIONS OF AN
ENARGITE CONCENTRATE
HY23 Y. Shneerson DEVELOPMENT OF HYDROMETALLURGICAL
TECHNOLOGY OF SULFIDE COPPER
CONCENTRATES UDOKAN DEPOSIT.
HY24 Luis, N. And Montes-Atenas,
G.
INCORPORATING THE EFFECT OF ORE
MINERALOGY AND PROCESS UNCERTAINTY IN
THE INTERPRETATION OF LEACHING DATA USING
THE SHRINKING CORE MODEL
HY25 Rubio-Lopetegui LEACHING OF ENARGITE TOWARDS SELECTIVELY
SEPARATE COPPER AND ARSENIC: A CRITICAL
REVIEW FROM THE MEDIATOR PROCESS
PERSPECTIVE
HY26 Lilian Velasquez Y. AN ELECTROCHEMICAL STUDY OF THE EFFECT
OF CUPRIC IONS ON THE DISSOLUTION OF
ENARGITE IN ACIDIC SOLUTIONS
HY27 Lilian Velasquez Y. INFLUENCE OF SEA WATER AND DISCARD BRINE
ON THE DISSOLUTION OF COPPER ORE AND
CONCENTRATES
HY28 P. Navarro PREDICTION OF PHASE SEPARATION TIME IN
COPPER EXTRATION USING NEURAL NETWORKS
HY29 Pablo Schmidt CUPROCHLOR: HYDROMETALLUGICAL
TECHNOLOGY FOR LEACHING SULFIDE ORES IN
CHLORIDE MEDIA
HY31 Juan Nuez IMPROVEMENTS IN THE VAT LEACH OPERATION
AT MANTOS BLANCOS DIVISION OF
ANGLOAMERICAN COPPER
HY32 P.N. Spiridonov ION EXCHANGE TECHNOLOGY: SOLVING
EXISTING PROBLEMS IN COPPER HEAP LEACHING
HY33 Alvaro Aracena CHALCOPYRITE MINERAL LEACHING IN
PRESENCE OF HYDROGEN PEROXIDE AT 20 - 50 C
HY34 Alvaro Aracena INCREASE IN CU DISSOLUTION THROUGH THE
OPTIMIZATION OF THE AGGLOMERATION -
CURING STAGE
HY35 C. Caro LEACHING LOW GRADE CHALCOPYRITE FROM
RUN-OF-MINE STOCKPILES
HY36 Sebastian Badilla C RECOVERY IMPROVEMENTS IN COPPER HEAP
LEACHING BY USING EMEW TECHNOLOGY
HY53 Bugueo, R HYDRODYNAMICS IN LABORATORY COLUMN
LEACHING: EXPERIMENTS AND NUMERICAL
SIMULATION
HY54 Mostafa Mollaei EVALUATING THE BIOLEACHING OF MIDUK ORE
HY55 J.P. Ibaez COPPER CONCENTRATED LEACHING IN
CHLORIDE-SULFURIC MEDIA

Hydrometallurgy

HY56 Katja Weichert THE INFLUENCE OF PROCESS PARAMETERS ON
ANODE SLIME LEACHING
HY57 Rami Saario CAPEX COMPARISON BETWEEN CONVENTIONAL
AND MODULAR TYPE SOLVENT EXTRACTION
MIXER-SETTLERS AND PLANTS
HY58 David Dreisinger METALLURGICAL DEVELOPMENT OF THE
ESCALONES DEPOSIT
HY59 Enrique Delgado LAS CRUCES COPPER PLANT START-UP: BEYOND
DESIGN PERFORMANCE THROUGH PROCESS
IMPROVEMENTS IMPLEMENTATION
HY60 Jorge Retamal CHALLENGES OF LARGE-SCALE MINING IN
PLANTS OF SOLVENT EXTRACTION
HY61 C. Gutierrez DEVELOPMENT OF A MATHEMATICAL MODEL TO
PREDICT HEAT TRANSFER PHENOMENA IN
SOLVENT EXTRACTION PROCESS
HY62 G.T. Lapidus FACTORS INFLUENCING THE ELECTRO-ASSISTED
REDUCTION OF CHALCOPYRITE
HY63 Jack Bender DEVELOPMENT OF A NEW GENERATION OF
COPPER SOLVENT EXTRACTION REAGENTS
HY64 Rodrigo.Zambra@Cytec.Com THE PHENOMENON OF NITRATION IN THE
CHILEAN COPPER HYDROMETALLURGY
HY66 Jorge M. Menacho and
Francisco J. Troncoso
SCALE UP OF HEAP AND DUMP LEACHING
RESULTS
HY67 Jorge M. Menacho and
Francisco J. Troncoso
OPTIMIZATION STRATEGIES FOR BIOLEACHING
OPERATIONS

Hydrometallurgy

HY01

GLOBAL SURVEY OF COPPER SOLVENT EXTRACTION OPERATIONS AND
PRACTICES

Kathryn C. Sole, Consulting hydrometallurgist, Johannesburg, South Africa
Jacklyn Steeples, Freeport McMoRan, Morenci, AZ, USA
Gabriel Zarate, Anglo American, Santiago, Chile
Timothy G. Robinson, Republic Alternative Technologies, Strongsville, OH, USA
Michael S. Moats, Missouri University of Science & Technology, Rolla, MO, USA
kathysole09@gmail.com

ABSTRACT
Continuing from similar surveys carried out in 1997, 1999, 2003, and 2007, global
practice in copper solvent extraction is reviewed, based on individual plant operating data
for 2012. Trends in feed and electrolyte compositions and flow rates, and extractant and
diluent selection, together with their impact on copper recovery and operating costs are
reviewed.
Optimisation of copper transfer and copper production by changing circuit
configurations with changing feed composition during the life of mine is discussed. The
rapid adoption and expansion of this technology in the African Copper Belt is also
assessed, together with emerging trends in equipment design that are appropriate to
operating conditions in this region.

Hydrometallurgy

HY02

HOMOGENOUS TURBULENT MIXING FOR REDUCING ENTRAINMENT IN
COPPER SX

Jason Morgan, Nick Ostberg-Freeport-McMoRan Copper & Gold
Roman Sheinman, Leonid Braginsky, Yuri Kokotov -Turbulent Technologies Ltd,
Mark F Vancas - Tenova Bateman Technologies

ABSTRACT

Freeport-McMoRan Copper & Gold in conjunction with Turbulent Technologies
Ltd. (TT), and Tenova Bateman Technologies has tested TT mixing at the Technology
Center (TC) Test Facility. Non-uniform energy dissipation in a primary mix box causes a
wide distribution of droplets sizes with fine droplets being the primary concern. Fine
droplet sizes do not readily coalesce, and are often the majority source of organic
entrainment in aqueous.
TT mixing technology generates homogenous energy dissipation throughout the
auxiliary mixer volume, resulting in effective coalescence of fine droplets. Since larger
droplets are formed, higher coalescence occurs, resulting in more effective phase
separation.
Large pilot scale testing occurred at the TC with two trains side-by-side. One train
was a control parallel-strip train run with and without hydrofoil auxiliary mixing, whereas
the experimental train utilized TT auxiliary mixing technology. Both trains utilized a
primary pump mixer with curved vanes at maximum speed to increase the generation of
fines. Results proved TT auxiliary mixers decreased organic entrainment in aqueous by 50-
75% as compared to the control train. TT system performance yielded lower organic losses
during plant instability due to forced phase continuity changes as compared to primary
mixing only.

Hydrometallurgy

HY03

CONCENTRATED ACID ADDITION INTO WASH STAGES CASE STUDY AT
FREEPORT-MCMORAN COPPER & GOLD MORENCI OPERATIONS

Jacklyn Steeples
Jacklyn_steeples@fmi.com

ABSTRACT
A series of tests was conducted at the Freeport-McMoRan Copper & Gold Morenci Stargo
Solvent Extraction facility to determine if adding concentrated sulfuric acid to a wash stage
was an effective alternative to adding Lean Electrolyte (LE).
Tests were conducted with the objective of increasing operational flexibility within the
production plant as well as decreasing the amount of LE bleed required. Four different
tests were performed over ten weeks. It was determined that concentrated sulfuric acid was
an acceptable solution that can be added without negatively affecting the performance of
the wash stage.
Hydrometallurgy

HY04

HIGH RECOVERY OF COPPER. GOLD AND SILVER FROM COPPER
CONCENTRATES WITH HYDROMETALLURGICAL PROCESSING
TECHNOLOGIES OF OUTOTEC

Janne Karonen

ABSTRACT
Interest in exploiting low-grade and low quality copper ore deposits is increasing
due to the growing copper demand and declining ore grades. Outotec has been active in
developing hydrometallurgical copper processing technologies and is now launching a
novel and sustainable technology suitable for treatment of wide variety of copper
containing feed materials, especially for primary copper sulphides with gold and silver
content.
The technology is based on atmospheric reactor leaching after which copper, silver
and gold are purified with solvent extraction. Copper is recovered as LME A grade cathode
in electrowinning. Gold and silver can be recovered from purified streams with reduction,
cementation or precipitation.
Process has been tested in bench-pilot scale with high extractions in both leaching
and metals recovery circuits. Process technology has been engineered and standard, readily
available and proven equipment can be utilized. Materials of construction are well defined
and tested in industrial scale.
Hydrometallurgy

HY05

BUILDING COST EFFECTIVE L/SX/EW PLANTS

Wayne R. Hopkins
Technical Design Associate
Faradelk Ltd.

ABSTRACT
A discussion paper which covers plants built in North and South America and
Africa over the last 40 years. It highlights points of design and equipment selection which
bring significant reductions in capital investment to both large and small facilities and
shows how these have been applied in various locations for heap leaching, solvent
extraction and electrowinning . A detailed account is provided of the development of one of
the most cost effective designs in the copper industry.
Hydrometallurgy

HY06

PLUGGING OF DRIP EMITTERS IN FREEPORT-MCMORAN COPPER
LEACHING OPERATIONS: CAUSES, CHARACTERIZATION, AND
PREVENTION

Boris Y. Calienes
Technology Center, Freeport-McMoRan Copper & Gold, Arizona

ABSTRACT
Plugging of drip emitters is a common issue in copper leaching operations. Plugged
emitters may seriously increase operational costs and affect the uniform distribution of
leach solutions, and as consequence, the extraction of copper. In this paper, the experiences
with plugged emitters at Freeport-McMoRan leaching operations are discussed, the sources
of contamination of the leach solutions and the analytical tools used to characterize the
plugging agents are described. Most importantly, the development and application of
metallurgical improvements and operational practices that have reduced the plugging rates
in our industrial leaching sites are presented.

Hydrometallurgy

HY07

EFFECT OF TEMPERATURE AND AIR SPARGING ON SELECTED
CHEMICAL AND PHYSICAL PROPERTIES OF THE ACORGA M5640 /
SHELLSOL 2046 ORGANIC SYSTEM

K.R. Barnard1, P. Miovski1 and J. Li and D.J. Robinson1
1CSIRO Minerals Down Under Flagship, CSIRO Process Science and Engineering, PO
Box 7229,
Karawara, Western Australia, 6152

ABSTRACT

As part of the AMIRA P706 solvent extraction project which preceded the
MERIWA SXT projects, the effect of temperature (40, 55 C) and intermittent air sparging
on organic solutions of 25% v/v Acorga M5640 / Shellsol 2046 under copper strip
conditions was assessed. Stoichiometric decomposition of aldoxime extractant to aldehyde
was observed in all systems. Whilst increased operating temperatures hastened the rate of
degradation, regular air sparging, which provided the possibility of oxidative degradation of
aldoxime, was actually found to inhibit it. The impact of the degradation conditions on crud
formation, formation of water soluble organic species, and the interfacial tension, phase
disengagement time, copper extraction kinetics and copper over iron selectivity of the
resulting organic solutions is presented.
Hydrometallurgy

HY08

IMPROVING SOLVENT EXTRACTION TECHNOLOGY

K.R. Barnard1 and D.J. Robinson1
Box 7229,

ABSTRACT

Efficient Solvent Extraction (SX) performance is crucial to an increasingly broad range of
mineral processing operations. The challenge is to understand how to increase throughput,
reduce entrainment, optimise performance, reduce costs and improve operational stability.
With the financial help of industrial sponsors, CSIRO has been undertaking research
targeting SX operation over the past decade, via the AMIRA P706 (2004-2006) and
MERIWA projects M401 (2007-2010) and M418 (2010-2013).

A multiple-pronged research approach has been adopted, including a combination of SX
chemistry, small scale physical modelling, development of a variety of measurement tools
and probes for mixer settler characterisation, and development and ongoing refinement of
computational fluid dynamics capabilities, including extension to three phase (air, aqueous,
organic) models. The research developments, which have included successful site-based
investigations of liquid flow patterns in commercial settlers, have provided a deeper
fundamental understanding of SX processes which have been translated into tangible
outcomes for operating plants. The present paper summarises some of the key
developments and successes achieved to date and outlines planned future research
directions which are expected to continue to deliver tangible benefits to the industry.
Hydrometallurgy

HY09

NOVEL FERRIC LEACHING PROCESS TO RECOVER COPPER FROM
CONVERTER DUST

llidctoshi Sasaoka, Daisuke Kobayashi, Yasukatsu Sasaki
Hitachi Works

ABSTRACT
JX Nippon Mining & Metals Corp. has launched a new plant in 2008 at Hitachi
works to recover valued metals such as Cu, Pb and rare metals (Ni, Sn, Sb, Bi, etc.) from
secondary products of copper smelter and a wide range of recycling materials.
The plant is composed of pyro- and hydro-metallurgical processes whose
technology has been accumulated over the years through the smelting business of
nonferrous metals. The main Pb source of the plant is converter dust of copper smelter.
Copper included in the converter dust resulted in not only a contamination of Pb bullion but
also an increase of intermediate substance. As the countermeasure to these problems,
secondary products of copper smelter are treated through hydrometallurgical de-coppering
process, namely ferric leaching process, at first. And the de-coppered substance is smelted
in an electric furnace together with other raw materials.
For the purpose of enhancing performance of the plant, various improvements in the
decoppering process have been implemented since the commencement of the process. The
advancement brought us not only upgrading the performance but also increase of recovery
rate of copper and the other valued metals. This paper mainly describes these
improvements.
Hydrometallurgy

HY10

EVALUATION OF A HYDROMETALLURGICAL ROUTE FOR TREATMENT
OF A SILVER-RICH SLAG GENERATED AT MDCS PRECIOUS METAL
PLANT

A. Robles-Vega
1
, G. Soto-Gamez
1
and I. Lzaro
2

1
Mexicana de Cobre, S.A. de C.V., Kilmetro 21, Carretera Nacozari-Agua Prieta,
Nacozari Sonora Mxico, 84340
2
Instituto de Metalurgia-Facultad de Ingeniera, Universidad Autnoma de San Luis
Potos, Av. Sierra Leona 550, Lomas 2 Seccin, 78210, San Luis Potos, Mxico.

ABSTRACT

Mexicana de Cobre (MDC) produces gold, silver, selenium and tellurium at its
precious metal plant. The process involves treatment of decopperized anode slimes in a
Kaldo furnace to obtain a Dor product. These anode slimes come from the copper
refining process, and as it is known they contain not only valuable metals, but also
impurities that have to be removed to prevent contamination of the Dor. The impurities
removed then have to be bled by means of a slagging stage. The main impurities in this
alkaline molten slag are: lead, antimony, bismuth, arsenic, copper, selenium and tellurium.
Another characteristic of this slag is that it has a high content of silver.

At the beginning of MDCs precious plant operation, the silver-rich slag was
commercialized, but later on it was decided to incorporate it in the feed of the copper
smelter with the aim of recovering the silver. However, this action resulted in an increase of
the antimony and tellurium content in the copper anodes. Thus, a change was made and
acid leaching treatment of the slag was carried out at MDCs effluent treatment plant,
which unfortunately was also inadequate.

Currently, a detailed leaching study for impurities removal and recovery of valuable
metals is being achieved. The study involves individual and sequential acid-alkaline
leaching and so far the results have shown that this could be a viable approach for treatment
of the silver-rich slag.

Hydrometallurgy

HY12

COPPER EXTRACTION AND RECOVERY FROM CHALCOPYRITE IN
CHLORIDE MEDIA

Michael L. Free, Baoping Zhang

ABSTRACT
Many of the worlds copper ore reserves are associated with chalcopyrite.
Hydrometallurgical extraction of copper from chalcopyrite is difficult by conventional
sulfuric acid heap leaching technology. Significant research and development to improve
chalcopyrite leaching have involved the use of thermophilic microorganisms and to a more
minor extent chloride. In this paper, some of the technology that has been explored for
chloride based extraction and recovery will be discussed and related data will be presented.
Hydrometallurgy

HY13

COPPER ORE AGGLOMERATION EVALUATION, CHARACTERIZATION,
AND MODELING

Michael L. Free, Michael S. Moats, Nikhil Dhawan, Raj K. Rajamani, Jan D. Miller, and
Chen L. Lin

ABSTRACT
Agglomeration is often utilized to reduce fine particle migration as well as to
provide acid for improved copper extraction during heap leaching of copper ores. In order
to improve the benefits of agglomeration, the process must be appropriately understood,
characterized, and modeled. This paper describes some of the fundamentals associated
with agglomeration, tools for characterizing agglomeration, and models that can be used to
predict agglomeration.

Hydrometallurgy

HY14

INVESTIGATION OF TENNANTITE/TETRAHEDRITE TREATMENT PROCESS
BY ALKALINE LEACHING AND PRECIPITATION

Atsushi SHIBAYAMA, Kazutoshi HAGA
Akita University, JAPAN

ABSTRACT

A copper ore containing mixture of tennantite (Cu
12
As
4
S
13
) and tetrahedrite
(Cu
12
Sb
4
S
13
) was used in the current study to investigate arsenic (As) and antimony (Sb)
leaching and precipitation behaviors in NaHSNaOH media.
Leaching results showed that in 6 hours of contact time, at 95 C and NaHS
concentration of 250 g/L (3.375 M), both As and Sb contents in the ore were reduced to <
0.5 mass % from 45 mass %. Further, experiments were conducted at very high pulp
density (1000 g/L) in order to know field applicability of the NaHSNaOH media, is also
produced high dissolution of As/Sb (< 0.5 mass %) with 600 g/L of NaHS concentration
within 6 hours of leaching time at 95 C.
In order to remove As and Sb from leachate (30-40 g/L concentration of As/Sb)
addition of 0.2 M elemental sulfur in the ratio to As/Sb at 95 C were carried out. As and Sb
in the leachate were oxidized as As
3+
(Sb
3+
) to As
5+
(Sb
5+
) by sulfur addition. Further,
leachate has been rapidly cooled to 30C for the formation Na
3
AsS
4
/Na
3
SbS
4
precipitate.
As and Sb concentrations of leachate after precipitation process were found to be 5 g/L.

Hydrometallurgy

HY15

IMPROVING PRIMARY COPPER PRODUCTION BY COUPLING
PYROMETALLURGY AND HYDROMETALLURGY

MASSIMO MACCAGNI
R&D Manager
Engitec Technologies S.p.A.
Via Borsellino e Falcone, 31
20026 Novate Milanese (MI)
Italy
Phone: +39 02 38207203
Fax: +39 02 3562086
e-mail: m.maccagni@engitec.com
Website:www.emg
itec.com

ABSTRACT

Copper production through traditional technologies requires some pyrometallurgical steps
and a heavy recycling loop of materials. The SO
2
scrubbing and its conversion to H
2
SO
4
is done by
feeding a dilute gas stream.
Some extensive tests and a pilot campaign for the direct conversion of copper matte/white
metal to cathode were run through the ECUPREX process, a hydrometallurgical process based on a
fluoborate electrolyte.
The experience made in recent years using the same electrolyte in a successful emonstration
plant campaign for the production of lead from concentrate allowed us to test equipment, to solve
technical problems and to design the industrial cell which can also be applied to copper.
In this paper we will show the results achieved during this test campaign.

Hydrometallurgy

HY16

CUPRO MEX EXTRACTANTS AS EQUIVALENT ALTERNATIVES FOR
COPPER RECOVERY

Mauro Torres B., Technical Manager, SNF FloMin

Marco Torres M., Oxide Plant Chief of Operations, Anglo American Chile, El Soldado
Division
R. Brantley Sudderth, P.E., Principal, RB SUDDERTH LLC, Metallurgical Consultant to
SNF FloMin, Inc.

ABSTRACT
SNF FloMin, Inc. has introduced a complete line of extractants for various metals
recovery. Among them are the CuPRO MEX Brand of copper extractants that are based
on the well known 2-hydroxy 5-nonylsalicylaldoxime and 2-hydroxy acetophenoneoxime.
This paper presents the laboratory, pilot plant, and industrial trial results for SNF FloMins
CuPRO MEX 3302 reagent, the equivalent to the well known Acorga M5640
extractant, and the composition of CuPRO MEX 3302 is described. To date, laboratory
and pilot plant studies have been carried out at SNF FloMins metallurgical/analytical
laboratory in Chile and at Anglo American Chiles Mantos Blancos and Mantoverde mines.
An industrial trial is being carried out at Anglo American Chile, El Soldado Division since
August, 2012, as further industrial trials are being confirmed.
This paper presents metallurgical and physical comparisons of CuPRO MEX
3302 and the M 5640 extractant in numerous experiments, both bench scale and continuous
pilot plant scale. These results include: copper extraction points, kinetics, net transfer,
recovery, Cu/Fe selectivity, and re-extraction data. Physical properties include: phase
separation in both continuities, density, viscosity, surface tension, and interfacial tension.
The pilot plant results were completed in side-by-side mini-pilot plants, calibrated for
precise comparison. The chemical compositions of each extractant are further compared by
GC-MS and GC-FID analyses.

Hydrometallurgy

HY17

PROCESSING OF GOLD FIELDS ARCTIC PLATINUM PROJECT ORES FOR
RECOVERY OF Cu-Ni-Co-Pt-Pd-Au

J.A. Brown, E. Legault and C.A. Fleming
SGS Minerals Services
185 Concession Street
Lakefield, Canada K0L 2H0
james.brown@sgs.com

C. le Roux
Gold Fields Ltd
150 Helen Road Sandton, 2196
Johannesburg, South Africa

ABSTRACT

The Arctic Platinum Project, or APP, located in northern Finland includes a number
of shallow Cu-Ni-PGE (platinum group elements) deposits. The processing route currently
under investigation for extraction of the metal values involves bulk sulphide flotation
followed by hydrometallurgical treatment of the concentrate using the Platsol process.
The major processing steps include: crushing, milling and flotation of a bulk concentrate,
chloride assisted total pressure oxidation of the concentrate for extraction of base and
precious metals, reduction and precipitation of PGEs from the autoclave solution, partial
neutralization followed by copper SX-EW for production of copper cathode and nickel and
cobalt recovery by mixed hydroxide precipitation from the Cu SX raffinate. The processes
have been extensively tested at SGS Minerals Services labs in Lakefield, Canada at both
lab and pilot plant scale. The overall process flowsheet, chemistry and bench and pilot
plant test data will be presented covering both the flotation and hydrometallurgical
processes.

Hydrometallurgy

HY18

TECKS CESL COPPER PROCESS: A COMMERCIAL READY CONCENTRATE
LEACHING ALTERNATIVE

Keith Mayhew Teck Resources Limited (keith.mayhew@teck.com)
Tannice McCoy Teck Resources Limited (tannice.mccoy@teck.com)
Rob Mean Teck Resources Limited (rob.mean@teck.com)
James Woeller Teck Resources Limited (james.woeller@teck.com)

ABSTRACT

As demand for global refined copper rises, the need for producers to find cost
effective ways to develop copper porphyry deposits is becoming increasingly important.
Brownfield projects in South America with depleting heap leach production and an
underlying sulphide deposit represents an opportunity to integrate concentrate leaching with
existing solvent extraction and electrowinning infrastructure to establish a value added on-
site metal production alternative to conventional concentrate sales. Over the last 15 years,
Teck has been at the forefront of developing copper pressure leaching technology, known
as the CESL Process, which has been tested at an industrial scale and has the potential to
achieve cost competitive metallurgical recoveries while effectively handling impurities in
concentrates which render them difficult to market.

This paper will highlight the successful development history of Tecks copper
pressure leaching technology while providing standard operating parameters and resulting
metallurgical performance from a range of primary copper sulphide concentrates tested. A
conceptual level case study will be presented to assess the integration of a commercial
pressure leach circuit with existing SX/EW infrastructure. The technical, economic,
environmental and social aspects of this alternative will be compared to conventional
concentrate marketing to smelters.

Hydrometallurgy

HY19

RELEVANCE OF HYDRO-GEOMECHANICAL-GEOCHEMICAL PROCESSES
IN THE DESIGN AND MANAGEMENT OF COPPER HEAP LEACH PADS

Mayu Tincopa
Amphos 21 Consulting Espaa
Albert Nardi
Gabriela Roman-Ross
Jorge Molinero
David Arcos
Orlando Silva
Eduardo Ruiz
Amphos 21 Per

ABSTRACT
Heap leach pads constitute a common practice in the mining industry. In the design
and management it is not common to take into account criteria based on coupled hydro-
geomechanical-geochemical processes, and these are of paramount importance for two
main reasons: (1) they could play an important role on the physical stability of the pad and;
(2) they are keys for the metallurgical efficiency, especially in the mid-long term.
As an example of the relevance of such a complex coupled phenomena it could be
mentioned that geotechnical stability of the heap is related to the distribution of liquid
pressures which, at the same time, is related to the permeability through the Darcys law. In
its turn, permeability will be affected by porosity changes, which depends on the
consolidation state and the dissolution/precipitation of minerals. Obviously,
hydrometallurgical performance of the heap ore is also strongly linked with the
abovementioned coupled processes.
In this work, we present a numerical model to solve the hydro-geomechanical-
geochemical coupled processes, developed with COMSOL-PHREEQC, a java interface
developed for combining COMSOL Multiphysics a well-known commercial FEM
Hydrometallurgy

platform with PHREEQC, the open-software geochemical simulator developed at USGS
and used worldwide. The resulting numerical tool is able to solve simultaneously
unsaturated liquid flow, soil effective stress and geochemical dissolution and precipitation.
Geochemical changes affecting porosity and permeability are coupled explicitly in
the hydraulic and geomechanical calculations.
In this paper we provide a demonstrative simulation of a synthetic copper heap
leach pad case in order to show the relevance of the coupling, as well as the capabilities of
the numerical tool.

Hydrometallurgy

HY20

PILOT PLANT PRESSURE OXIDATION OF COPPER CONCENTRATE

M.J. Collins
Sherritt Technologies
Sherritt International Corporation
8301 113 Street
Fort Saskatchewan, Alberta, Canada T8L 4K7
(Corresponding author: mcollins@sherritt-tech.com)

ABSTRACT

Sherritt Technologies recently completed a test program to evaluate the application
of pressure oxidation technology to the treatment of copper sulphide concentrate from
South America. The testwork included an eight-day pilot plant campaign, comprising
continuous, integrated operation of pressure leaching, counter-current decantation washing,
leach liquor neutralization, solvent extraction, raffinate neutralization and electrowinning
circuits.
The main copper-bearing minerals in the concentrate were chalcopyrite and bornite,
and the pilot plant feed contained 38% Cu, 22% Fe and 28% S. Copper extraction in
pressure leaching was 98.5 to 99%, recovery of copper in the wash circuit was >99.5% and
there was no measurable precipitation of copper in the neutralization circuits. LME Grade
A copper cathode was produced in electrowinning, with current efficiency in excess of
95%.

Hydrometallurgy

HY21

AMMONIA LEACHING OF CHALCOPYRITE IN LOW GRADE ORES A
FRESH PERSPECTIVE

Jochen Petersen
a,b,
*, Caroline Muzawazi
b
, Thandazile Moyo
a,b
, Jean-Paul Franzidis
a

a
Minerals to Metals Research Initiative), Department of Chemical Engineering, University
of Cape Town, Rondebosch 7700, South Africa. *Corresponding author:
jochen.petersen@uct.ac.za
b
Centre for Bioprocessing Engineering (CEBER), Department of Chemical Engineering,
University of Cape Town, Rondebosch 7700, South Africa.

ABSTRACT
Ammonia leaching of copper minerals has been explored many times and for many
materials in the past 60 years. Although it has been shown to be an effective leach
environment for chalcopyirite dissolution, its commercial application has remained niche.
Reasons relate to high reagent loss, difficulty with the recovery of ammonia from wate
solutions, and economic sulphate recovery, amongst others. Recent work around the
recovery of copper and nickel from a PGM bearing ore has indicated the potential to
recover at least 90-95% Cu from concentrates and 80-90% directly from coarse ore within
much shorter time periods compared to bio-leaching. This data is discussed in more detail
it suggests that NH
3
leaching of Cu is first order in NH
3
and has an acivation energy of 36
kJ/mol.
Peliminary fundamental electrochemistry work suggets a surface adsorption
mechanism facilitated by the ammonia molecul. The data potentually supports heap-
leaching using NH
3
, which remains almost entirely unexplored as a technology choice.
Some work on whole ore leaching on the same material is presented, which suggests that
near complete extraction of Cu is still posible. NH
3
losses to the atmosphere remain
significant and have been monitored in model systems and are acceptable only at ambient
temperatures. While problems such as these remain challenges, these can nonetheless be
overcome through further process improvements. Thus ammonia leaching remains a strong
contender in this area of research, but requires more concerted efforts around other aspects
of the flowsheet.

Hydrometallurgy

HY22

EFFECT OF SULFURIC ACID CONCENTRATION ON THE EXTRACTIONS OF
ARSENIC AND COPPER IN CATALYZED LEACHING CONDITIONS OF AN
ENARGITE CONCENTRATE.

L.S. Quiroz-Castillo, O. Olvera, L. Dyer, and D.G. Dixon.
Department of Materials Engineering
University of British Columbia
6350 Stores Road
Vancouver, Canada V6T 1Z4
luissquiroz@gmail.com

ABSTRACT
The effect of sulfuric acid concentration on the extractions of arsenic and copper in
the catalyzed leaching process of an enargite concentrate was studied. The concentration
range was 15 60 g/L sulfuric acid. The experimental series yielded maximum copper
extractions of 84 to 90%; the rates of Cu extraction increased with acid concentration.
Arsenic extractions ranged from 18% to 66%; the maximum values of As in solution also
increased with acid concentration; As concentrations decreased steeply after reaching these
values, followed by decreases in pH and progressive increases in ORP; the steep decrease
in As concentrations indicate a precipitation event occurred; according to the literature and
process conditions, the precipitate is a stable form of iron arsenate similar to scorodite. The
plateaus in copper extraction can be attributed to acid depletion and possibly co-
precipitation of copper values. The leaching residues stability was tested using TCLP tests
for As leach; the three lower acid concentrations passed the TCLP test as per EPA
regulations, leaching below 5 ppm of As, the higher acid residue leached ~6.5 ppm As.
This hydrometallurgical process yields high copper dissolution while producing stable,
manageable iron arsenate residues, making it a promising extractive leaching technology
for copper-arsenic sulfides.

Hydrometallurgy

HY23

DEVELOPMENT OF HYDROMETALLURGICAL TECHNOLOGY OF SULFIDE
COPPER CONCENTRATES UDOKAN DEPOSIT.

Y. Shneerson
1
, D. Lapshin
2
, A. Lapin
1
1 - LLC "NIC Hydrometallurgy"
2 - LLC "BMC"

ABSTRACT
Udokan deposit is one of the largest undeveloped copper deposits in the world.
Deposit, the mixed sulphide-oxidized ores containing copper and silver. At present, a
flotation method of processing ore Udokan deposit to produce oxidized and sulfide
concentrates. In this case, currently under research for the development and selection of the
optimal technology for processing of copper concentrates.
This paper presents research on the development of hydrometallurgical processing
technology sulfide concentrate. As part of the study the effect of the main parameters of
pressure leaching and cyanide to extract copper and silver to the solution. As a result, the
conditions for the work achieves a recovery in copper solution at 99% and silver 90%.

Hydrometallurgy

HY24

INCORPORATING THE EFFECT OF ORE MINERALOGY AND PROCESS
UNCERTAINTY IN THE INTERPRETATION OF LEACHING DATA USING THE
SHRINKING CORE MODEL

Luis, N. and Montes-Atenas, G.
2
CS) Group, Mining Engineering
Department, University of Chile, Av. Tupper 2069, Santiago, Chile

ABSTRACT
The classic shrinking core model has been widely used to analyse and to interpret
experimental kinetics leaching data. The model has marveled not only by its simplicity
when applied to experimental data but also by its strength towards interpreting data
allowing unveiling the governing mechanisms involved in the metal extraction process.
Nevertheless, two aspects have not been incorporated in the analysis: the ore mineralogy
and the inherent uncertainty derived from the very use of the model. The aim of this
research is to incorporate the effect of mineralogy and the uncertainty inherent to the use of
the model and apply these concepts to column leach data.
On one hand, the presence of one or more copper-bearing minerals in the ore having
different reactivities distorts the recovery vs time curve. This effect is accounted for
determining fast and slow leaching components. On the other hand, the evaluation of the
model uncertainties derived from the measuring variables is accounted for using the error
by propagation analysis. These two aspects will ultimately set the boundaries for predicting
the metal leaching extraction. Finally, incorporating these two aspects onto the data
interpretation would procure a more realistic scenario to understand and interpret leaching
kinetic data.

Hydrometallurgy

HY25

LEACHING OF ENARGITE TOWARDS SELECTIVELY SEPARATE COPPER
AND ARSENIC: A CRITICAL REVIEW FROM THE MEDI ATOR PROCESS
PERSPECTIVE

Rubio-Lopetegui, A. and Montes-Atenas, G.
2
CS) Group, Mining Engineering
Department, University of Chile, Av. Tupper 2069, Santiago, Chile

ABSTRACT
The occurrence of enargite (Cu
3
AsS
4
) in hydrometallurgical plants bears a number
of challenges. One question lies on how Copper and Arsenic can be selectively extracted
from the solid surface structure when immersed in aqueous solution. The leaching of
enargite in ambient conditions has been extensively studied; nevertheless, challenges
regarding the process kinetics and surface structures enabling the extraction process remain
ill-understood. Prior knowledge indicates that different conditions of pH, E
h
, speciation of
the aqueous phase or variations of these parameters defines the overall rate at which metals
and other elements will be transferred to the solution.
One aspect that research studies have seldom addressed involves studying the main
features of the surface structures formed during the leaching process at the outmost surface
atomic layer. Such structures will mediate between the solid bulk and the solution to
undertake subsequent stages of leaching process. The aim of this research work is to
critically analyse the state of the art of enargite electrochemistry from the mediator
formation-dissolution mechanisms standpoint occurring at the mineral-solution interface.
Acquiring insights on the surface structures rising from the enargite-aqueous solution
interactions may procure new experimental protocols towards selectively separating Copper
and Arsenic through hydrometallurgical paths.

Hydrometallurgy

HY26
AN ELECTROCHEMICAL STUDY OF THE EFFECT OF CUPRIC IONS ON THE
DISSOLUTION OF ENARGITE IN ACIDIC SOLUTIONS

Mara Virginia Ramrez Anselme, Lilian Velsquez Yvenes*
Departamento de Ingeniera Metalrgica y Minas/Facultad de Ingeniera y
Ciencias Geolgicas, Universidad Catlica del Norte, Antofagasta, Chile,
Candidato a Magister en Metalurgia,
Departamento de Ingeniera Metalrgica y Minas/Facultad de Ingeniera y
Acadmico 55-355656, livelas@ucn.cl

ABSTRACT
As demand for copper continues to grow, the need to source copper from all
resources including those that contain arsenic is necessary and as such more economical
and environmentally acceptable processing options will be sought. Leaching of copper
sulphide minerals can be a practical alternative to treat them, minimizing atmospheric
pollution, especially when arsenic is an important accompanying impurity. However, it is
well known that the leaching of sulphide minerals under ambient conditions is extremely
slow, even under highly oxidizing conditions. There has been comparatively little work
published on enargite dissolution in acid media at ambient conditions. The electrochemical
behaviour of enargite has been studied in sulphuric acid solutions using an electrode
prepared from a massive crystal. Cyclic voltammetry was performed to study the effects of
chloride, cupric and ferric ions.

Both electrochemical and chemical methods have shown that the oxidative
dissolution of enargite is a potential dependent process with higher dissolution rates
favoured by high oxidizing potentials. However, this strong effect of potential is
apparently limited to the initial stages of the dissolution process, after which the so-called
passivation of the mineral results in rates of dissolution which do no longer exhibit the
expected potential dependence. Thus the relevant leaching potential region has been
established as 0.6 to 0.8 V. A comparison of the rates of dissolution values obtained by
electrochemical experiments and those using leaching show excellent agreements. Ferric,
chloride and cupric ions were found to show a marked influence on the measured current
density, with an increase in current density with cupric addition and unexpected decrease in
current density with addition of ferric and chloride ions. A reaction mechanism has been
proposed where cupric ions act as the primary oxidant at the mineral surface.
Hydrometallurgy

HY27

INFLUENCE OF SEA WATER AND DISCARD BRINE ON THE DISSOLUTION
OF COPPER ORE AND CONCENTRATES

Vctor Quezada R., Lilian Velsquez Y*

*Departamento de Ingeniera Metalrgica y Minas, Facultad de Ingeniera y
Acadmico, 055-355656, livelas@ucn.cl.

Departamento de Ingeniera Metalrgica y Minas, Facultad de Ingeniera y
Postulante a Magister en Metalurgia, victor.quezada.r@gmail.com.

ABSTRACT
It is well known that the Chilean mining is facing a shortage of water resources for
the sustainable operation of not only existing plants but also of future projects. In addition,
the depletion of oxide ores and those containing secondary sulfide copper will leave
chalcopyrite ores as the main source of copper for future plants. This paper will report a
study on the dissolution kinetics of finely ground copper oxide ore and chalcopyrite
concentrate leached in agitated reactors and of a secondary copper sulfide ore leached in
small columns to evaluate and compare the use of sea water and discard brine from a
desalination plant.
It will be demonstrated that enhanced rates of dissolution of copper from
chalcopyrite concentrate and secondary sulfide ore can be achieved at moderate
temperatures using the saline solutions. The use of sea water and discard brine also do not
have any negative effect on the dissolution of finely ground copper oxide ore, achieving
100% of dissolution in agitated reactors. When the secondary sulfide ore is leached in small
columns, enhanced rates are obtained using the discard brine. This can be explained by the
higher content of chloride ions, which can form copper complexes in solution that improve
the dissolution of copper. The discard brine and sea water as a water source could
eventually become a valid option for the copper industry.

Hydrometallurgy

HY28

PREDICTION OF PHASE SEPARATION TIME IN COPPER EXTRATION USING
NEURAL NETWORKS

P. Navarro and S. Jara
Universidad de Santiago de Chile
Departamento de Ingeniera Metalurgica
Av. Libertador Bernardo OHiggins # 3363
Estacin Central, Santiago, Chile
sebastian.jaram@usach.cl

ABSTRACT

In this work, it was study the influence of five variables on the phase separation time
(primary breakup time) of the process of copper solvent extraction (SX) for oxide ores. The
phenomenon was studied in aqueous continuity, inside a cylindrical glass reactor of 1 liter
capacity, used as mixer-settler reactor. The variables studied were: the copper concentration
in the leach solution, the concentration of the extractant in the organic phase, the stirring
time, the speed of agitation of the phases and the initial pH of the aqueous solution. The
correlation between phase separation time and the others experimental variables was made
by neural networks tool.

The most influent variables on the phase separation time were: the concentration of
the extractant reagent and the stirring speed. In aqueous continuity, the increase of the
extractant reagent increases the density difference between the phases, producing a
decrease in the phase separation time. By increasing the agitation rate, the smallest droplet
size of the dispersed phase, produces an increase of the phase separation time.

Hydrometallurgy

HY29

CUPROCHLOR: HYDROMETALLUGICAL TECHNOLOGY FOR LEACHING
SULFIDE ORES IN CHLORIDE MEDIA

Pablo Schmidt
Antofagasta Minerals S.A-
Apoquindo4001, 18
th
Floor
7550162, Las Condes
Santiago, Chile
pschmidt@aminerals.cl

Abraham Backit
Minera Michilla S.A.
Apoquindo4001, 13
th
Floor
7550162, Las Condes
Santiago, Chile
abackit@michilla.cl

Jaime Jacob
Minera Michilla S.A.
Apoquindo4001, 13
th
Floor
7550162, Las Condes
Santiago, Chile
jjacobc@michilla.cl

ABSTRACT

This paper gives a description of the current operation of the CuproChlor process
at Minera Michilla which has been successfully implemented since 2001 to date for
leaching secondary copper sulfide ore. The technology incorporates as many other copper
hydrometallurgical plants, a process of agglomerate and acid curing but adding an
additional additive that is calcium chloride, CaCl2. This allows produces an agglomerated
with better physical properties that achieves a heap with better permeability properties
which allows improving the copper recovery in the leaching process.

Hydrometallurgy

An important feature of this technology is a stage of resting after the acid curing
stage before start the irrigation. The leaching period is around 120-130 days total with an
effective irrigation time from 80-90 days, obtaining a copper recovery of secondary sulfide
minerals, in the order of 90% for copper grade between 1-3%. Tests for ore with primary
copper sulfides are in development.

Industrial results demonstrate that the CuproChlor process is very efficient for the
extraction of copper from sulfide and mixed, minerals being very competitive technology in
the world mining market.
Hydrometallurgy

HY31

IMPROVEMENTS IN THE VAT LEACH OPERATION AT MANTOS BLANCOS
DIVISION OF ANGLOAMERICAN COPPER

Juan Nuez, Mantos Blancos Division, Antofagasta, Chile
Jessica Cueto, Mantos Blancos Division, Antofagasta, Chile
Saddy Peroncini, Mantos Blancos Division, Antofagasta, Chile
Gabriel Zarate, Anglo American Chile, Santiago, Chile

ABSTRACT
Mantos Blancos Division of AngloAmerican Copper started the treatment of oxide
ore in March 1961 at a production capacity of 13,300 tpy of copper, which was later
expanded to 30,000 tpy in 1967. The process included vat leaching, cuprous chloride
precipitation, pelletizing and smelting. In November 1995, this process was replaced by vat
leaching, solvent extraction and electrowinning at a production capacity of 44,000 tpy of
copper which was later expanded to 60,000 tpy.
The vat leach cycle was modified with the introduction of the SX-EW plant when
copper grade was well above 1 %Cusol (sulphuric acid soluble copper). The total leach
cycle was 98 hours, 70 hours of which were dedicated to the leaching itself.
As the copper ore grade has decreased significantly with time, a number of
modifications have been implemented in the operation to deal with this lower copper grade
ore, among them leach cycle, particle size, acid addition in curing stage and specific flow
rates.
The modifications implemented in the vat leach operation and the results obtained
are discussed in this paper.

Hydrometallurgy

HY32

ION EXCHANGE TECHNOLOGY: SOLVING EXISTING PROBLEMS IN
COPPER HEAP LEACHING

P.N. Spiridonov
InnovEco Australia
contact@innoveco.com.au

ABSTRACT

The methods of hydrometallurgical extraction enable nowadays about 20% of the
total primary copper production, which equals about 2.5 million tonnes of copper per year.
The essential hydrometallurgical technique used currently in copper mining is heap
leaching. One of the problems that reduces the efficiency of the heap leaching process is the
presence of fine fraction in the ore. The excessive amount of fines may even totally prevent
heap leaching and make it uneconomical.

An alternative method based on ion exchange technology has been developed by
InnovEco Australia. The laboratory tests and mini pilot plant trials have demonstrated that
the copper extraction rate from fine solids may reach 97-98%. The proposed method could
be a cost effective way to process fines, low grade ores, tailings and cut-offs. This paper
presents results of testing the proposed technique in several applications that might solve
existing problems in copper heap leaching.

Hydrometallurgy

HY33

CHALCOPYRITE MINERAL LEACHING IN PRESENCE OF HYDROGEN
PEROXIDE AT 20 50 C

A. Aracena, I. Daz and H. Olivares
Escuela de Ingeniera Qumica
Pontificia Universidad Catlica de Valparaso
General Cruz 34
Valparaso, Chile
alvaro.aracena@ucv.cl

N. Miranda
Andina Division
CODELCO
Santa Teresa 513
Los Andes, Chile

ABSTRACT

In this work, a preliminary study of the effect of hydrogen peroxide (H
2
O
2
) in a
chalcopyrite mineral containing 15 g of Cu, in a temperature range between 20 and 50C;
and it suggests possible reaction mechanisms. The experimental work was carried out in an
acrylic column equipped with a feed tank, a coil surrounding the column that carries a high
temperature solution, thermocouples and container to collect the percolated solution.
Samples were taken every once in a while to be analysed for Cu and Fe. In addition, solid
residues were collected to be analysed by DRX.

The results without H
2
O
2
showed that when leaching with Fe
2
(SO
4
)
3
+ NaCl, a leached
copper mass of 0.2 g was obtained in 25 days, while pre-treating the material with NaCl
increased the amount of Cu in solution to 0.6 g in a period of 11 days. The results with
H
2
O
2
showed that when using the Fe
2
(SO
4
)
3
+ NaCl + H
2
O
2
solution (30% v/v) through
pulse leaching, 0.85 g of copper was recovered after 17 days. This was due to the action of
the hydrogen peroxide reaction. When the mineral was pre-treated with NaCl, the mineral
dissolution velocity was increased, resulting in a recovery of 0.65 g of Cu in 5 days.
Finally, when increasing the solution temperature up to 50 C, copper recoveries of 0.9 g
were obtained in only 3 days of leaching.

Hydrometallurgy

HY34

INCREASE IN Cu DISSOLUTION BY OPTIMIZING OF THE
AGGLOMERATION CURING STAGE

A. Aracena, R. Crdenas and H. Olivares
Escuela de Ingeniera Qumica
Pontificia Universidad Catlica de Valparaso
General Cruz 34
Valparaso, Chile
alvaro.aracena@ucv.cl

ABSTRACT

In this work, we conducted a study on Cu dissolution and sulphuric acid (H
2
SO
4
)
consumption in the agglomeration curing stage applied to a mixed mineral, an a function
of variables such as H
2
SO
4
, curing time, impurity dissolution, NaCl effect and particle size.
The experimental work was carried out in a pilot-scale agglomeration drum that turned
without reaching its critical speed. The feed to the drum was H
2
SO
4
and H
2
O that contacted
the mixed copper ore. Liquid samples were taken after some time to analyse their Cu, Fe,
Al, Ca and Mg content. In addition, solid residues were collected to make DRX analyses.
The results showed that when using a 25% H
2
SO
4
-75% H
2
O ratio, Cu recovery was 17.3%
with a consumption of 35.9 kg H
2
SO
4
/kg Cu in 3 days, while at 6 days, 18.8% Cu was
recovered, but with a consumption of 45.6 kg H
2
SO
4
/kg Cu.

The impurities dissolution was less than 3%. Later, a Fe
3+
and Fe
+3
+Cl
-
solution was
added, resulting in an increase in recoveries of 19.7 and 21.0%, respectively. Later, solid
NaCl was used for agglomeration; resulting in a recovery of 23.2% Cu. Impurities
remained under 5%. When the particle size was decreased, Cu recovery increased to 26.3%
Finally, hydrogen peroxide with ferric iron was added to the raffinate, hence increasing Cu
recoveries up to 31%.

Hydrometallurgy

HY35

LEACHING LOW GRADE CHALCOPYRITE FROM RUN-OF-MINE
STOCKPILES

C. Caro, M. Ekenes, M. Chavez

ABSTRACT
Leaching copper from low-grade chalcopyrite dominant run-of-mine (ROM)
stockpiles can be challenging and rewarding. Freeport-McMoRan Copper & Gold (FMI)
has tested and implemented an Engineered Heap (EH) process for increasing copper
extraction from such stockpiles by means of controlling heap design, construction and
operating parameters. This includes ore control, air injection, bacterial augmentation, and
pulse leaching. EH process technology was first applied on a commercial scale to ROM
stockpiles by FMI at its Morenci Arizona mine in 2006. Experience to date is presented
along with updates on application of this technology to other operating mine sites.

Hydrometallurgy

HY36

RECOVERY IMPROVEMENTS IN COPPER HEAP LEACHING BY USING
EMEW TECHNOLOGY

Sebastin Badilla C.
1

lvaro Aracena C.
2

Francisco Haussmann P.
3

ABSTRACT
Lifetime of copper oxides in Chile is reaching end and mining companies are very
aware of this inevitable event. As time goes, ore grade decreases resulting in a direct impact
to the copper production and there are no many ways to soften the decay. Nevertheless,
recent studies on copper recovery from electrowinning bleed streams may prove all wrong.
Mining companies with hydrometallurgical processes have the intrinsic need to bleed a
percentage of their rich electrolyte to maintain impurities concentration to a certain level
(such as chloride and ferric / ferrous ions). As this stream has a high concentration of
copper, acid and pollutants, the destiny used for this solution is commonly the raffinate
pond. It is well known by Ficks Law that this procedure impacts negatively on the leaching
recovery as copper contribution to the raffinate increases the cationic load and therefore
decreases the diffusional flux.
In a recent research, copper from electrowinning bleed was recovered using emew
technology before sending it to the raffinate. Two leaching columns with raffinate fed
with both emew-treated and untreated bleed were set to determine whether this copper
depletion has an appreciable impact on the leaching recovery. The results threw a
difference of 8.9 % of copper recovery in favor of the emew treated stream. The follow
publication details the procedure, results and discussions of this interesting breakthrough.
Hydrometallurgy

HY53

HYDRODYNAMICS IN LABORATORY COLUMN LEACHING: EXPERIMENTS
AND NUMERICAL SIMULATION

Bugueo, R.
(1,2)
, Caldern, W.
(1,2)
, Montes-Atenas, G.
(2)
1
2
CS) Research Group. Mining
Engineering Department. Universidad de Chile, Av. Tupper 2069, Santiago, Chile.
2
Department of Mechanical Engineering. Universidad de Chile, Beaucheff 850, Santiago,
Chile.

ABSTRACT
From the point of view of industrial performance of metal extraction, the efficiency
of a column leaching operation depends largely on the leaching agent and the ore properties
such as mineral composition, mineral liberation and particle size distribution. One aspect
that has become particularly important is how the leaching solution flows through the
porous structure which contains the valuable minerals. It is known that the flow rate of
leaching solution depends on factors such as mineral wettability, material porosity, reaction
rates and temperature of the structure. This investigation has the purpose of determining the
dependency of the residence time of a volume of leaching solution with the column
diameter by using experimental data and numerical simulations. The simulations were
performed with the software SVFlux which incorporates material properties such as
drying and wetting soil-water characteristic curve and hydraulic conductivity to understand
the behavior of the residence time. Preliminary results indicated a non-linear behavior of
the residence time with respect to the overall volume of solids in the column. Results from
numerical simulations showed this non-linear behavior in terms of the wall effect and the
production of channeling within the column. Further analysis concerning to the effect of
transpiration and evaporation mechanisms is discussed.

Hydrometallurgy

HY54
EVALUATING THE BIOLEACHING OF MIDUK ORE

Mostafa Mollaei1 ,Mohammad Amin Taheri2

ABSTRACT
Miduk mine is located on 42km far from north east of Share babak city in Keraman
province of Iran . Sampling procedure done on Miduk mine to considering the possibility of
bioleaching study on Miduk ore. Tow aim followed in this regard .firstly searching any
native Bactria and secondly preparing a representative sample to carrying out the tests.
Accordingly an acidithiobacillus ferrooxidans bacteria species were identified with
ability of oxidizing Iron and sulphor .
Preliminary tests using Native Bactria showed 94% a recovery of copper and it was
the best result comparing the other Bacteria .with optimizing the situation we reach 96% as
a recovery.
Hydrometallurgy

HY55

COPPER CONCENTRATED LEACHING IN CHLORIDE-SULFURIC MEDIA

J.P. Ibez, J. Ipinza, F. Guerrero, J.I. Gonzlez and J. Vsquez
Departamento de Ingeniera Metalrgica y de Materiales
Universidad Tcnica Federico Santa Mara
Avda. Espaa 1680, Valparaso, Chile.

ABSTRACT

The mixed leaching of a Chilean copper concentrated (predominantly chalcopyrite)
was studied by using sulphate-chloride aqueous solution under normal pressure at different
temperatures and constant pH. The use of sea water to increase the chloride concentration
was studied as well. The leaching rate in sulphate-chloride solution was faster than in
sulphate solution by a factor of ten in 7 days. The use of sea water led to a dissolution of
28% of the total copper in the same period of time at 60 C, when the chloride
concentration was around 60 g/L the dissolution was near to 36% at 60 C.

The iron content in the concentrate was around 30%, and remains as solid after 7
days of leaching. The brown, reddish and yellow colour solutions resulting after
experiments indicate the presence of different copper chloride complexes ions. Additional
experimental work is carrying out on to improve the copper recovery by analysing addition
of sodium chloride on the copper concentrate cured with sulphuric acid, to generate in
situ hydrochloric acid.

Hydrometallurgy

HY56

THE INFLUENCE OF PROCESS PARAMETERS ON ANODE SLIME LEACHING

Katja Weichert, Thorsten Prei, Harald Kadereit, Peter Stantke, Gnther Leuprecht

ABSTRACT

During copper electrorefining, precious metals as well as valuable metals such as
selenium or tellurium accumulate in the anode slime. Anode slime leaching at Aurubis,
carried out with sulphuric acid under oxidative conditions, aims mainly at the extraction of
copper and nickel. Precious metals and selenium are intended to stay in the residue for
further treatment by oxidative smelting. Depending on the concentrates, the resulting anode
slimes have different compositions and leaching behaviours.

Regarding anode slime treatment, atmospheric leaching and pressure leaching can
be performed. While pressure leaching usually leads to very low copper contents in the
residue, it is also more challenging in terms of maintenance and safety. On the other hand,
additives can be used to enhance the extraction rates during atmospheric leaching.
Here we report the leaching rates of several elements such as Cu and Ni depending on
different process parameters, e.g. temperature, sulphuric acid concentration and oxygen
partial pressure.

Hydrometallurgy

HY57

CAPEX COMPARISON BETWEEN CONVENTIONAL AND MODULAR TYPE
SOLVENT EXTRACTION MIXER-SETTLERS AND PLANTS

Rami Saario
1
, Henri Fredriksson
1
, Jussi Vaarno
1
, Juri Matinheikki
1

1
Outotec (Finland) Oy, Espoo, Finland

ABSTRACT
Outotec has been developing a wide range of solvent extraction technologies
for decades and is now introducing the new Outotec VSFX Plant. The standardized and
modularized Outotec VSFX Plant provides a novel way to design, manufacture, transport,
install, operate and maintain a solvent extraction plant far more efficiently than in the past
with highly sustainable and safe methods.
This paper presents capex comparison between conventional and modular type
VSFX solvent extraction mixer-settler and also evaluates the trends and demands for the
future.
New benefits of the VSFX mixer-settlers include: considerably shorter lead times
for projects, easy capacity expansion possibilities and decreased downtime for settler
maintenance. Furthermore, possible leaks are easy to detect and repair, so that soil
contamination is totally avoided. VSFX mixer-settlers have extra residual value after the
project lifetime since they are easy to disassemble and transport to a new site.
Health and safety issues are essential elements of Outotecs solvent extraction
technologies. We ensure that our technologies are easy to control and have a low
maintenance requirement. The operators safety is strictly observed from the design phase
forward. Safety with respect to operation, equipment, the environment and personnel is
enhanced in an easy and convenient manner with the help of advanced automation.

Hydrometallurgy

HY58

METALLURGICAL DEVELOPMENT OF THE ESCALONES DEPOSIT

David Dreisinger
South American Silver Corp.
650 West Georgia Street, Suite 2100
Vancouver, Canada V6B 4N8

Mike Ounpuu
22 Crestwood Avenue
Peterborough, Canada K9J 1M8

Germain Labonte and Niels Verbaan
SGS Minerals Services Lakefield site
PO Box 4300
185 Concession Street
Lakefield, Canada K0L 2H0

ABSTRACT
The Escalones deposit of South American Silver is located 97 km south of Santiago,
Chile. The deposit is being explored as a large porphyry system with associated skarn. The
Escalones deposit has an inferred mineral resource of 420 million tonnes of mineralized
material containing 3.8 billion pounds of copper, 56.9 million pounds of molybdenum,
610,000 ounces of gold and 16.8 million ounces of silver using a 0.2% copper equivalent
cut off grade. Samples of various types of mineralization from Escalones have been
selected for metallurgical testing including materials with porphyry, skarn, hornfels
mineralization. The detailed results of flotation, leaching and comminution studies on
Escalones mineral samples are presented.

Hydrometallurgy

HY59

LAS CRUCES COPPER PLANT START-UP: BEYOND DESIGN PERFORMANCE
THROUGH PROCESS IMPROVEMENTS IMPLEMENTATION

Enrique Delgado, Plant director
Carlos Fras, Director of Technology
Joaqun Gotor, Process Control chief

ABSTRACT
Las Cruces Copper hydrometallurgical plant was started up in May 2009. Nominal
production of 6000 t cathodes/month was reached in April 2012. During the ramp-up and
subsequent period a series of improvements were carried out, regarding flow sheet
modifications, materials, process parameters and process control. All these modifications
led to settle and even exceed production and process recovery among other parameters.
This paper comprises all the changes implemented and their impact in the process
performance

Hydrometallurgy

HY60

CHALLENGES OF LARGE-SCALE MINING IN PLANTS OF SOLVENT
EXTRACTION

Jorge Retamal, jreta003@codelco.cl, Codelco Chile Divisin Gabriela Mistral.
Jos Espada, jespada@codelco.cl, Codelco Chile Divisin Gabriela Mistral.
Mara Szabo, maria.szabo@inprocessconsulting.com, INprocess Consulting Ltda.
Alexis Soto, alexis.soto@inprocessconsulting.com, INprocess Consulting Ltda.
Mauricio Morales, mauricio.morales@inprocessconsulting.com, INprocess Consulting
Ltda.

ABSTRACT

At present the large-scale mining of Chile presents significant challenges, since over
time CuT grade in oxidized ores have been declining and production programs continue to
be demanding. This forces the current operations of solvent extraction to innovate in a new
way to make more efficient the current facilities.

As an alternative, this new condition requires to analyze the way of supplementing
low grade with greater flows of processing and define what is the best configuration for the
particular conditions of each operation.

Given this situation, Codelco Chile, Gabriela Mistral Division, is studying the
transformation of their solvent extraction plant, in order to process a higher volume of PLS
to lower copper concentrations.

This study shows the alternatives configurations evaluated to meet productions
levels settled until the year 2024.

Hydrometallurgy

HY61

DEVELOPMENT OF A MATHEMATICAL MODEL TO PREDICT HEAT
TRANSFER PHENOMENA IN SOLVENT EXTRACTION PROCESS

C. Gutirrez and J.C. Lpez
Fundacin Chile
Avda. Parque Antonio Rabat Sur 6165, Vitacura
Santiago, Chile 6671199
cgutierrez@fundacionchile.cl

P. Navarro
Universidad De Santiago De Chile
Avda. Libertador Bernardo OHiggins 3363, Estacin Central
Santiago, Chile 32349

ABSTRACT
Developed in Excel a mathematical model has been produced that predicts the
thermal behavior presented by Solvent Extraction process (SX) and the transfer of heat
generated in their flows, mainly in the rich electrolyte and raffinate, when there are changes
temperatures in PLS (pregnant leach solution) due to reactions caused by bacteria within
the stockpile, as in the case of bioleaching, or by environmental conditions to which this is
located.
The model was developed for a particular plant that used bacterial leaching and this
consist in to enter flow data, physical properties and inlet temperatures, to a sequence of
equations based primarily in energy balances performed at different stages of the SX
process. Keeping constant the inlet temperature of the lean electrolyte, were used historical
temperatures of the PLS recorded by the plant to perform sensitization of the thermal
impact generated en SX. Rich electrolyte temperatures and raffinate, delivered by the
model showed an average deviation of 0.63 C, compared to the actual values.
Hydrometallurgy

HY62

FACTORS INFLUENCING THE ELECTRO-ASSISTED REDUCTION OF
CHALCOPYRITE

G.T. Lapidus

and E. Martnez-Jimenez

Universidad Autnoma Metropolitana Iztapalapa
Depto. Ingeniera de Procesos e Hidrulica
Av. San Rafael Atlixco 184, Col. Vicentina, Mxico, D.F. 09340, Mxico
gtll@xanum.uam.mx

Carlos Lara-Valenzuela

Servicios Administrativos Peoles, S.A.
Torren, Coahuila, Mxico

ABSTRACT
Electro-assisted reduction is an effective pretreatment to render chalcopyrite less
refractory towards oxidative leaching. In this process, chalcopyrite is selectively converted
to chalcocite or copper metal in an electrolytic cell under ambient conditions, while ferrous
ion is leached into solution. It has the additional advantage of being selective for copper
and some silver phases, and therefore, can be used on complex sulfide concentrates.
However, the reaction velocity is still subject to passivation, especially at elevated solid to
liquid ratios. In the present work, the influence of solution composition, temperature,
cathode/particle contact and electrode materials were tested and are discussed, in reference
to the proposed reaction mechanism. Electro-assisted reduction and, subsequent oxidative
leaching tests for copper show that, once the solution formulation was optimized, the
cathode/particle contact time and electrode materials were found to be the most significant
variables, while the temperature was deemed unimportant. Although this last finding is
counterintuitive, it is consistent with the dominant mechanism.
Keywords: Chalcopyrite, Leaching, Electro-assisted Reduction

Hydrometallurgy

HY63

DEVELOPMENT OF A NEW GENERATION OF COPPER SOLVENT
EXTRACTION REAGENTS

Jack Bender, Nathan Emmerich, Andy Nisbett
BASF Mining Solutions
2430 N Huachuca Drive
Tucson, AZ, 85745
jack.bender@basf.com

ABSTRACT
BASF Mining Solutions have developed a new generation of copper solvent
extraction reagents that are not based on the current oxime chemistry. Initial laboratory
studies have shown that these new reagents offer the benefits of a dramatic increase in
resistance to degradation and are nitration proof.
From an operational standpoint, the new reagents show acceptable copper net
transfer capabilities from typical leach solutions together with a step change improvement
in copper : iron selectivity in comparison to the existing highly modified aldoxime
formulations. This paper details some of the fundamental laboratory studies completed to
date as well as some preliminary data from a continuous pilot plant evaluation at a
commercial solvent extraction operation.
Hydrometallurgy

HY64

THE PHENOMENON OF NITRATION IN THE CHILEAN
COPPER HYDROMETALLURGY

Rodrigo Zambra, Alejandro Quilodran and Osvaldo Castro
Cytec Chile Ltda.
Los Orfebres 305, La Reina
Santiago, Chile
rodrigo.zambra@cytec.com

ABSTRACT

The phenomenon of nitration in the solvent extraction plants has been an
important factor in the projects and operations in northern Chile, mainly due to its
adverse effects on the good copper transfer to electrowinning.

Since it was discovered in the 90s as a result of the events that occurred at the
Lomas Bayas solvent extraction plant, different studies have been carried out in order to
understand this chemical phenomenon that affects the organic phase and to be able to
offer a better alternative regarding the formulation of the extractant for the plants
affected by nitration.

This study explains the phenomenon of nitration from the chemical-operational
perspective and the alternatives of extractants that are resistant to this phenomenon. The
results respond to different studies and operational results in solvent extraction plants
currently in operation and showing the best operational practices. Comparative results
of extractants based on modified Aldoximes (ACORGA NR) and Ketoximes, both
with protection against nitration, are also shown.

Finally, the best metallurgic response of extractant ACORGA NR, in relation
to extraction efficiency, Cu:Fe selectivity and high protection against nitration, is
shown.

Hydrometallurgy

HY67

OPTIMIZATION STRATEGIES FOR BIOLEACHING OPERATIONS
Jorge M. Menacho and Francisco J. Troncoso
Chile, (562)-738-4493, drm@drm.cl

ABSTRACT
Options to improve the bioleach business results are discussed, such as
systematic strain inoculation, pyrite addition, heating of solutions, on-off irrigation
strategies and finer feed size distribution.
Options for a typical dump leach operation are evaluated assisted by a robust
phenomenological model, previously tuned with industrial plant response.
Examples are given related to impact of the optimizing changes into the
production results.
Hydrometallurgy

HY66

SCALE UP OF HEAP AND DUMP LEACHING RESULTS
Jorge M. Menacho and Francisco J. Troncoso
drm@drm.cl

ABSTRACT
A novel procedure to project heap leaching results from one scale to a different
one is proposed. The procedure is based on a phenomenological approach which
considers decoupling the dissolution kinetics and the flow pattern through a variable-
saturation porous bed and then sequentially projecting individual effects to finally
predict the overall scaled results.
The above-mentioned procedure has been successfully applied to heap leaching
of crushed ores, ROM dump leaching and ripios secondary leaching, bioleaching and
chloride processes. It equally applies to copper, gold and other non-ferrous metals as
well as caliches heap leaching processes.
The new procedure has been extensively validated and several real examples are
presented showing the high predictability of the scale up procedure.
Electrowinning and Electrorefining

SYMPOSIUM: 05 ELECTROWINNIG AND ELECTROREFINING
CODE AUTHOR TITLE ABSTRACT
ER01 Shunsuke Kawai CFD SIMULATION OF COPPER ELECTROREFINING PROCESS
AND ANALYSIS FOR THE TANKHOUSE OPERATION AT
NAOSHIMA SMELTER AND REFINERY
ER02 Luis Navarro CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE
ASARCO REFINERY
ER06 Jari Aromaa CORROSION OF STAINLESS STEEL CATHODE BLANKS IN
COPPER ELECTROREFINING
ER07 Michael Moats, Tim
Robinson
GLOBAL SURVEY OF COPPER ELECTROREFINING OPERATIONS
AND PRACTICES
ER09 Shuklin, M.A. TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMC'S
(URALELECTROMED) NEW COPPER ELECTRO REFINERY
ER10 Guillermo Rios RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE
TREATMENT PLANT AT ATLANTIC COPPER
ER11 G. Leuprecht - N. Izatt THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF
THE MODERNIZATION PROJECT
ER14 Ari Rantala USE OF REAL-TIME INFORMATION IN TANKHOUSE
OPERATIONAL EFFICIENCY IMPROVEMENT AND QUALITY
CONTROL
ER16 Jimmy Bidwell TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE
PRECIPITATION
ER17 Hidehiro Sekimoto SOLUBILITY PRODUCT OF ANTIMONY ARESENATE AND
BISMUTH ARSENATE
ER18 Takahito Kasuno SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING
DIFFERENT METALS DURING COPPER ELECTROREFINING
ER19 Masaomi Kanazawa RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI
REFINERY
ER20 Yuuki Watanabe QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT
NAOSHIMA SMELTER & REFINERY
ER21 Masaaki Kato THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE
INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND
REFINERY
ER23 A.E. Wraith ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY
AND THE WORLD`S FIRST COMMERCIAL ELECTROREFINERY
ER24 Michael J Nicol IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR
POOR CONTACTS?
ER25 Shijie Wang DETERMINATION OF BISMUTH CONTAMINATION IN COPPER
ER28 Nedelcho Dragoev AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE
ER31 Rodrigo Abel STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)

ER33 Stefan Konetschnik COST COMPARISON BETWEEN A CONVENTIONAL ER
TANKHOUSE AND A HIGH CURRENT DENSITY ER TANKHOUSE
USING THE METTOP-BRX-TECHNOLOGY
ER34 Gerardo Cifuentes COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC
PROCESSES
ER54 Gnter Leuprecht DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY
LIBERATOR CELLS AT AURUBIS, HAMBURG USING EMEW
ELECTROWINNING TECHNOLOGY
ER59 J.P. Ibaez REDUCING THE SCRAP IN ELECTRO-REFINING BY USING
EARLESS SYSTEM. LABORATORY INVESTIGATION
ER60 Clyde Wright - Marty
Wessman
MOVING COPPER MATERIAL HANDLING FORWARD USING
ADVANCED DESIGNS BY BROCHOT COMPANY
ER61 Cristian Cortes E CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC
REFINERY OF THE VENTANAS DIVISION
ER62 Michael Stelter PURER CATHODES BY NEW ADDITIVES IN COPPER
ELECTROERFINING
ER63 Songlin Zhou COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING
AT HIGH CURRENT DENSITY
ER66 Marco Cifuentes A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE
EXTRACTION OF ANTIMONY
EW03 Patricio Melani - P.A.
Aylwin - N.I. Lagos
SELE MODULAR TECHNOLOGY TO ACHIEVE SUSTAINABLE
DEVELOPMENT AND EFFICIENT IN EW PLANTS
EW04 Scott Sandoval OPERATION OF ALTERNATIVE ANODES AT CHINO SXEW
EW05 Tim Johnston HATCH HELM TRACKERTM SYSTEM FOR GUIDING CELL HOUSE
PERFORMANCE IMPROVEMENT
EW12 R. Rajasingam ELIMINATION OF ACID MIST IN COPPER ELECTROWINNING
EW15 Luis G. Navarro SMALL COLUMN TESTING OF SUPERLIG 83 FOR BISMUTH
REMOVAL FROM COPPER ELECTRO REFINING ELECTROLYTE
EW22 Robert P. Dufresne CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT
SHORT CIRCUITS
EW26 M. Morimitsu A STATE OF THE ART ANODE TECHNOLOGY: SMART ANODE,
MSA, FOR COPPER ELECTROWINNING
EW27 Rob Fraser COMPARISON OF INTERCELL CONTACT BARS FOR
ELECTROWINNING PLANTS CONSIDERING THERMAL EFFECTS
EW29 Abbas Mirza OPTIMIZATION OF THE USABLE LIFE OF LEAD
ELECTROWINNING ANODES
EW30 Andreas Siegmund ELECTROLYTIC TANKHOUSE ACID MIST CONTROL - MEETING
STRINGENT WORKER EXPOSURE LIMITS AND EMISSION
TARGETS
EW35 Francisco Sanchez ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS
ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL
DIVISION

EW36 Michael Moats -Tyler
Helsten
AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND
POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE
ROUGHNESS IN COPPER ELECTROWINNING
EW38 Tomas Vargas THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING
ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION
AND CATHODE QUALITY
EW53 Ricardo Fuentes EXPERIENCIES ON DESIGN, MANUFACTURING AND
OPERATION OF HIGH CONTROLLED TRANSFORMER-
RECTIFIERS FOR SX-EW COPPER PLANTS
EW55 A. Fiorucci DE NORA'S SOLUTION - PART I, DSA ANODES FOR CU
ELECTROWINNING
EW56 A. Fiorucci DE NORA'S SOLUTION - PART II, ACID MIST ABATEMENT
EW57 Gabriel Zarate MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS
EW58 Michael J Nicol MASS TRANSPORT TO CATHODES IN THE ELECTROWINNING
OF COPPER
EW64 A.Lillo EXMAJET, POTENTIAL FOR IMPROVED ACID MIST CAPTURE
AND CATHODE QUALITY AT HIGH CURRENT DELSITY
ELECTROWINNING
EW65 P. Los - A. Lukomska - S.
Kowalska - M. Masalski -
M. Kwartnik
POTENTIAL-CONTROLLED ELECTROLYSIS AS A NEW METHOD
OF COPPER ELECTROREFINING AND ELECTROWINNING -
DISCUSSION OF SOME BASIC ASPECTS


ER01

CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND
ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER &
REFINERY

S. Kawai and T. Miyazawa
Computer-Aided Materials Engineering Department, Central Research Institute, Mitsubishi
Materials Corporation
1002-14 Mukohyama, Naka-shi, Ibaraki 311-0102, Japan
skawai@mmc.co.jp

ABSTRACT

Copper market has been requesting its smooth appearance on the LME Grade A
Copper in addition to its composition. It is considered that nodular growth on cathode
surfaces is inhibited by preventing the adhesion of anode slime particles to cathodes and
supplying additives optimally to cathodes. The way of circulating electrolyte, such as
bottom inlet to top outlet, side inlet to top outlet etc., may affect both the slime
behavior and the additive supply to cathodes. The authors have simulated flow patterns in
the cell generated by several different ways of circulating electrolyte and analyzed the
amount of slime particles reaching cathodes and the delivering time of fresh additives to
cathodes using the computational fluid dynamics (CFD) model. The calculation results
have revealed that the electrolyte circulation of side inlet to top outlet which Naoshima
Smelter and Refinery has adopted has some advantages, such as inherent flows that
contribute to the reduction of slime particles reaching cathodes, and the uniform time to
deliver additives to every cathode, which can minimize the cell flow rate necessary to keep
smooth appearance of cathodes. Detailed advantages of side inlet to top outlet are
discussed in comparison with other conventional ways of electrolyte circulation.


ER02

CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO
REFINERY

Luis Navarro
1
, Tracy Morris
1
, Weldon Read
1
, Neil E. Izatt
2
, Ronald L. Bruening
2
, and
Steven R. Izatt
2
,

1
Asarco
7001 State Highway 136
Amarillo, Texas 79106, U.S.A.

2
IBC Advanced Technologies, Inc.
856 E. Utah Valley Drive,
American Fork, Utah 84003, U.S.A.

ABSTRACT

An effective removal system for the separation of dissolved bismuth from copper
electrolyte to reach desired bismuth levels has been developed by IBC Advanced
Technologies, Inc (IBC). This system is being operated at ASARCO in Amarillo, Texas to
produce high purity electrolytic copper. Control of bismuth concentration is necessary
because bismuth levels exceeding 2 ppm in the final copper product result in brittleness
making the product unsuitable for wire production. The bismuth removal system is based
on IBCs Molecular Recognition Technology (MRT) process.

This process employs proprietary non-ion exchange resin materials, termed
SuperLig, to effect the separation. Key benefits of the MRT process for bismuth removal
include (1) easy control of the bismuth levels in the tank house electrolyte, (2) avoidance of
brittle copper, and (3) flexibility to handle dirty copper concentrates as feedstock. This
paper describes the bismuth MRT plant at the Asarco refinery, the operating process, and
the results. Limitations of alternate technologies for bismuth control are discussed,
particularly with respect to their environmental concerns compared to the MRT
process. Benefits of the MRT system to copper refineries where bismuth problems exist
are presented.


ER06

CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER
ELECTROREFINING

Jari Aromaa, Antti Kekki, Olof Forsn
Aalto University
Department of Materials Science
PO Box 16200
00076 Aalto
Espoo, FINLAND

ABSTRACT

The AISI 316L type stainless steel is considered corrosion resistant in copper
electrorefining electrolyte, both as permanent cathode blank material and in process
equipment and piping. Damaged cathode blanks show increased surface roughness,
corrosion pits and deeper grain boundaries. The test hypothesis was that too high chloride
concentration and temperature can cause localized corrosion.

A synthetic electrolyte with 180 g/l H
2
SO
4
, 45 g/l Cu, 15 g/l Ni and 10 g/l As was
used. Test variables were temperature 50-70
o
C and chloride concentrations from 40 ppm to
1000 ppm. Test method was cyclic polarization curve based on ASTM standard G61-86.

No pitting or crevice corrosion was seen in the test series but highest chloride
concentration resulted in wider active peak and higher passive current densities. In
transpassive corrosion tests localized corrosion on grain boundaries and detachment of
grains was seen. Two main possibilities for blank corrosion have been identified. High
chloride concentration can cause active dissolution. The concentration of chlorides has to
be at least 10 times higher than the normal chloride level. Polarization to transpassive
potentials causes corrosion on grain boundaries and detachment of grains. The only
possibility for transpassive dissolution is stray currents.


ER07

GLOBAL SURVEY OF COPPER ELECTROWINNING OPERATIONS AND
PRACTICES

Michael Moats
Associate Professor of Metallurgical Engineering,
Materials Research Center
Department of Materials Science and Engineering
Missouri University of Science and Technology
Rolla, MO 65409, U.S.A.
moatsm@mst.edu

Tim Robinson
Senior Vice President
Republic Alternative Technologies, Inc.
11288 Alameda Dve
Strongsville, OH 44149, U.S.A.
trobinson@republicgreentech.com

Shijie Wang
Princple Advisor Process Engineering
Rio Tinto - Kennecott Utah Copper
Magna, UT 84044, U.S.A.
shijie.wang@riotinto.com

Andreas Filzwieser
Info

Andreas Siegmund
Gas Cleaning Technologies (GCT) LLC
4953 N. OConnor Road
Irving, TX 75062 U.S.A
siegmund@gcteng.com

William Davenport
Professor Emeritus
University of Arizona
Tucson, AZ 85721, U.S.A.
billdavenport@live.com


ABSTRACT

World copper electrorefining tankhouse operating practices have been surveyed and
reviewed. Previous surveys have been conducted in association with all International
Copper-Cobre conferences. This survey will include detailed analyses of historical and
current data to identify trends and operating correlations. Examples of recent design and
operational choices to increase productivity, improve copper quality and/or decrease
electrical energy consumption will be given.


ER09

TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMCS

Shuklin, M.A., Romanov, A.A, Bakhirov, N.Y
JSC Uralelektromed
1 Lenin str., Verkhnyaya Pyshma,
Sverdlovsk region, 624091, Russia
Phone +7 (34368) 4 71 38, 4 61 22
Fax: +7 (34368) 4 60 99, 4 26 26
Larinkari,M., Hukkanen, R.
Outotec (Finland) Oy
Riihitontuntie 7D (P.O Box 84)
02201, Espoo, Finland
Phone +358 20 529 211
Fax: +358 20 529 2200

ABSTRACT
A modern tankhouse relies on high performance material handling, fully automated
process control systems, quality assessment data and consistent operations reporting to
ensure high efficiency of operation and stable quality of final product. In 2012, Outotecs
and Uralelectromeds specialists have developed comprehensive tankhouse process
automation solution called Tankhouse Information Management System (TIMS), which has
been implemented at UMMCs (Uralelektromed) new 150 tpa copper electro refinery in
Verkhnyaya Pyshma, Russia.

TIMS collects process data from different systems and material handling equipment
into a central database, providing material tracking and process key performance indicator
calculations. TIMS automates daily production reporting and provides various analytical
views of the process which can be used at higher level in business control systems.

As a result an essential part of the new tankhouse operation information is provided
by TIMS. Systematic and accurate reporting is based on real-time information which
requires minimal manual work by the personnel. Gained benefits are increased visibility

and awareness of the process, which has already supported both active supervision and
continuous improvement of tankhouse operations.


ER10

RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT
PLANT AT ATLANTIC COPPER

G. Ros, R. Ramrez, C. Arbizu, I. Ruiz,
Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold)
Av. Francisco Montenegro, s/n
21001 Huelva, Spain

ABSTRACT
Approximately 160 m3/day of electrolyte bleed from the Atlantic Copper Refinery
Tankhouse is sent daily to the Electrolyte Treatment Plant to control the copper content and
impurities (As, Sb and Bi) in the electrolyte. Much of the solution leaving the 3rd stage
liberator circuit is returned to the tankhouse, but a small portion (~28 m3/day) is bled to the
weak acid neutralization plant for minor element control (Fe, Ca). Laboratory and pilot
scale tests have been carried out in order to recover the nickel from this bled solution as
nickel carbonate, using different ion exchange resins technologies. Based on the excellent
results obtained from these tests, Atlantic Copper decided to build a nickel carbonate
production plant, which is expected to be commissioned in February 2013. ECOTEC
Recoflo technology has been chosen for removing the sulphuric acid from the feed
solution.Once the acid is removed, then, through a neutralization process, it is possible first,
to purify the electrolyte and then, to precipitate nickel as nickel carbonate.


ER11

THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE
MODERNIZATION PROJECT

G. Leuprecht and R. Behlmer
Aurubis AG
Hovestrasse 50
D-20539 Hamburg, Germany
g.leuprecht@aurubis.com

ABSTRACT

The Hamburg tankhouse of Aurubis was built in 1989 and expanded in 1992. After
more than 20 years of operation, the old lead lined cells had reached the end of their lifes.
During a 3-year program, 1080 old cells have been replaced by polymer concrete cells. The
replacement was executed section by section during normal operation of the tankhouse.
Each turnaround was completed during an anode cycle of 21 days. All steps will be
described in this presentation. In parallel to the replacement program, longer cells with an
increased number of anodes and cathodes were installed.

This fact combined with the full utilization of the rectifier capacity has maintained an
increase of cathode capacity to 416,000 mt per year. Beside the change of the cells, some
modifications into the handling systems were necessary. So the inlet and outlet conveyors
of the stripping machines and the spacing conveyor of the anode preparation machine had
to be adapted to the increased number of electrodes in the cells. Also a special construction
of the crane bale was required for operating old and new cells during the conversion time.
After the retrofit, the modernized tankhouse has increased its productivity and will be
able to achieve the technical and economical demands for the next future.


ER14

USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL
EFFICIENCY IMPROVEMENT AND QUALITY CONTROL

Ari Rantala
Manager, Advanced Process Control

ABSTRACT

Optimizing the operations efficiency and cathode quality of a tankhouse requires not
only the efficient use of energy and labor, but also high availability of machinery and the
ability to rapidly observe and react to disturbances. With the use of proven innovative on-
line monitoring and information management systems now available in the market
parameters such as efficiency, productivity and quality can be assessed in real-time mode.
Some of the systems discussed in the paper include systematic surface quality inspection of
anodes and cathodes and permanent cathode condition.
Another system indicates cell performance on-line, facilitating early reaction to
critical events such as short-circuiting, flow blockages, anode passivation or electrolyte
temperature excursion at the cells. Obviously, it is also highly desirable to integrate such
abovementioned information into one overall management system, along with other
important plant information such as that provided by material handling machinery, process
control systems, on-line analysers and laboratory. Such a management system provides
transparency for operations through real-time production efficiency and quality reporting
and material tracking. Practical benefits of utilizing such systems are described and
illustrated with case examples.


ER16

TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE
PRECIPITATION

Jimmy Bidwell, Luis G. Navarro, Weldon Read, Tracy Morris
ASARCO LLC, Groupo Mexico, 7001 State Highway 136, Amarillo Texas, 79108

ABSTRACT

The liberator cells department at Amarillo Copper Refinery has the objective of
reducing metal impurities in the copper electrolyte to achieve high quality cathodes via
electrowining. Insoluble lead anodes are used and the copper is depleted from the
electrolyte and then electrodeposited to copper starter sheets.

After the electrowinning process, the decopperized electrolyte solution is sent to the
Acid Purification Unit (APU), where sulfuric acid and arsenic are absorbed into the resin
and then desorbed using water which is then returned to the tankhouse to be reused as acid
make up and to increase arsenic concentration in the electrolyte. During this process, the
APU generates a byproduct stream that is high in nickel and other valuable metals that can
be further processed and the metals recovered.

This paper discusses how it is possible to precipitate a Nickel Carbonate product
when the de-acidified electrolyte is treated using sodium carbonate. The pH selective, 2-
step process first recovers copper still present in the solution and transforms it into a
product that can be processed and further recovered at the Hayden Smelter in Arizona.


ER17

SOLUBILITY PRODUCT OF ANTIMONY ARSENATE AND BISMUTH
ARSENATE HIDEBIRO SEKIMOTO

Fuyuhiko Miyanaga and Katsunori Yamaguchi

ASBTRACT

The solubility product of compounds consist mainly of the 15 group elements
(arsenic, antimony and bismuth) is essentially important information for understanding the
mechanism of the formation of anode slimes in electrolytic refining process and is useful
for prevention of the formation of floating slimes which are adversely affect the current
density and the quality of copper cathode.

The empirical value of the solubility product of several arsenates has been reported
using the operation data in some copper refineries. However, there is no report on the
solubility product based on the equilibria of dissolved chemical species. In this study, the
solubility product of typical antimony arsenate and bismuth arsenate represented as ShAs04
and BiAs04, respectively, in sulfuric acid solutions were investigated.

The sulfuric acid solution containing arsenic acid was saturated with the arsenates
prepared in our laboratory, and then, the concentration of As, Sb and Bi in the solution was
measured by 1CP-AES. Using the results, the solubility product of SbAs04 and BiAs04
was determined.


ER18

SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT
METALS DURING COPPER ELECTROREFINING

Takahito KASUN0,1 Atsushi KITADA,1 Kimihiro SH1MOKAWA,2 and Kuniaki
MURASE1
1 Department of Materials Science and Engineering, Kyoto University, 36-1
Yoshida-hornrnachi, Sakyo-ku, Kyoto 606-8501, Japan 2 PAN PACIFIC COPPER Co.
Ltd., Refinery Manager, 3-3382 Saganoseki, Oita-shi, Oita, 879-2201, Japan
E-mail: kasuno.takahito.53w@st.kyoto-u.ac.jp (Takahito KASLNO)

ABSTRACT

Electrolytic copper contains, on average, 10 ppm silver as impurity, which leads to a
loss of silver as a cash-cow product for copper smelters. Most of silver included in blister
copper anodes passes into anode slime when electrolyzed, keeping the elemental state.
However, once a part of elemental silver oxidatively-dissolves from the anode or from
anode slime for some reason, then silver can co-deposit with electrolytic copper cathode,
since silver is nobler than copper. In the present work, the dissolution behavior of silver
from anode slime was examined using granular silver as a model of the slime.

We have shown that the silver dissolution is caused by dissolved oxygen in the
electrolyte, and that thiourea and/or chloride ions as usual additives play a role to suppress
the silver dissolution approximately to half. Moreover, it was found that the dissolution of
silver was almost perfectly suppressed by galvanic contacting of the granular silver with
less noble metals (Pb or Cu) immersed in the same electrolyte.

ER19

RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY

Masaomi Kanazawa, Akira Ueno, Kimihiro Shimokawa
Saganoseki Smelter & Refinery Pan Pacific Copper Co., Ltd. Japan Tel 81-97-575-3555,
Fax 81-97-575-3513 kanazawa@ppcu.co.jp Address, postcode: 879-2201, 3-3382
Saganoseki Oita-shi, Oita, Japan

ABSTRACT

Saganoseki Refinery of Pan Pacific Copper Co., Ltd. integrated three existing
tankhouses into two by introducing the Waxless ISA type permanent cathode process in
2006. To achieve the higher current efficiency and better cathode quality at current density
over 300 A/m2, the electrolyte filtering system was introduced to remove the suspended
solids (S.S) in the electrolyte in 2009.

The additives continuous feeding system, jointly developed with Taman Refinery
of Hibi Kyodo Smelting Co., Ltd., has been installed in 2011, achiving over 97% current
efficiency at 311A/m2 current density. Several improvements were also executed to ensure
the steady operation and to increase the productivity. Owing to the improvements,
Saganoseki Refinery currently continues the stable and efficient operation with maintaining
the adequate cathode quality. This paper describes the outlines of improvements as well as
the current operational status.

ER20

QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSLAMA
SMELTER & REFINERY

Yuuki Watanahe, Shigehiro Arakawa
Naoshima Smelter and Refinery Mitsubishi Materials Corporation 4049-1, Naoshima-eho,
Kagawa-gun, Kagawa 761-3110, Japan TEL +81-87-892-3201 FAX +81-87-892-4091

ABSTRACT

Copper tank house in Naoshima Smelter Gr Refinery started with a capacity of
7,500 Um of electrolytic copper in 1969 and subsequently enhanced the capacity to
19,500t/rn until 2006 by expanding the number of tank-house cells and raising the current
density of commercial cells. After the expansion above, the tank-house operation has
focused on obtaining customer satisfaction by improving cathode quality and smoothing
cathode surface. An on-site automatic analysis was introduced to control the chemistry of
electrolyte stringently. Filtration equipments were expanded in the capacity from 10% of
the electrolyte to whole electrolyte.

These modifications have reduced dense nodules and smoothed the cathode surface
much. Integral electro-deposition on the cathode has lowered the frequency of short circuits
between electrodes and resulted in increasing in current efficiency from 96.5% to over
97.5%. Mitsubishi materials corporation naoshima smelter & refinery tank house section

ER21

THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE
INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY

Masaaki Kato
Manager of Refinery Onahama Smelter & Refinery Onahama Smelting and Refinery Co,
Ltd e-mail: m-katommc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-3951

Masanori Yoshida
Manager of Production Division Onahanna Smelter & Refinery Onahama Smelting and
Refinery Co, Ltd rnyoshida@nunc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-3951

Tetsuro Sakai
Managing Director & General Manager Onahama Smelter & Refinery Onahama Smelting
and Refinery Co, Ltd e-mail: tesakaigmmc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-
3951

ABSTRACT

Since 2007, Onahama Smelter and refinery has operated the 0-SR process which
comprises the S-furnace of the Mitsubishi process is followed by two hearths of
reverberatory furnaces in order to increase the capacity of copper concentrates. Such
enhancement at the smelter requested the tank-houses to increase the productivity more
than 25% coping with impurities load of electrolyte. The productivity has been enhanced by
increasing current density which reinforced rectifiers of No.1 and No.2 tank-houses, and
have supplied and increasing the number of daily operation cells by 25%. Impurities in
electrolyte have been managed by resuming the operation of the secondary liberator cells
and controlling impurities load of the electrolyte. Furthermore,

ER23

ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE
WORLD'S FIRST COMMERCIAL ELECTROREFINERY

A.E. Wraith*,
Consultant, Exeter, UK.

P.J. Mackey,
P.J. Mackey Technology Inc., Kirkland QC, Canada.

R. Protheroe Jones,
National Museum of Wales, Swansea, UK.

ABSTRACT

It is well known that the worlds first copper electro-refinery started production in
1869 at Pembrey in South Wales. Built within the Pembrey Copper Smelter which had
commenced operations in 1849, the new refinery was based on principles described in the
British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices
pioneered there were key to the foundation of modern electro-refining practice in what is
now a dominant international industry producing 14 Mt of electrical grade copper annually.
This paper explores the background to this pioneering application of the new, early 19th
century, science of electro-metallurgy and examines its links to the contemporary
decorative electro-plating industry and to the shortcomings of 19th century fire refining.
The beginnings and early years of the Pembrey electrorefinery are briefly discussed in
relation to the quality, applications and pyrometallurgy of copper at the time. Elkingtons
ideas and the commissioning of the Pembrey refinery can now be recognised as vital
precursors of the modern electrical age.


ER24

IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR
CONTACTS?

Michael J Nicol and Justin McGinnity
Murdoch University, Perth, W. Australia

ABSTRACT

Measurements of cell voltages on several copper, zinc and nickel tankhouses have
been made with a view to assessing the reliability of cell voltage as an indicator of shorts or
poor contacts in electrowinning cells. In addition, simulations of current distribution in
contiguous cells have been made using commercial electrical circuit simulation software
adapted to the flow of current in electrowinning cells using the normal Walker
configuration.

The results of both plant measurements and simuations have revealed that the use of
cell voltage as an indicator of the presence of shorts or poor contacts in electrowinning cells
can be ambiguous. Both in the measured cell and in adjacent cells, erroneous conclusions
can be drawn depending on the location of the voltage measurement.

The important factors which determine the variations in measured cell voltages have
been identified. It is recommended that operations make simple voltage measurements in a
number of locations in a number of cells to establish the reliability of such measurements
for their operations.


ER25

DETERMINATION OF BISMUTH CONTAMINATION IN COPPER

Daniel Kim, Shijie Wang
Rio Tinto Kennecott Utah Copper
Magna, UT 84044
wangs@kennecott.com

ABSTRACT
Bismuth is a most critical impurity to cause copper grain boundary cracks in
wiredrawing. How to control bismuth in copper electrorefining process is an interesting
topic for most copper refineries in the world. From the London Metal Exchange (LME)
and the American Society for Testing and Materials (ASTM), specifications for bismuth
content in copper are 2.0 ppm and 1.0 ppm, respectively. Due to a fact that copper anodes
at KUC contain a significant amount of bismuth, it is a very critical task to determine,
minimize, and control the bismuth contamination in the copper production. This article
presents the methods and techniques used in the study of bismuth contamination. It also
summarizes the contamination mechanism identified in the process control of copper
electrorefining process at KUC.


ER28

AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE

Iv. Djurov
D. Kirilov; N. Dragoev; L. Gerov; K. Nedeleva; A. Saraev;
AURUBIS BULGARIA
Industrial zone
i.djurov@aurubis.com

ABSTRACT

ISA 2000 Refinery was put into operation on July 2008 with design capacity of 180
000 tons copper cathodes per year. Refinery includes two electrolyte circulation systems
and Deep electrolyte decopperization section. Final treatment of the bleed electrolyte is
performed in Waste Water Treatment Plant.

As permanent cathodes are used SS blanks. Between both electrolyte circulation
systems there are situated Anode Preparation machine, Full Deposit Stripping machine and
Anode Scrap Washing machine. Control of each machine is made by its own control panel.
The building of the Refinery is divided into two bays. In each bay one completely
automated overhead crane Single bale Single lift system operates.

During past years Refinerys capacity was increased up to 231 000 tons of cathodes
per year through adjustment and improvement of technological process and its parameters
as a whole, without any investments.


ER31

STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)

Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Corts Egaa***, Luis
Felipe Ramirez****

*Senior Process Engineer, Ventanas Refinery, Codelco Chile, rabel@codelco.cl.
**Process Engineer, Ventanas Refinery, Codelco Chile, ivene001@codelco.cl.
***Refinery Superintendent, Ventanas Refinery, Codelco
Chile,ccort002@codelco.cl.
**** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS),
framirez@mirs.cl

ABSTRACT
Most SXEW and Refineries currently use permanent stainless steel cathodes.
However, there are refineries and SxEw operations that use starter sheets/traditional
cathodes technology: In Chile, Ventanas and Salvador Refineries; in Peru, Ilo Refinery and
Cerro Verdes SxEw plant; several in EEUU and Mexico, ASARCOs Amarillo Refinery
among them. They require copper starter sheets for their final cathode harvesting.
Stripping starter sheets manually is boring, tiring, unsafe and may produce lower
quality sheets which impacts directly in the quality of commercial cathodes and therefore in
operator revenue.
MIRS designed and developed a Starter Sheet Robotic Stripping Machine (SSRSM)
focusing in improving safety and occupational health and reduce hazards in the process.
The patented method and separation device also improves the quality of starter sheets.
In a standard Layout 4 robotic arms interact in the system: the input robot picks
each cathode from a conveyor and places it in the stripping station; 2 stripping robots strip
each sheet and the output robot picks the empty plate from the stripping station and places
it in the output conveyor. This robot also handles rejects and blank reposition.
One MIRS SSRSM was commissioned at Ventanas during 2011. An industrial test
was carried out whose objective was to demonstrate functionality to strip in typical
operating conditions. Test results were: capacity 160 plates per hour and stripping
performance higher than 98%.

Now we are incorporating a washing station, and two laser scanners, one for sheets
and another for base plate quality and a starting sheet weighing station to sort them into
different qualities.
Because the SSRSM is robotic, it is more compact, flexible and configurable so it
adapts to existing layout and equipment. It also is capable of using different stripping
strategies according to cathode quality.


ER33

COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A
HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-
TECHNOLOGY

Stefan Konetschnik
(1)
, Andreas Filzwieser
(1)
, Iris Filzwieser
(1)
and Andreas Anzinger
(2)
(1) METTOP GmbH
Peter-Tunner-Strasse 4
8700 Leoben
Austria
(2) Montanwerke Brixlegg AG
Werkstrasse 1
6230 Brixlegg
Austria

ABSTRACT
In 2011, the first two electrorefining tankhouses using the METTOP-BRX-
Technology went into operation one producing cathodes out of ore and one out of
secondary raw material. Both tankhouses show the possibility of achieving Grade A
cathodes at a current density of more than 400 A/m while maintaining a current efficiency
of 97.0 98.5 per cent.
After almost two years of operation it is now possible to directly compare the costs
of the two-part tankhouse of Montanwerke Brixlegg AG. While half of the tankhouse is
operated at standard current density, the other half is equipped with the METTOP-BRX-
Technology.
Basis of the technology is an optimized electrolyte feed system in each electrolytic
cell. Even though the higher current density is directly proportional to the consumption of
electrical energy, the overall operational expenditures keep the same due to the lower costs

for bound capital. Furthermore, the higher productivity results in a smaller footprint of the
tankhouse.
The present paper gives a detailed insight into the additional costs and economical
benefits when operating a tankhouse at high current densities. It shows the mathematical
background of the calculation, as well as the result the capital and operational cost
savings when using the METTOP-BRX-Technology.

ER34

COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES

Gerardo Cifuentes and Rodolfo Mannheim G2M Ingeniera Ltda., Chile
gerardocifuentes@yahoo.es

ABSTRACT

When an electric current flow is present in an electrolysis cell, it follows that the
cell potential,
Cell
E , achieved is equivalent to the voltage difference of the theoretical
thermodynamic equilibrium resulting from the anode and cathode reactions,
Eq
E , plus the
algebraic sum of the terms that reflects the inertia of the reactions involved, normally called
electrode overpotential,
c a
, plus a resistive term in solution, I R
e
, and finally plus the
resistive term due to the external electric circuit, System losses.

Losses in the external electric circuit refer mainly to the Joule effect due to the flow
of current through the conductors. Indeed, intercell bars, also called intercell busbars, work
at an average temperature of 70 to 90 C, and in short circuit the temperature can go up to
200 C and higher.

Our CoolBar (WIPO International Patent pending), which has a higher current
conductivity compared to presently used regular intercell bars, will decrease the cell
potential by 2% to 7%, decreasing the specific energy consumption, SEC, by an equivalent
amount. In addition, the Coolbar optimizes the use of thermal energy in the electrolytic
plant by allowing better current flow distribution in the cell, causing a significant drop in
the carbon footprint of the electrolytic process.

Finally, an existing intercell bar can be easily replaced in situ by a Coolbar by just
placing the latter over the cell capping board and making a few small adjustments.


ER54

DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS
AT AURUBIS, HAMBURG USING EMEW ELECTROWINNING TECHNOLOGY

Gnter Leuprecht, Peter Stantke (Aurubis);SiddarthGadia (Electrometals);Andreas Siegmund
(GCT)

ABSTRACT
A series of on-site trials were conducted at Aurubis AG, Hamburg refinery using EMEW
electrowinning to remove copper from the liberator solution in high quality form with no arsine
emission. The liberator solution at Aurubis Hamburg works is particularly difficult to process as
it contains high acid concentration of 350-400 g/l and other impurities such as chloride (60ppm)
and arsenic 20 g/l. The results of the test program confirm that harvestable copper cathode can
be produced at copper concentrations below 1 g/l with low arsenic content such that arsenic in air
or solid emissions is eliminated.
The data from the series of trials over a range of copper concentrations from 1-8 g/l and
200-450 A/m
2
enables an operating curve to produce solid copper product at various copper
concentrations in solution. Operating current efficiency averaged 93% (DC) which confirms
significant power savings in addition to handling and process cost savings.


ER59

REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS
SYSTEM. LABORATORY INVESTIGATION

J.P. Ibez
1
, S. Corts
1
, P. Suarez
2
, A. Labra
2
, A. Moyano
3

1
Department of Metallurgical Engineering and Materials -Universidad Tcnica Federico
Santa Mara (juan.ibanez@usm.cl)
2
Innovaxxion Spa
3
Codelco Chile - Divisin Chuquicamata

ABSTRACT
A new system for reducing the anode scrap in a conventional electro-refining plant
was investigated at laboratory scale. The new system called Earless is based in the use of
anodes without ears, which are easily mounted in an ad-hoc designed case that provides the
electrical contacts and transportation capability.
Experimental work was carried out to make a critical comparison of the electro-
refining behavior between a typical anode and two types of anodes in the Earless system.
All the anodes (cathodic copper) and cathodes (stainless steel) were made in a scale of 1:10,
and were processed under the same experimental conditions of current density, anodic
cycle period, electrolyte temperature, electrolyte flow rate and synthetic electrolyte
composition.
The main results indicate that was possible to reach a reduction of the scrap
generation from around 20% (traditional anode) to around 10% (anode in the Earless
system), all the cathodes obtained having the same quality and furthermore a significant
decrease of the specific energy consumption higher than 20% was observed as well.


ER60

MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED
DESIGNS BY BROCHOT COMPANY

Clyde Wright
Marty Wessman

ABSTRACT

Our paper will present new material handling developments. The theory is to review
existing copper refinery processes, compare and contrast with the newest scientifically
proven technologies available. The aim is to improve and simplify material handling to
increase reliability thus reducing refineries cost curves.

The paper will develop all new concepts
- Robotic handling of electrodes: We eliminate old style mechanical transferring of
electrodes and replace with state of the art robotics. These robots give variable speed,
accurate control, and yet remain flexible for future process changes. Robotics require less
operator and maintenance intervention therefore enhance personnel plant safety.
- Copper Stripping from stainless steel mother blanks: A new copper stripping system has
been developed to eliminate all hydraulics, prolong mother blank life...
- New Cathode Wash Concept: Conventional copper washing can leave impurities. The
development of a new cathode wash system offers a full face wash using minimal water
consumption.

The paper will present all the Copper Projects
Our company has on going copper projects in Mexico, Peru, Russia, Kazakhstan, and the
Middle East

ER61

CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC

C. Corts, E. Bahamondes and N. Cornejo
Codelco, Ventanas Division
Carretera F-30 E 58270
Ventanas, Puchuncav
Chile
ccort002@codelco.cl; ebaha005@codelco.cl; ncornejo@codelco.cl

ABSTRACT

The Electrolytic Refinery of the Ventanas Division in recent years the Refinery has
focused on improving the productivity of its installation through a series of highly creative
initiatives requiring low-cost investments, in order to reinforce the competitiveness of the
Refinery in an increasingly complex business environment. In this context, during the last
four years, projects such as the "Electrode Optimization in Electrolytic Cells" and the
"High Current Density Stripper Circuits Operation" have been carried out.

The project "Electrode Optimization in Electrolytic Cells Phase II" consisted in
reducing the anode spacing to 100 mm, increasing the number of electrodes per cell and
maintaining the current density at 305 A/m2. The project "Stripper circuit operation with
high current density " consisted of reducing the starting sheet production cycle, operating at
a current density of 330 A/m2. Another prominent change of practices implemented in
2009 was the closure of the electrolyte purification plant, owing to the high cost of the
process, which established new trade opportunities by selling the electrolyte to third parties.
This has resulted in a dramatic change in managing impurities control, as well as, in new
improvements. The combination of these projects of improving and changing the practices
resulted in the production of 401,500 t of electrolytic copper in the year 2011.


ER62

PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING

M. Stelter, H. Bombach, J. Baumbach
Institute for Nonferrous Metallurgy and Purest Materials
TU Bergakademie Freiberg
Leipziger Str. 34
D-09599 Freiberg
stelter@inemet.tu-freiberg.de

ABSTRACT

In copper electrorefining additives are used for a smooth electrodeposition of
copper cathodes. The classical additives glue and thiourea show some disadvantages like
the relatively fast decomposition during electrolysis and the incorporation of sulfur from
thiourea into the cathodes. Only new additive systems avoiding thiourea can help to reduce
the sulfur content in the copper cathodes. Additionally the decomposition of glue and
thiourea forces a continuous dosing of the additives.

Our investigations show that alternative additives can be used in copper
electrorefining indeed. Polyethylene glycols (PEG) act strongly polarizing and can
substitute glue. Current density potential curves show that Bis-(3-sodiumpropyl)disulfide
(SPS), dimethylthiourea, methionin and cystein have a stronger depolarizing effect
compared to thiourea.

Electrolysis experiments with PEG and SPS proceeded without short circuits at a
current density of 500 A/m. However, the cathodes were rough and nodulous. Smoother
cathodes were produced when using glue and thiourea or glue and SPS. In the first case the
sulphur concentration in the cathodes ranged from 4 to 10 g/g and in the second case only
from 0.3 to 1.5 g/g. SPS is considerably more stable than thiourea. Thus, there is no need
for continuous addition during electrolysis.


ER63

COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH
CURRENT DENSITY

Songlin Zhou

ABSTRACT

This paper introduces the Parallel Flow Device (PFD) technology and production
practices for high current density copper electrolytic refining. The technology has been
successfully implemented for the first time on a large industrial scale, enabling the copper
electrolysis current density to reach 420 A/m, thereby substantially increasing copper
electrolytic productivity. Through this technology, a new level in copper electrolytic
refining has been achieved.


ER66

A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE

Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Ziga (3)
(1) codelco chile, divisin chuquicamata, e-mail: mcifuent@codelco.cl .
(2) departamento de ingeniera metalrgica, facultad de ingeniera, universidad de
santiago de chile, santiago, chile.
(3) departamento de ingeniera qumica, facultad de ingeniera, universidad de santiago de
chile, santiago, chile.

ABSTRACT

An ion exchange pilot plant, located at the University of Santiago of Chile, was
tested for antimony control in the electrolyte of Chuquicamata Refinery. In the pilot plant
were used three different resins: MX-2, UR-3300S and Duolite C-467. The results showed
that the best behavior for antimony extraction follow the sequence UR3300S >Duolite C
467 > MX 2. A model with the experimental results was used as comparative tools to
increase the knowledge of this process.


EW01

CFD SIMULATION OF COPPER ELECTROREFINING PROCESS AND
ANALYSIS FOR THE TANKHOUSE OPERATION AT NAOSHIMA SMELTER &
REFINERY

S. Kawai and T. Miyazawa
Computer-Aided Materials Engineering Department, Central Research Institute, Mitsubishi
Materials Corporation
1002-14 Mukohyama, Naka-shi, Ibaraki 311-0102, Japan
skawai@mmc.co.jp

ABSTRACT

Copper market has been requesting its smooth appearance on the LME Grade A
Copper in addition to its composition. It is considered that nodular growth on cathode
surfaces is inhibited by preventing the adhesion of anode slime particles to cathodes and
supplying additives optimally to cathodes. The way of circulating electrolyte, such as
bottom inlet to top outlet, side inlet to top outlet etc., may affect both the slime
behavior and the additive supply to cathodes. The authors have simulated flow patterns in
the cell generated by several different ways of circulating electrolyte and analyzed the
amount of slime particles reaching cathodes and the delivering time of fresh additives to
cathodes using the computational fluid dynamics (CFD) model. The calculation results
have revealed that the electrolyte circulation of side inlet to top outlet which Naoshima
Smelter and Refinery has adopted has some advantages, such as inherent flows that
contribute to the reduction of slime particles reaching cathodes, and the uniform time to
deliver additives to every cathode, which can minimize the cell flow rate necessary to keep
smooth appearance of cathodes. Detailed advantages of side inlet to top outlet are
discussed in comparison with other conventional ways of electrolyte circulation.


EW02

CONTROL OF BISMUTH IN TANK HOUSE ELECTROLYTES AT THE ASARCO
REFINERY

Luis Navarro
1
, Tracy Morris
1
, Weldon Read
1
, Neil E. Izatt
2
2
, and
Steven R. Izatt
2
,

1
Asarco
7001 State Highway 136
Amarillo, Texas 79106, U.S.A.

2
IBC Advanced Technologies, Inc.
856 E. Utah Valley Drive,
American Fork, Utah 84003, U.S.A.

ABSTRACT

An effective removal system for the separation of dissolved bismuth from copper
electrolyte to reach desired bismuth levels has been developed by IBC Advanced
Technologies, Inc (IBC). This system is being operated at ASARCO in Amarillo, Texas to
produce high purity electrolytic copper. Control of bismuth concentration is necessary
because bismuth levels exceeding 2 ppm in the final copper product result in brittleness
making the product unsuitable for wire production. The bismuth removal system is based
on IBCs Molecular Recognition Technology (MRT) process.

This process employs proprietary non-ion exchange resin materials, termed
SuperLig, to effect the separation. Key benefits of the MRT process for bismuth removal
include (1) easy control of the bismuth levels in the tank house electrolyte, (2) avoidance of
brittle copper, and (3) flexibility to handle dirty copper concentrates as feedstock. This
paper describes the bismuth MRT plant at the Asarco refinery, the operating process, and
the results. Limitations of alternate technologies for bismuth control are discussed,
particularly with respect to their environmental concerns compared to the MRT
process. Benefits of the MRT system to copper refineries where bismuth problems exist
are presented.


EW03

SELE
MODULAR TECHNOLOGY FOR SUSTAINABLE DEVELOPMENT AND

EFFICIENT EW PLANT

P.A. Aylwin and N.I. Lagos
New Tech Copper SpA
3397 Exequiel Fernndez
Macul, Santiago, Chile
paylwin@ntc.cl

ABSTRACT

Sustainable development is an evolving concept that emerged in the 1980s in
response to a growing realisation of the need to balance economic and social progress with
concern for the environment and the stewardship of natural resources. The idea has been
defined as using, conserving and enhancing the communitys resources so that ecological
processes on which life depends, are maintained, and the total quality of life, now and in
the future, can be increased. This paper proposes a framework for sustainability indicators
for EW industry in an attempt to further contribute to this on-going work and it compares
qualitatively the SELE Technology against the conventional technology, showing as an
example on the studies that must carry on in accordance to measure the sustainable
development.


EW04

OPERATION OF ALTERNATIVE ANODES AT CHINO SXEW

S. Sandoval, R. Garcia, T. Neff, and N. Schnebly
Freeport-McMoRan Mining Company
4521 U.S. Highway 191
Morenci, USA

ABSTRACT

In 2006, the Freeport-McMoRan Copper & Gold Inc. (FCX) Technology Center in
Safford, Arizona undertook research to develop an alternative anode for copper
electrowinning. An anode development lab was established that included bench-scale
electrowinning cells as well as accelerated life testing cells. In 2008, the Chino
electrowinning plant was fully converted to the new FCX anode becoming the first copper
electrowinning plant in the world to exclusively utilize non-lead anodes. A 15%
electrowinning voltage reduction was achieved. Cleaning of electrowinning cells for lead
sludge and addition of cobalt to the circuit for stabilizing lead anodes were discontinued.
Lead content of copper cathodes measured less than 0.3 ppm.

This paper describes operational results and findings with alternative anodes at Chino
over the ensuing years. Chino has exhibited higher than expected current efficiency,
measuring 93% at 3.8 g/L iron in electrolyte. Chino is operating without heat retention
balls on the cells and achieves low acid mist with only small additions of FC1100. Use of
Cyquest 900, a polyacrylamide, as the cathode smoothing agent has allowed Chino to
operate with over 300 ppm Mn in electrolyte without depositing Mn on the alternative
anode surfaces.


EW05

HATCH HELM TRACKER
TM
SYSTEM FOR GUIDING CELL HOUSE
PERFORMANCE IMPROVEMENT

Rob Fraser (Hatch)
Tim Johnston (Hatch)
John Yesberg (Hatch)
Ephrem Gebrehiwot (Freeport McMoRan)
Jacklyn Steeples (Freeport McMoRan)
Guang Yeung (Freeport McMoRan)

ABSTRACT
In electrowinning and electrorefining operations, the detection of operational issues
associated with electrode currents has long been a highly labour intensive reactive
operations task. The Hatch HELM tracker system makes this proactive and targeted
reducing effort and increasing efficiency. The system measures and records the current
flow of every cathode and anode in real time and presents this information to the operators
through an interactive display clearly indicating the existence of shorts, poor contacts, and
any uneven current distribution. This allows the operators to prioritise and correct current
distribution issues. Expected benefits include increases in current efficiency, and thus
reduction in operating costs and/ or increases in production as well as reduction in electrode
damage due to shorts.
Hatch has been demonstrating the robustness and performance of the HELM
tracker system at commercial copper electrowinning plants including at FCXs Safford and
Morenci plants with assistance from FMI management and operating personnel. This paper
includes the latest observations and outcomes from these two plants. It also describes the
latest developments for this exciting technology that have been implemented for
electrowinning and electrorefining plant applications.


EW06

CORROSION OF STAINLESS STEEL CATHODE BLANKS IN COPPER
ELECTROREFINING

Jari Aromaa, Antti Kekki, Olof Forsn
Aalto University
Department of Materials Science
PO Box 16200
00076 Aalto
Espoo, FINLAND

ABSTRACT

The AISI 316L type stainless steel is considered corrosion resistant in copper
electrorefining electrolyte, both as permanent cathode blank material and in process
equipment and piping. Damaged cathode blanks show increased surface roughness,
corrosion pits and deeper grain boundaries. The test hypothesis was that too high chloride
concentration and temperature can cause localized corrosion.

A synthetic electrolyte with 180 g/l H
2
SO
4
, 45 g/l Cu, 15 g/l Ni and 10 g/l As was
used. Test variables were temperature 50-70
o
C and chloride concentrations from 40 ppm to
1000 ppm. Test method was cyclic polarization curve based on ASTM standard G61-86.

No pitting or crevice corrosion was seen in the test series but highest chloride
concentration resulted in wider active peak and higher passive current densities. In
transpassive corrosion tests localized corrosion on grain boundaries and detachment of
grains was seen. Two main possibilities for blank corrosion have been identified. High
chloride concentration can cause active dissolution. The concentration of chlorides has to
be at least 10 times higher than the normal chloride level. Polarization to transpassive
potentials causes corrosion on grain boundaries and detachment of grains. The only
possibility for transpassive dissolution is stray currents.


EW07

GLOBAL SURVEY OF COPPER ELECTROWINNING OPERATIONS AND
PRACTICES

Michael Moats
Associate Professor of Metallurgical Engineering,
Materials Research Center
Missouri University of Science and Technology
Rolla, MO 65409, U.S.A.
moatsm@mst.edu

Tim Robinson
Republic Alternative Technologies, Inc.
11288 Alameda Dve
Strongsville, OH 44149, U.S.A.
trobinson@republicgreentech.com

Shijie Wang
Princple Advisor Process Engineering
Rio Tinto - Kennecott Utah Copper
Magna, UT 84044, U.S.A.
shijie.wang@riotinto.com

Andreas Filzwieser
Info

Andreas Siegmund
Gas Cleaning Technologies (GCT) LLC
4953 N. OConnor Road
Irving, TX 75062 U.S.A
siegmund@gcteng.com

William Davenport
Professor Emeritus
University of Arizona
Tucson, AZ 85721, U.S.A.
billdavenport@live.com


ABSTRACT

World copper electrorefining tankhouse operating practices have been surveyed and
reviewed. Previous surveys have been conducted in association with all International
Copper-Cobre conferences. This survey will include detailed analyses of historical and
current data to identify trends and operating correlations. Examples of recent design and
operational choices to increase productivity, improve copper quality and/or decrease
electrical energy consumption will be given.


EW09

TIMS-TANKHOUSE INFORMATION MANAGEMENT AT UMMCS

Shuklin, M.A., Romanov, A.A, Bakhirov, N.Y
JSC Uralelektromed
1 Lenin str., Verkhnyaya Pyshma,
Sverdlovsk region, 624091, Russia
Phone +7 (34368) 4 71 38, 4 61 22
Fax: +7 (34368) 4 60 99, 4 26 26
Larinkari,M., Hukkanen, R.
Riihitontuntie 7D (P.O Box 84)
02201, Espoo, Finland
Phone +358 20 529 211
Fax: +358 20 529 2200

ABSTRACT
A modern tankhouse relies on high performance material handling, fully automated
process control systems, quality assessment data and consistent operations reporting to
ensure high efficiency of operation and stable quality of final product. In 2012, Outotecs
and Uralelectromeds specialists have developed comprehensive tankhouse process
automation solution called Tankhouse Information Management System (TIMS), which has
been implemented at UMMCs (Uralelektromed) new 150 tpa copper electro refinery in
Verkhnyaya Pyshma, Russia.

TIMS collects process data from different systems and material handling equipment
into a central database, providing material tracking and process key performance indicator
calculations. TIMS automates daily production reporting and provides various analytical
views of the process which can be used at higher level in business control systems.

As a result an essential part of the new tankhouse operation information is provided
by TIMS. Systematic and accurate reporting is based on real-time information which
requires minimal manual work by the personnel. Gained benefits are increased visibility

and awareness of the process, which has already supported both active supervision and
continuous improvement of tankhouse operations.


EW10

RECOVERY OF NICKEL FROM BLEEDING ELECTROLYTE TREATMENT
PLANT AT ATLANTIC COPPER

G. Ros, R. Ramrez, C. Arbizu, I. Ruiz,
Atlantic Copper (Subsidiary of Freeport McMoRan Copper & Gold)
Av. Francisco Montenegro, s/n
21001 Huelva, Spain

ABSTRACT
Approximately 160 m3/day of electrolyte bleed from the Atlantic Copper Refinery
Tankhouse is sent daily to the Electrolyte Treatment Plant to control the copper content and
impurities (As, Sb and Bi) in the electrolyte. Much of the solution leaving the 3rd stage
liberator circuit is returned to the tankhouse, but a small portion (~28 m3/day) is bled to the
weak acid neutralization plant for minor element control (Fe, Ca). Laboratory and pilot
scale tests have been carried out in order to recover the nickel from this bled solution as
nickel carbonate, using different ion exchange resins technologies. Based on the excellent
results obtained from these tests, Atlantic Copper decided to build a nickel carbonate
production plant, which is expected to be commissioned in February 2013. ECOTEC
Recoflo technology has been chosen for removing the sulphuric acid from the feed
solution.Once the acid is removed, then, through a neutralization process, it is possible first,
to purify the electrolyte and then, to precipitate nickel as nickel carbonate.


EW11

THE HAMBURG TANKHOUSE OF AURUBIS AFTER FINISHING OF THE
MODERNIZATION PROJECT

G. Leuprecht and R. Behlmer
Aurubis AG
Hovestrasse 50
D-20539 Hamburg, Germany
g.leuprecht@aurubis.com

ABSTRACT

The Hamburg tankhouse of Aurubis was built in 1989 and expanded in 1992. After
more than 20 years of operation, the old lead lined cells had reached the end of their lifes.
During a 3-year program, 1080 old cells have been replaced by polymer concrete cells. The
replacement was executed section by section during normal operation of the tankhouse.
Each turnaround was completed during an anode cycle of 21 days. All steps will be
described in this presentation. In parallel to the replacement program, longer cells with an
increased number of anodes and cathodes were installed.

This fact combined with the full utilization of the rectifier capacity has maintained an
increase of cathode capacity to 416,000 mt per year. Beside the change of the cells, some
modifications into the handling systems were necessary. So the inlet and outlet conveyors
of the stripping machines and the spacing conveyor of the anode preparation machine had
to be adapted to the increased number of electrodes in the cells. Also a special construction
of the crane bale was required for operating old and new cells during the conversion time.
After the retrofit, the modernized tankhouse has increased its productivity and will be
able to achieve the technical and economical demands for the next future.


EW12

ELIMINATION OF ACID MIST IN COPPER ELECTROWINNING

R. Rajasingam1, W. Yang2, K. Mohanarangam2, B. Tadesse2 and D.J. Robinson1
Box 7229, Karawara,
Western Australia, 6152
Box 312, Clayton South,
Victoria, 3169

ABSTRACT

Acid mist is a ubiquitous problem throughout all tank houses of the copper industry.
Various approaches to alleviate the problem have been adopted by companies from
chemical additives to hoods, but all with varying degrees of success. All of these really
have been attempts to treat the symptom (acid mist) rather than the inherent problem and
indeed many of these band-aids have proven both expensive and in some cases
ineffectual.

CSIRO has established a full size (width and height) transparent cell capable of
simulating plant operating conditions (across the range currently used) and generating
bubbles under very controlled conditions. With the use of sophisticated diagnostic
analytical tools and in parallel to quantification of acid mist under each condition, we are
now able to study all the operating variables independently for their effect on bubble size,
bubble velocity and consequently acid mist generation. The early results of our
consideration of the underlying factors contributing to acid mist generation will be
presented.

EW14

USE OF REAL-TIME INFORMATION IN TANKHOUSE OPERATIONAL
EFFICIENCY IMPROVEMENT AND QUALITY CONTROL

Ari Rantala
Manager, Advanced Process Control

ABSTRACT

Optimizing the operations efficiency and cathode quality of a tankhouse requires not
only the efficient use of energy and labor, but also high availability of machinery and the
ability to rapidly observe and react to disturbances. With the use of proven innovative on-
line monitoring and information management systems now available in the market
parameters such as efficiency, productivity and quality can be assessed in real-time mode.
Some of the systems discussed in the paper include systematic surface quality inspection of
anodes and cathodes and permanent cathode condition.
Another system indicates cell performance on-line, facilitating early reaction to
critical events such as short-circuiting, flow blockages, anode passivation or electrolyte
temperature excursion at the cells. Obviously, it is also highly desirable to integrate such
abovementioned information into one overall management system, along with other
important plant information such as that provided by material handling machinery, process
control systems, on-line analysers and laboratory. Such a management system provides
transparency for operations through real-time production efficiency and quality reporting
and material tracking. Practical benefits of utilizing such systems are described and
illustrated with case examples.


EW15

SMALL COLUMN TESTING OF SUPERLIG 83 FOR BISMUTH REMOVAL
FROM COPPER ELECTRO REFINING ELECTROLYTE

Luis G. Navarro
1
, Weldon Read
1
, Tracy Morris
1
, Jimmy Bidwell
1
2
,
Neil E. Izatt
2

1
2
IBC Advanced Technologies, Inc, 856 E. Utah Valley Drive, American Fork, Utah 84003

ABSTRACT

The removal of Bismuth from Copper electro refining electrolyte using SuperLig
83 was studied in a small column with a resin bed volume of 150mL. Several loading and
elution cycles were performed. The research showed that no considerable loading
performance variability was observed between the first loading cycles and a high selectivity
for removing Bismuth was also achieved. The Bismuth elution was sharp and rapid and
accomplished with small bed volumes of 9M Sulfuric Acid.

The Superlig 83 showed a propensity to amass small amounts of Pb and Sb
making it necessary to perform a 6M HCl wash to elute these elements and regain the initial
capacity of the Superlig 83 without any considerable detriment.


EW16

TREATMENT OF DECOPPERIZED ELECTROLYTE BY CARBONATE
PRECIPITATION

Jimmy Bidwell, Luis G. Navarro, Weldon Read, Tracy Morris

ABSTRACT

The liberator cells department at Amarillo Copper Refinery has the objective of
reducing metal impurities in the copper electrolyte to achieve high quality cathodes via
electrowining. Insoluble lead anodes are used and the copper is depleted from the
electrolyte and then electrodeposited to copper starter sheets.

After the electrowinning process, the decopperized electrolyte solution is sent to the
Acid Purification Unit (APU), where sulfuric acid and arsenic are absorbed into the resin
and then desorbed using water which is then returned to the tankhouse to be reused as acid
make up and to increase arsenic concentration in the electrolyte. During this process, the
APU generates a byproduct stream that is high in nickel and other valuable metals that can
be further processed and the metals recovered.

This paper discusses how it is possible to precipitate a Nickel Carbonate product
when the de-acidified electrolyte is treated using sodium carbonate. The pH selective, 2-
step process first recovers copper still present in the solution and transforms it into a
product that can be processed and further recovered at the Hayden Smelter in Arizona.


EW17

SOLUBILITY PRODUCT OF ANTIMONY ARSENATE AND BISMUTH
ARSENATE HIDEBIRO SEKIMOTO

Fuyuhiko Miyanaga and Katsunori Yamaguchi

ASBTRACT

The solubility product of compounds consist mainly of the 15 group elements
(arsenic, antimony and bismuth) is essentially important information for understanding the
mechanism of the formation of anode slimes in electrolytic refining process and is useful
for prevention of the formation of floating slimes which are adversely affect the current
density and the quality of copper cathode.

The empirical value of the solubility product of several arsenates has been reported
using the operation data in some copper refineries. However, there is no report on the
solubility product based on the equilibria of dissolved chemical species. In this study, the
solubility product of typical antimony arsenate and bismuth arsenate represented as ShAs04
and BiAs04, respectively, in sulfuric acid solutions were investigated.

The sulfuric acid solution containing arsenic acid was saturated with the arsenates
prepared in our laboratory, and then, the concentration of As, Sb and Bi in the solution was
measured by 1CP-AES. Using the results, the solubility product of SbAs04 and BiAs04
was determined.


EW18

SUPPRESSION OF SILVER DISSOLUTION BY CONTACTING DIFFERENT
METALS DURING COPPER ELECTROREFINING

Takahito KASUN0,1 Atsushi KITADA,1 Kimihiro SH1MOKAWA,2 and Kuniaki
MURASE1
1 Department of Materials Science and Engineering, Kyoto University, 36-1
Yoshida-hornrnachi, Sakyo-ku, Kyoto 606-8501, Japan 2 PAN PACIFIC COPPER Co.
Ltd., Refinery Manager, 3-3382 Saganoseki, Oita-shi, Oita, 879-2201, Japan
E-mail: kasuno.takahito.53w@st.kyoto-u.ac.jp (Takahito KASLNO)

ABSTRACT

Electrolytic copper contains, on average, 10 ppm silver as impurity, which leads to a
loss of silver as a cash-cow product for copper smelters. Most of silver included in blister
copper anodes passes into anode slime when electrolyzed, keeping the elemental state.
However, once a part of elemental silver oxidatively-dissolves from the anode or from
anode slime for some reason, then silver can co-deposit with electrolytic copper cathode,
since silver is nobler than copper. In the present work, the dissolution behavior of silver
from anode slime was examined using granular silver as a model of the slime.

We have shown that the silver dissolution is caused by dissolved oxygen in the
electrolyte, and that thiourea and/or chloride ions as usual additives play a role to suppress
the silver dissolution approximately to half. Moreover, it was found that the dissolution of
silver was almost perfectly suppressed by galvanic contacting of the granular silver with
less noble metals (Pb or Cu) immersed in the same electrolyte.

EW19

RECENT OPERATIONAL IMPROVEMENTS AT SAGANOSEKI REFINERY

Masaomi Kanazawa, Akira Ueno, Kimihiro Shimokawa
Saganoseki Smelter & Refinery Pan Pacific Copper Co., Ltd. Japan Tel 81-97-575-3555,
Fax 81-97-575-3513 kanazawa@ppcu.co.jp Address, postcode: 879-2201, 3-3382
Saganoseki Oita-shi, Oita, Japan

ABSTRACT

Saganoseki Refinery of Pan Pacific Copper Co., Ltd. integrated three existing
tankhouses into two by introducing the Waxless ISA type permanent cathode process in
2006. To achieve the higher current efficiency and better cathode quality at current density
over 300 A/m2, the electrolyte filtering system was introduced to remove the suspended
solids (S.S) in the electrolyte in 2009.

The additives continuous feeding system, jointly developed with Taman Refinery
of Hibi Kyodo Smelting Co., Ltd., has been installed in 2011, achiving over 97% current
efficiency at 311A/m2 current density. Several improvements were also executed to ensure
the steady operation and to increase the productivity. Owing to the improvements,
Saganoseki Refinery currently continues the stable and efficient operation with maintaining
the adequate cathode quality. This paper describes the outlines of improvements as well as
the current operational status.

EW20

QUALITY IMPROVEMENT OF ELECTROLYTIC COPPER AT NAOSLAMA
SMELTER & REFINERY

Yuuki Watanahe, Shigehiro Arakawa
Naoshima Smelter and Refinery Mitsubishi Materials Corporation 4049-1, Naoshima-eho,
Kagawa-gun, Kagawa 761-3110, Japan TEL +81-87-892-3201 FAX +81-87-892-4091

ABSTRACT

Copper tank house in Naoshima Smelter Gr Refinery started with a capacity of
7,500 Um of electrolytic copper in 1969 and subsequently enhanced the capacity to
19,500t/rn until 2006 by expanding the number of tank-house cells and raising the current
density of commercial cells. After the expansion above, the tank-house operation has
focused on obtaining customer satisfaction by improving cathode quality and smoothing
cathode surface. An on-site automatic analysis was introduced to control the chemistry of
electrolyte stringently. Filtration equipments were expanded in the capacity from 10% of
the electrolyte to whole electrolyte.

These modifications have reduced dense nodules and smoothed the cathode surface
much. Integral electro-deposition on the cathode has lowered the frequency of short circuits
between electrodes and resulted in increasing in current efficiency from 96.5% to over
97.5%. Mitsubishi materials corporation naoshima smelter & refinery tank house section

EW21

THE MODIFICATIONS OF TANK-HOUSE OPERATION WITH THE
INTRODUCTION OF S FURNACE AT ONAHAMA SMELTER AND REFINERY

Masaaki Kato
Manager of Refinery Onahama Smelter & Refinery Onahama Smelting and Refinery Co,
Ltd e-mail: m-katommc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-3951

Masanori Yoshida
Manager of Production Division Onahanna Smelter & Refinery Onahama Smelting and
Refinery Co, Ltd rnyoshida@nunc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-3951

Tetsuro Sakai
Managing Director & General Manager Onahama Smelter & Refinery Onahama Smelting
and Refinery Co, Ltd e-mail: tesakaigmmc.co.jp TEL: +81-246-54-4841 FAX: +81-246-53-
3951

ABSTRACT

Since 2007, Onahama Smelter and refinery has operated the 0-SR process which
comprises the S-furnace of the Mitsubishi process is followed by two hearths of
reverberatory furnaces in order to increase the capacity of copper concentrates. Such
enhancement at the smelter requested the tank-houses to increase the productivity more
than 25% coping with impurities load of electrolyte. The productivity has been enhanced by
increasing current density which reinforced rectifiers of No.1 and No.2 tank-houses, and
have supplied and increasing the number of daily operation cells by 25%. Impurities in
electrolyte have been managed by resuming the operation of the secondary liberator cells
and controlling impurities load of the electrolyte. Furthermore,

EW22

CREATION OF ELECTRICAL CONNECTION SYSTEM WITHOUT SHORT
CIRCUITS

Robert P. Dufresne

ABSTRACT

Its now possible to operate entire Electrowinning or Electrorefining processing
plants Without Short Circuits. Research in the design of capping boards and contact system
calculations have been integrated and synchronized to create entire sections of refinerys
that are devoid of even the possibility of short circuits. This design is adaptable to every
type of contact system in the industry, including symmetrical and non-symmetrical
electrodes and single, double, triple or quadruple contact bars on the same insulator. Our
Without Short Circuit systems capping board design guarantees your production rates
during the stripping process are fully maintained. Symmetrical electrode capping boards
have been successfully redesigned into a Single bus bar insulator. Mechanical strength
studies and simulations of electrical fluidity have been performed, using CAD 3D
technology, to optimize efficiency of the electric current within the contact system - which
incorporated into the Without Short Circuit design - reduces resistivity compared to
existing contact systems. Research has yielded a chemical formulation that resists sulphuric
acid concentrations above 80%. Our standard bus bar insulators are considered permanent,
with operational lifetimes of up to 20 years or more with no maintenance and without
increasing sulphatation during refining.


EW23

ORIGINS OF ELECTROREFINING: BIRTH OF THE TECHNOLOGY AND THE
WORLD'S FIRST COMMERCIAL ELECTROREFINERY

A.E. Wraith*,
Consultant, Exeter, UK.

P.J. Mackey,
P.J. Mackey Technology Inc., Kirkland QC, Canada.

R. Protheroe Jones,
National Museum of Wales, Swansea, UK.

ABSTRACT

It is well known that the worlds first copper electro-refinery started production in
1869 at Pembrey in South Wales. Built within the Pembrey Copper Smelter which had
commenced operations in 1849, the new refinery was based on principles described in the
British patents issued to J.B. Elkington in 1865 and 1869. Refining principles and practices
pioneered there were key to the foundation of modern electro-refining practice in what is
now a dominant international industry producing 14 Mt of electrical grade copper annually.
This paper explores the background to this pioneering application of the new, early 19th
century, science of electro-metallurgy and examines its links to the contemporary
decorative electro-plating industry and to the shortcomings of 19th century fire refining.
The beginnings and early years of the Pembrey electrorefinery are briefly discussed in
relation to the quality, applications and pyrometallurgy of copper at the time. Elkingtons
ideas and the commissioning of the Pembrey refinery can now be recognised as vital
precursors of the modern electrical age.


EW24

IS CELL VOLTAGE A RELIABLE INDICATOR OF SHORTS OR POOR
CONTACTS?

Michael J Nicol and Justin McGinnity

ABSTRACT

Measurements of cell voltages on several copper, zinc and nickel tankhouses have
been made with a view to assessing the reliability of cell voltage as an indicator of shorts or
poor contacts in electrowinning cells. In addition, simulations of current distribution in
contiguous cells have been made using commercial electrical circuit simulation software
adapted to the flow of current in electrowinning cells using the normal Walker
configuration.

The results of both plant measurements and simuations have revealed that the use of
cell voltage as an indicator of the presence of shorts or poor contacts in electrowinning cells
can be ambiguous. Both in the measured cell and in adjacent cells, erroneous conclusions
can be drawn depending on the location of the voltage measurement.

The important factors which determine the variations in measured cell voltages have
been identified. It is recommended that operations make simple voltage measurements in a
number of locations in a number of cells to establish the reliability of such measurements
for their operations.


EW25

DETERMINATION OF BISMUTH CONTAMINATION IN COPPER

Daniel Kim, Shijie Wang
Rio Tinto Kennecott Utah Copper
Magna, UT 84044
wangs@kennecott.com

ABSTRACT
Bismuth is a most critical impurity to cause copper grain boundary cracks in
wiredrawing. How to control bismuth in copper electrorefining process is an interesting
topic for most copper refineries in the world. From the London Metal Exchange (LME)
and the American Society for Testing and Materials (ASTM), specifications for bismuth
content in copper are 2.0 ppm and 1.0 ppm, respectively. Due to a fact that copper anodes
at KUC contain a significant amount of bismuth, it is a very critical task to determine,
minimize, and control the bismuth contamination in the copper production. This article
presents the methods and techniques used in the study of bismuth contamination. It also
summarizes the contamination mechanism identified in the process control of copper
electrorefining process at KUC.


EW26

A STATE OF THE ART ANODE TECHNOLOGY: SMART ANODE, MSA
, FOR
COPPER ELECTROWINNING

M. Morimitsu, T. Zhang, Y. Yamada
Department of Environmental Systems Science, Doshisha University, Kyoto, Japan

ABSTRACT

This paper presents the preparation, characterization, and performance of a novel
oxide coated titanium anode for copper electrowinning. The anode consists of a mixture of
RuO
2
and Ta
2
O
5
formed on a titanium substrate by thermal decomposition of a precursor
solution containing Ru (III) and Ta (V). The oxide coating comprises 10-20 nm ultra fine
RuO
2
particles which are uniformly dispersed in amorphous Ta
2
O
5
matrix; it is like a sea-
island hybrid structure.

This novel anode gives some excellent properties for use in copper electrowinning.
Oxygen evolution on the anode occurs at a low overpotential so that the cell voltage of Cu
EW is much reduced by 700 mV compared to lead alloy anodes and is 100 mV lower than
the oxide coated titanium anodes with amorphous IrO
2
. Some unwanted side reactions such
as depositions of PbO
2
or manganese oxide are suppressed on the anode, which usually
occurs on lead alloy anodes. This smart anode is produced by Republic Alternative Tech.
(Ohio, USA) under the patent licensing from Doshisha University (Kyoto, Japan) and is
under commercialization with the registered trademark, MSA
.


EW27

COMPARISON OF INTERCELL CONTACT BARS FOR ELECTROWINNING
PLANTS CONSIDERING THERMAL EFFECTS

Rob Fraser, Chris Boon, Tim Johnston, Peter Allen

ABSTRACT

In normal practice, the design of intercell contact bars (ICCB) for electrowinning
and electrorefining are based on previously used designs or rules of thumb, rather than first
principles. Power consumption is a major operating cost for electrowinning. A significant
portion of the power costs is due to the electrical resistance of the ICCB which comprises
electrode contact resistances and ICCB bulk resistance. Theory suggests that contact
resistance is a function of electrode mass, whilst the bulk resistance is calculated using an
integral function of cross-sectional area.

The electrical resistivity of copper, which is the normal ICCB material, increases
with temperature, resulting in an increase in the resistance through the ICCB electrical
circuit. Electrical resistance also causes heat generation due to the Joule effect. By reducing
the amount of heat that is generated or by allowing rejection of heat, it is possible to
minimise the power consumption associated with the ICCB. This paper uses validated
computational techniques to assess several common ICCB configurations to determine their
thermal performance and hence impact on electrical resistance in both ideal and extreme
short circuit scenarios. The influence of ICCB sizing and cell furniture design is also
examined.


EW28

AURUBIS BULGARIA ISA 2000 REFINERY CAPACITY INCREASE

Iv. Djurov
D. Kirilov; N. Dragoev; L. Gerov; K. Nedeleva; A. Saraev;
AURUBIS BULGARIA
Industrial zone
i.djurov@aurubis.com

ABSTRACT

ISA 2000 Refinery was put into operation on July 2008 with design capacity of 180
000 tons copper cathodes per year. Refinery includes two electrolyte circulation systems
and Deep electrolyte decopperization section. Final treatment of the bleed electrolyte is
performed in Waste Water Treatment Plant.

As permanent cathodes are used SS blanks. Between both electrolyte circulation
systems there are situated Anode Preparation machine, Full Deposit Stripping machine and
Anode Scrap Washing machine. Control of each machine is made by its own control panel.
The building of the Refinery is divided into two bays. In each bay one completely
automated overhead crane Single bale Single lift system operates.

During past years Refinerys capacity was increased up to 231 000 tons of cathodes
per year through adjustment and improvement of technological process and its parameters
as a whole, without any investments.


EW29

OPTIMIZATION OF THE USABLE LIFE OF LEAD ELECTROWINNING
ANODES

Abbas Mirza#, Eben Lombard*, Larry Webb*, Matt Burr
#
and Timothy Ellis#
RSR Anode Group*and RSR Technologies
#

*RSR Anode Group: Quemetco Metals Limited, Castle Lead Works and Le Plomb Francais

ABSTRACT
Lead (Pb) based anodes are the dominant technology for electrowinning process in
sulfate based media, e.g. Copper, Nickel, Cobalt, & Manganese. The lifecycle of
electrowinning anodes is very dependent upon tank house operating conditions and
maintenance of the anodes including cleaning and straightening. A presentation is made
which relates optimal operational condition to enhance anode lifecycles. This presentation
will focus on the operational aspects of maximizing the utilization of Pb electrowinning
anodes.


EW30

ELECTROLYTIC TANKHOUSE ACID MIST CONTROL - MEETING
STRINGENT WORKER EXPOSURE LIMITS AND EMISSION TARGETS

Dr. Andreas Siegmund and Amandeep Randhawa
Gas Cleaning Technologies LLC,
4953 N. OConnor Blvd.
Irving, TX 75062
siegmund@gcteng.com

ABSTRACT

SX/EW operations are commonplace due to their lower operating costs. However,
one of the undesirable consequences of this operation is the evolution of acid mist in the
electrowinning step in the process. This acid mist creates a significant worker exposure
hazard, results in corrosion to building and equipment requiring excessive maintenance,
and presents an environmental concern when discharged to the atmosphere. Therefore,
addressing these concerns is key to meeting tighter hygiene and environmental regulations.
This paper presents a summary of the latest process techniques to minimize acid mist
formation, the engineering methods used for evaluation including the use of Computational
Fluid Dynamic (CFD) modeling to optimize tankhouse ventilation systems and cost
effective gas cleaning methods to reduce acid mist discharge to the atmosphere.


EW31

STARTER SHEET ROBOTIC STRIPPING MACHINE (SSRSM)

Rodrigo Abel Fuentes*, Isabel Venegas Fuentes**, Cristian Corts Egaa***, Luis
Felipe Ramirez****

*Senior Process Engineer, Ventanas Refinery, Codelco Chile, rabel@codelco.cl.
**Process Engineer, Ventanas Refinery, Codelco Chile, ivene001@codelco.cl.
***Refinery Superintendent, Ventanas Refinery, Codelco
Chile,ccort002@codelco.cl.
**** Chief Commercial Officer, Mining Industry Robotic Solutions, (MIRS),
framirez@mirs.cl

ABSTRACT
Most SXEW and Refineries currently use permanent stainless steel cathodes.
However, there are refineries and SxEw operations that use starter sheets/traditional
cathodes technology: In Chile, Ventanas and Salvador Refineries; in Peru, Ilo Refinery and
Cerro Verdes SxEw plant; several in EEUU and Mexico, ASARCOs Amarillo Refinery
among them. They require copper starter sheets for their final cathode harvesting.
Stripping starter sheets manually is boring, tiring, unsafe and may produce lower
quality sheets which impacts directly in the quality of commercial cathodes and therefore in
operator revenue.
MIRS designed and developed a Starter Sheet Robotic Stripping Machine (SSRSM)
focusing in improving safety and occupational health and reduce hazards in the process.
The patented method and separation device also improves the quality of starter sheets.
In a standard Layout 4 robotic arms interact in the system: the input robot picks
each cathode from a conveyor and places it in the stripping station; 2 stripping robots strip
each sheet and the output robot picks the empty plate from the stripping station and places
it in the output conveyor. This robot also handles rejects and blank reposition.
One MIRS SSRSM was commissioned at Ventanas during 2011. An industrial test
was carried out whose objective was to demonstrate functionality to strip in typical
operating conditions. Test results were: capacity 160 plates per hour and stripping
performance higher than 98%.

Now we are incorporating a washing station, and two laser scanners, one for sheets
and another for base plate quality and a starting sheet weighing station to sort them into
different qualities.
Because the SSRSM is robotic, it is more compact, flexible and configurable so it
adapts to existing layout and equipment. It also is capable of using different stripping
strategies according to cathode quality.


EW33

COST COMPARISON BETWEEN A CONVENTIONAL ER TANKHOUSE AND A
HIGH CURRENT DENSITY ER TANKHOUSE USING THE METTOP-BRX-
TECHNOLOGY

Stefan Konetschnik
(1)
, Andreas Filzwieser
(1)
, Iris Filzwieser
(1)
and Andreas Anzinger
(2)
(1) METTOP GmbH
Peter-Tunner-Strasse 4
8700 Leoben
Austria
(2) Montanwerke Brixlegg AG
Werkstrasse 1
6230 Brixlegg
Austria

ABSTRACT
In 2011, the first two electrorefining tankhouses using the METTOP-BRX-
Technology went into operation one producing cathodes out of ore and one out of
secondary raw material. Both tankhouses show the possibility of achieving Grade A
cathodes at a current density of more than 400 A/m while maintaining a current efficiency
of 97.0 98.5 per cent.
After almost two years of operation it is now possible to directly compare the costs
of the two-part tankhouse of Montanwerke Brixlegg AG. While half of the tankhouse is
operated at standard current density, the other half is equipped with the METTOP-BRX-
Technology.
Basis of the technology is an optimized electrolyte feed system in each electrolytic
cell. Even though the higher current density is directly proportional to the consumption of
electrical energy, the overall operational expenditures keep the same due to the lower costs

for bound capital. Furthermore, the higher productivity results in a smaller footprint of the
tankhouse.
The present paper gives a detailed insight into the additional costs and economical
benefits when operating a tankhouse at high current densities. It shows the mathematical
background of the calculation, as well as the result the capital and operational cost
savings when using the METTOP-BRX-Technology.

EW34

COOLBAR: A NEW INTERCELL BAR FOR ELECTROLYTIC PROCESSES

Gerardo Cifuentes and Rodolfo Mannheim G2M Ingeniera Ltda., Chile
gerardocifuentes@yahoo.es

ABSTRACT

When an electric current flow is present in an electrolysis cell, it follows that the
cell potential,
Cell
E , achieved is equivalent to the voltage difference of the theoretical
thermodynamic equilibrium resulting from the anode and cathode reactions,
Eq
E , plus the
algebraic sum of the terms that reflects the inertia of the reactions involved, normally called
electrode overpotential,
c a
, plus a resistive term in solution, I R
e
, and finally plus the
resistive term due to the external electric circuit, System losses.

Losses in the external electric circuit refer mainly to the Joule effect due to the flow
of current through the conductors. Indeed, intercell bars, also called intercell busbars, work
at an average temperature of 70 to 90 C, and in short circuit the temperature can go up to
200 C and higher.

Our CoolBar (WIPO International Patent pending), which has a higher current
conductivity compared to presently used regular intercell bars, will decrease the cell
potential by 2% to 7%, decreasing the specific energy consumption, SEC, by an equivalent
amount. In addition, the Coolbar optimizes the use of thermal energy in the electrolytic
plant by allowing better current flow distribution in the cell, causing a significant drop in
the carbon footprint of the electrolytic process.

Finally, an existing intercell bar can be easily replaced in situ by a Coolbar by just
placing the latter over the cell capping board and making a few small adjustments.


EW35

ELECTROLYTE SOFT AERATION SYSTEM FOR EW CELLS
ELECTROWINING TANKHOUSE OF GABRIELA MISTRAL DIVISION

Francisco Snchez Pino
Codelco Chile, Gabriela Mistral Division, Calama, Chile, Innovation and Technology
Superintendent, 56-55-328576, fsanchez@codelco.cl.

ASBTRACT
For our objective of promoting continuous improvement of processes, the
application of electrolyte soft aeration technology has been evaluated since 2009, focused
on quality improvement of cathode production; a pilot testing program culminated, after 3
month, with excellent metallurgical results and data that justified the investment to equip
the 504 Electrowining cells in the Tankhouse.

Soft aeration of the electrolyte inside Electrowining cells contributes to uniform
mass transfer, cinematic viscosity and flow velocity across the entire surfaces of the
cathodes, generating homogenous deposits, without preferential growths, and therefore,
virtually exempt of nodules and short circuits, with enhanced physical and chemical quality
of production, and furthermore, optimizing the efficient use of energy by sustaining in time
electric current efficiencies of 94%, specific consumption of 1.750 kWh/TM of fine copper,
with AR elongation test over 40%, and overall grade A quality copper cathodes above 80%.

The technology implemented homogenizes copper concentration in the "permanent
cathode plate-electrolyte" interphase and uniform migration of copper ions throughout the
deposit surfaces, thus diminishing limit layer thickness.

Electrowining process management is enhanced by allowing cell operation at
current densities above 300 A/m
2
, enabling 100 kg cathodes to be harvested in less than 6
day cycles.


EW36

AN INVESTIGATION OF MODIFIED POLYSACCHARIDE AND
POLYACRYLAMIDE ON PLATING POLARIZATION AND SURFACE
ROUGHNESS IN COPPER ELECTROWINNING

Tyler Helsten
1
and Michael S. Moats
2

1 University of Utah
2 - Missouri University of Science and Technology

ABSTRACT
Recently, the use of modified polysaccharides and polyacrylamides has been
reported as smoothing agents in commercial copper electrowinning operations. Very little
published data exist on the fundamental behavior of these compounds in copper
electrodeposition. In this study, the polarization behavior and surface roughness of short
term deposits grown in the presence of a modified polysaccharide, a polyacrylamide or a
50/50 mixture of guar and modified polysaccharide in synthetic copper electrowinning
electrolytes are reported. The polyacrylamide demonstrates classical behavior in that
polarization increases with increasing concentration which correlates to a smoother deposit.
The modified polysaccharide and combination of guar and modified polysaccharide did not
exhibit classical behavior in that increasing concentration did not affect polarization but
result in smoother deposits.


EW38

THE ROLE OF DISSOLVED IRON PRESENT IN ELECTROWINING
ELECTROLYTES: ITS INFLUENCE ON ENERGY CONSUMPTION AND
CATHODE QUALITY.

Toms Vargas1 and Paz Parra
Department of Chemical Engineering and Biotechnology
Advanced Mining Technology Center (AMTC)
University of Chile, Santiago Chile

ABSTRACT

Dissolved iron present either as ferrous or ferric ions is ubiquitous in electrowining
operations. Its presence arises from undesired incorporation through solvent extraction or
by addition as ferrous ion for reducing purposes. The presence of iron in the electrolyte is
mainly associated to its deleterious effect on current efficiency, which is enhanced if the
electrolyte is somehow stirred. However, the presence of iron in the electrolyte has other
effects which have been somehow overlooked and are not well studied, which could have
some positive influence on the process. The presence of iron as ferric ion helps to
depolarize the cathodic reaction, which can contribute to reduce the voltage drop and
energy consumption in the cell. Also, the presence of dissolved iron interferes with copper
electrocrystallization contributing to reduce the crystal size. The present work analizes
these aspects in detail based on electrochemical studies of the electrokinetics of
ferrous/ferric processes and the electrocrystallization of copper in electrolytes containing
ferrous/ferric ions.

EW53

EXPERIENCIES ON DESIGN, MANUFACTURING AND OPERATION OF HIGH
CONTROLLED TRANSFORMER-RECTIFIERS FOR SX-EW COPPER PLANTS

R Fuentes P Lagos J Estrada R Dunner L Neira
rfuentes@idt.cl plagos@idt.cl jestrada@idt.cl rdunner@idt.cl lneira@idt.cl

IDT SA Avda. Las Parcelas 5490, Estacin Central,
Santiago, Chile

ABSTRACT

This paper is focused to Chilean experiences on design, manufacturing,
maintenance and operation of high current controlled rectifiers for copper SX-EW and
refinery plant. It concern with new copper or greenfield projects and with the
reengineering of existing transformer-rectifiers or brownfield projects.
The extended paper deals with parameters for the design, boundary conditions,
current control, protection criteria, harmonics mitigation, maintenance and spare
components, focusing to the most important requirements of this type of equipment:
reliability and high efficiency. Finally, from the authors experience, this paper recommends
technical specification aspects for the future projects.


EW54

DECOPPERIZATION OF ELECTROLYTE FROM TERTIARY LIBERATOR CELLS
AT AURUBIS, HAMBURG USING EMEW ELECTROWINNING TECHNOLOGY

Gnter Leuprecht, Peter Stantke (Aurubis);SiddarthGadia (Electrometals);Andreas Siegmund
(GCT)

ABSTRACT
A series of on-site trials were conducted at Aurubis AG, Hamburg refinery using EMEW
electrowinning to remove copper from the liberator solution in high quality form with no arsine
emission. The liberator solution at Aurubis Hamburg works is particularly difficult to process as
it contains high acid concentration of 350-400 g/l and other impurities such as chloride (60ppm)
and arsenic 20 g/l. The results of the test program confirm that harvestable copper cathode can
be produced at copper concentrations below 1 g/l with low arsenic content such that arsenic in air
or solid emissions is eliminated.
The data from the series of trials over a range of copper concentrations from 1-8 g/l and
200-450 A/m
2
enables an operating curve to produce solid copper product at various copper
concentrations in solution. Operating current efficiency averaged 93% (DC) which confirms
significant power savings in addition to handling and process cost savings.


EW55

DE NORAS SOLUTION PART I, DSA ANODES FOR CU
ELECTROWINNING

A. Fiorucci, A. Calderara, L. Iacopetti, F. Timpano, G. Faita, C.W. Brown, Jr., M.H.
Barker and F. Prado (Infotrol).
De Nora - Via Bistolfi, 35 Milan, Italy
Infotrol - C. Ramon y Cajal, 7 MONZON, (Huesca) SPAIN

ABSTRACT

The main stay of industrial electrowinning practice today is based on lead alloy
anodes. De Noras advanced R&D combined with over 40 years of expertise & experience
in DSA anodes for chloride based electrowinning has led to the development of De
Noras Solution for sulfate based Copper Electrowinning (Cu EW).

In addition to the energy saving, elimination of cobalt from the process, improved
tankhouse operation, De Noras Solution will bring extra value to the Cu EW tankhouse - a
custom engineered titanium structure with the latest generation catalytic coating,
breakthrough dendrite mitigation system, simultaneous current & voltage monitoring and
an innovative acid mist abatement system.

This paper will describe De Noras rigorous process of testing and validation from
laboratory through to Industrial scale; simulating actual and extreme conditions for stable
operation, performance and longevity before introduction into the tankhouse. Results in
terms of dendrite mitigation, energy saving and cathode quality will be discussed. Acid
mist abatement results will be presented in part II.


EW56

DE NORAS SOLUTION PART II, ACID MIST ABATEMENT

A. Fiorucci, A. Calderara, F. Timpano, G. Faita, C.W. Brown, Jr. and M.H. Barker.
De Nora
Via Bistolfi, 35 Milan, Italy

ABSTRACT

Acid mist is an undesirable and costly by-product of copper electrowinning (Cu
EW), damaging to the health of people working in the tankhouse as well as corrosive and
dangerous for all the metal parts in the plant.

De Noras mission is to provide safe and environmentally friendly electrochemical
technology. De Noras Solution is built around DSA anodes, with an integrated anode-
frame structure and a permeable separator envelope which captures the acid mist at the
source. De Noras Solution thus allows the plant to operate with an unprecedented low
level of atmospheric acid mist, providing extra added value in safer Cu EW tankhouse
operations.

This paper describes the innovative acid mist containment system - an integral part
of De Noras Solution - and the related benefits obtained by confining the oxygen micro-
bubbles in an enclosed space. Significant improvement in operating practice, unexplored
areas for costs savings and environmental benefits generated by De Noras Solution will
also be presented.


EW57

MANGANESE AND REDOX POTENTIAL IN EW CU PLANTS

Gabriel Zarate,
Anglo American Chile, Santiago, Chile
gabriel.zarate@angloamerican.com

ABSTRACT

The information on redox potential and its relationship with manganese, iron and
chloride concentrations in the electrolyte has been reviewed for several SX-EW plants and
published elsewhere. The objective was to verify if the published recommendations to
maintain redox potential under control were met, namely:

A minimum Fe:Mn ratio of 8:1 or 10:1.
A minimum 1 g/l of total iron.
A Fe
+2
:Mn ratio of 6:1.

It was found that, in general, only one of these recommendations was partially met
and that the redox potential was highly dependent on the combined effect of chloride and
iron concentration in the electrolyte. The highest redox potentials, above 900 mV, are
obtained at chloride concentrations between 35 and 50 ppm when iron concentration is
below 1 g/l. In order to maintain redox potentials below 800 mV, at these chloride
concentrations, the iron concentration should be above 1.5 g/l.

This information has been updated, including the nitrate concentration in the
electrolyte, which effect in the redox potential is even more significant.
The data analysis carried out, as well as the conclusions and recommendations
obtained, are discussed in this paper.


EW58

MASS TRANSPORT TO CATHODES IN THE ELECTROWINNING OF COPPER

Michael J Nicol, Suchun Zhang, Allan Kwang, Loon Ang and Alessandro Fiorucci (De
Nora)
Industrie De Nora, Milan, Italy

ABSTRACT

Mass transport of copper ions to the cathode during the electrowinning of copper is
important in determining the optimum current density in order to achieve deposits of
acceptable physical and chemical quality. The results of pilot scale tests using full size
cathodes and anodes (both lead-calcium-tin and titanium mixed metal oxide, MMO) will be
described. In these tests, silver ions have been used as a tracer in order to determine local
mass transfer coefficients to 16 sections of each cathode. The results have shown that mass
transfer is slightly higher at the top and bottom of the cathode and that the distribution is
more uniform with MMO anodes than with conventional lead alloy anodes. The results
agree quantitatively with previously published data obtained using half width electrodes.
Measurement of the mass of each section has also been used to establish the current
distribution over the surface of the cathodes.
In addition, the reduced cell voltage obtained with the MMO anodes has been
quantified as have the voltage drops at the contact of the anode header bars with the busbar.


EW59

REDUCING THE SCRAP IN ELECTRO-REFINING BY USING EARLESS
SYSTEM. LABORATORY INVESTIGATION

J.P. Ibez
1
, S. Corts
1
, P. Suarez
2
, A. Labra
2
, A. Moyano
3

1
Department of Metallurgical Engineering and Materials -Universidad Tcnica Federico
Santa Mara (juan.ibanez@usm.cl)
2
Innovaxxion Spa
3
Codelco Chile - Divisin Chuquicamata

ABSTRACT
A new system for reducing the anode scrap in a conventional electro-refining plant
was investigated at laboratory scale. The new system called Earless is based in the use of
anodes without ears, which are easily mounted in an ad-hoc designed case that provides the
electrical contacts and transportation capability.
Experimental work was carried out to make a critical comparison of the electro-
refining behavior between a typical anode and two types of anodes in the Earless system.
All the anodes (cathodic copper) and cathodes (stainless steel) were made in a scale of 1:10,
and were processed under the same experimental conditions of current density, anodic
cycle period, electrolyte temperature, electrolyte flow rate and synthetic electrolyte
composition.
The main results indicate that was possible to reach a reduction of the scrap
generation from around 20% (traditional anode) to around 10% (anode in the Earless
system), all the cathodes obtained having the same quality and furthermore a significant
decrease of the specific energy consumption higher than 20% was observed as well.


EW60

MOVING COPPER MATERIAL HANDLING FORWARD USING ADVANCED
DESIGNS BY BROCHOT COMPANY

Clyde Wright
Marty Wessman

ABSTRACT

Our paper will present new material handling developments. The theory is to review
existing copper refinery processes, compare and contrast with the newest scientifically
proven technologies available. The aim is to improve and simplify material handling to
increase reliability thus reducing refineries cost curves.

The paper will develop all new concepts
- Robotic handling of electrodes: We eliminate old style mechanical transferring of
electrodes and replace with state of the art robotics. These robots give variable speed,
accurate control, and yet remain flexible for future process changes. Robotics require less
operator and maintenance intervention therefore enhance personnel plant safety.
- Copper Stripping from stainless steel mother blanks: A new copper stripping system has
been developed to eliminate all hydraulics, prolong mother blank life...
- New Cathode Wash Concept: Conventional copper washing can leave impurities. The
development of a new cathode wash system offers a full face wash using minimal water
consumption.

The paper will present all the Copper Projects
Our company has on going copper projects in Mexico, Peru, Russia, Kazakhstan, and the
Middle East

EW61

CHANGES IN OPERATIONAL PRACTICES IN THE ELECTROLYTIC

C. Corts, E. Bahamondes and N. Cornejo
Codelco, Ventanas Division
Carretera F-30 E 58270
Ventanas, Puchuncav
Chile
ccort002@codelco.cl; ebaha005@codelco.cl; ncornejo@codelco.cl

ABSTRACT

The Electrolytic Refinery of the Ventanas Division in recent years the Refinery has
focused on improving the productivity of its installation through a series of highly creative
initiatives requiring low-cost investments, in order to reinforce the competitiveness of the
Refinery in an increasingly complex business environment. In this context, during the last
four years, projects such as the "Electrode Optimization in Electrolytic Cells" and the
"High Current Density Stripper Circuits Operation" have been carried out.

The project "Electrode Optimization in Electrolytic Cells Phase II" consisted in
reducing the anode spacing to 100 mm, increasing the number of electrodes per cell and
maintaining the current density at 305 A/m2. The project "Stripper circuit operation with
high current density " consisted of reducing the starting sheet production cycle, operating at
a current density of 330 A/m2. Another prominent change of practices implemented in
2009 was the closure of the electrolyte purification plant, owing to the high cost of the
process, which established new trade opportunities by selling the electrolyte to third parties.
This has resulted in a dramatic change in managing impurities control, as well as, in new
improvements. The combination of these projects of improving and changing the practices
resulted in the production of 401,500 t of electrolytic copper in the year 2011.


EW62

PURER CATHODES BY NEW ADDITIVES IN COPPER ELECTROERFINING

M. Stelter, H. Bombach, J. Baumbach
Institute for Nonferrous Metallurgy and Purest Materials
TU Bergakademie Freiberg
Leipziger Str. 34
D-09599 Freiberg
stelter@inemet.tu-freiberg.de

ABSTRACT

In copper electrorefining additives are used for a smooth electrodeposition of
copper cathodes. The classical additives glue and thiourea show some disadvantages like
the relatively fast decomposition during electrolysis and the incorporation of sulfur from
thiourea into the cathodes. Only new additive systems avoiding thiourea can help to reduce
the sulfur content in the copper cathodes. Additionally the decomposition of glue and
thiourea forces a continuous dosing of the additives.

Our investigations show that alternative additives can be used in copper
electrorefining indeed. Polyethylene glycols (PEG) act strongly polarizing and can
substitute glue. Current density potential curves show that Bis-(3-sodiumpropyl)disulfide
(SPS), dimethylthiourea, methionin and cystein have a stronger depolarizing effect
compared to thiourea.

Electrolysis experiments with PEG and SPS proceeded without short circuits at a
current density of 500 A/m. However, the cathodes were rough and nodulous. Smoother
cathodes were produced when using glue and thiourea or glue and SPS. In the first case the
sulphur concentration in the cathodes ranged from 4 to 10 g/g and in the second case only
from 0.3 to 1.5 g/g. SPS is considerably more stable than thiourea. Thus, there is no need
for continuous addition during electrolysis.


EW63

COPPER ELECTROLYTIC REFINING TECHNOLOGY OPERATING AT HIGH
CURRENT DENSITY

Songlin Zhou

ABSTRACT

This paper introduces the Parallel Flow Device (PFD) technology and production
practices for high current density copper electrolytic refining. The technology has been
successfully implemented for the first time on a large industrial scale, enabling the copper
electrolysis current density to reach 420 A/m, thereby substantially increasing copper
electrolytic productivity. Through this technology, a new level in copper electrolytic
refining has been achieved.


EW64

EXMAJET
, POTENTIAL FOR IMPROVED ACID MIST CAPTURE AND

CATHODE QUALITY AT HIGH CURRENT DELSITY ELECTROWINNING

A.Lillo
METALEX
Hernando de Aguirre 162 Oficina 806
Santiago Chile
alillo@metalex.cl

ABSTRACT
This paper reviews the technological responses provided by EXMAJET
to the
traditional limitations in obtaining commercial grade copper and reduction of acid mist
at high current density. Integrating concepts of improved hydrodynamics and acid mist
capture with anodic oxygen recirculation into a unique technical solution, EXMAJET

uses a modified flow distributor which combines electrolyte feed with anodic oxygen
captured at the anode into a close loop. Results indicate that cathode quality is
improved due to the improved homogeneity in copper distribution due to equalization
of the plating conditions between bottom and top of the cathode surface. Also
commercial grade copper cathodes is possible to be produced at high current density,
with acid mist confined to an anodic compartment being recycled directly into the cell
by using a friendly flow distributor. The extension of these results confirm the
feasibility of commercial production of copper at high current density, reduction of the
overall generation of acid mist, elimination of tankhouse hardware such as ducting and
scrubbers and finally improve cell productivity allowing electrode gap to be potentially
reduced.


EW65

POTENTIAL-CONTROLLED ELECTROLYSIS AS A NEW METHOD OF
COPPER ELECTROREFINING AND ELECTROWINNING DISCUSSION OF
SOME BASIC ASPECTS

P. Los and A. Lukomska and S. Kowalska
Industrial Chemistry Research Institute,
ul. Rydygiera 8, 01-793 Warsaw, Poland
przemyslaw.los@ichp.pl

M. Masalski
Institute of Biomedical Engineering and Instrumentation,
Wroclaw University of Technology, Wybrzee Wyspiaskiego27, 50-370 Wroclaw, Poland
Department and Clinic of Otolaryngology Head and Neck Surgery,
Wroclaw Medical University, ul.Borowska 213, 50-556 Wroclaw, Poland

M. Kwartnik.
NANOMETALLURY SA,
Cieszkowskiego 20, 51-604 Wroclaw, Poland

ABSTRACT

Copper electrowinning and electrorefining are very effective methods of industrial
electrochemistry. These processes have been carried out without substantial fundamental
modifications for a pretty long time. For instance industrial copper electrowinning and
electrorefining processes are carried out on industrial scale as current-controlled processes.
Review of literature data shows that the fundamental understanding of copper
electrodeposition processes from industrial electrolytes is not sufficient. Although, the
industrial copper electrodeposition is a very complex multi-ion process realized in
concentrated electrolytes with migration, convection and diffusion as mass transfer modes,
most of the published theoretical and experimental copper electroreduction studies are
carried out in diluted electrolytes of relatively simple compositions and the theoretical
approach of diluted electrolytes is used to analyze the results. Consequently, many
conclusions concerning industrial copper electrorefining and electrowinning processes
which are considered as general are valid only in the case of current-control electrolysis
and/or for diluted electrolytes. Potential is the primary parameter of electrolysis to
determine the electrochemical reactions which might undergo at the electrode. In the
present paper some basic (theoretical and experimental) aspects of patented potential-
controlled electrolysis in copper industrial electrolytes as a new method of copper
electrorefining and electrowinning are presented and discussed.

EW66

A COMPARATIVE STUDY OF ION EXCHANGE PROCESS FOR THE

Marco Cifuentes (1), Gerardo Cifuentes (2), Jaime Simpson (2), Cesar Ziga (3)
(1) codelco chile, divisin chuquicamata, e-mail: mcifuent@codelco.cl .
(2) departamento de ingeniera metalrgica, facultad de ingeniera, universidad de
santiago de chile, santiago, chile.
(3) departamento de ingeniera qumica, facultad de ingeniera, universidad de santiago de
chile, santiago, chile.

ABSTRACT

An ion exchange pilot plant, located at the University of Santiago of Chile, was
tested for antimony control in the electrolyte of Chuquicamata Refinery. In the pilot plant
were used three different resins: MX-2, UR-3300S and Duolite C-467. The results showed
that the best behavior for antimony extraction follow the sequence UR3300S >Duolite C
467 > MX 2. A model with the experimental results was used as comparative tools to
increase the knowledge of this process.

Sustainable Develoment

SYMPOSIUM: 06 SUSTAINABLE DEVELOPMENT
SD01 Markus Reuter ENVIRONMENTAL FOOTPRINTING OF
METALLURGICAL COPPER PROCESSING
TECHNOLOGY
SD02 Peter Naumann EXPERIMENTAL STUDY AND COMPUTATIONAL
MODELLING OF PARTICULATE EMISSIONS FORM
OPEN-PITS IN VIETNAM
SD03 Carmen G.
Contreras
NEW REGULATION FOR REDUCING AIRBORNE
EMISSIONS FROM COPPER FOUNDRIES IN CHILE
SD04 Gina Roman INFLUENCE OF MINING PROJECTS IN SIERRA GORDA
SD05 V. Barrera
Sepulveda
BREAKABLE GROUND SUPPORT, A VERIFICATION
OF MECHANICAL PROPERTIES TO DIMINISH
FERROUS SOLID WASTE IN UNDERGROUND MINING
SD07 Naoki
Hashimoto
THE COMMERCIAL OPERATION OF ARSENIC
FIXATION BY DMSP
SD08 Fernando Torres RISK UNDER STUDY APPROACH ISO 31000/2009,
PLANT AREA, DIVISION TALCUNA MINING SAN
GERONIMO, COQUIMBO REGION
SD09 Fernando Torres PROPOSED DYNAMIC MODEL OF ENVIRONMENTAL
AND OCCUPATIONAL HAZARDS
SD11 Alejandro Labbe SUSTAINTABILITY, A MINERALS SECTOR
OPPORTUNITY
SD12 Miguel Paredes
Sadler
FLEXIBLE MINING CLOSURE PLANS: DEALING WITH
ENVIRONMENTAL REGULATION UNCERTAINTY
SD13 Daniel Jimenez-
Espinoza
CHILEAN REGULATION OF WORKING AT 3000-5500
METERS ALTITUDE: UNIQUENESS AND
CHALLENGES
SD14 Juan Giuliano PROCESS INNOVATION BY WORKING MINERS: A
CASE OF USER INNOVATION IN COPPER MINING
INDUSTRY
SD15 S. Nadolski ENERGY BENEFITS OF IMPLEMENTING DRILL-TO-
MILL STRATEGIES IN OPEN-PIT COPPER MINES
SD16 Patricio Perez
Oportus
WATER, ENERGY AND LABOR:KEY CRITICS TO
COMPETITIVENESS OF THE CHILEAN COPPER
INDUSTRY
SD20 Dirk
Hannemann
THE USE OF MICROWAVES IN THE SMELTING
INDUSTRY'S THERMO PROCESS TECHNOLOGY
SD21 Marcelo
Hormazabal
ELECTRICAL POWER QUALITY IN BIG COPPER
MINES
SD22 David
Mounissens
COFELY TRMIKA TO ESCO MODEL: NEW
ENVIRONMENTAL SOLUTIONS
SD23 Osvaldo Bascur DRASTIC ENERGY AND WATER REDUCTION IN

LARGE METALLURGICAL COMPLEXES
SD24 Osvaldo Bascur
- M. Halhead
ENTERPRISE MANUFACTURING SERVICES TO
ENHANCE ENERGY EFFECTIVENESS AND
SUSTAINABILITY MANAGEMENT AT ANGLOPLATS
SD27 P.H. Rodriguez ENVIRONMENTAL HAZARD CLASSIFICATION OF
COPPER CONCENTRATES
SD28 Fernando Silva
Calonge
RIESGOS EN LA MINERA DEL COBRE, DESDE LA
PERSPECTIVA DEL INCENDIO
SD29 Horacio Vergara COPPER MINING, GENERATING INNOVATION IN
CHILE
SD30 Alejandro
Morales
FROM THE SMOKE TRAGEDY TO THE SAN JOSE
MINE ENTRAPMENT. 68 YEARS OF OCCUPATIONAL
HEALTH AND SAFETY MANAGEMENT IN CHILE
SD31 A. Zolezzi INCREMENTAL VS. DISRUPTIVE INNOVATION,
SENSE OF OPPORTUNITY AND A PATH TO DEVELOP
DISRUPTIVE AND SUSTAINABLE TECHNOLOGICAL
INNOVATION FOR THE COPPER INDUSTRY
INTEGRATED OBJECTIVES MODEL (IOM)
SD32 Alejandro Canut
de Bon
REGULATORY CHALLENGES FOR THE MINING
INDUSTRY IN CHILE


SD01

ENVIRONMENTAL FOOTPRINTING OF METALLURGICAL COPPER
PROCESSING TECHNOLOGY

M.A. Reuter, I. Kojo, A. Roine and M. Jfs
Outotec Oyj
Riihitontuntie 7
Espoo, Finland 02201
markus.reuter@outotec.com

J. Gediga and H. Florin
PE-International
Hauptstrae 111-113
Leinfelden-Echterdingen, Germany 70771

ABSTRACT

This paper will discuss the use of HSC Sim (www.outotec.com/hsc) and GaBi
(www.pe-international.de) for foot-printing process technology and complete plant and
larger system solutions (e.g. recycling chains). In a recent development together with
PEInternational,

HSC Sims simulation functionality has been expanded to create files that can
be exported in a format that can be directly loaded into GaBi to create a GaBi-model
from a complete HSC Sim flowsheet and subsequently produce an environmental
assessment locally positioned wherever the plant is situated. This is very useful for the
evaluation of existing industrial plants represented by suitable HSC Sim flowsheets, as
well as the evaluation of various scenarios to estimate the impact of newly designed
solutions based on the rigor of metallurgical flowsheeting (mass and energy balances)
and associated process models. It goes without saying that this connection enables the
access to highly detailed process information through HSC Sim and thence providing a
rigorous basis on which to perform environmental impact assessment and identify the
best process options for each site based on the local conditions and energy footprints. In
addition to this LCA analysis, HSC

Sim has also been expanded to include exergy, which is rather useful to also understand
the entropy flows in systems permitting evaluating systems on a more fundamental
basis.


SD02

EXPERIMENTAL STUDY AND COMPUTATIONAL MODELLING OF
PARTICULATE EMISSIONS FROM OPEN-PITS IN VIETNAM

O. Nitzsche, K. Aygutzhiev, J.B. Pateiro Fernndez, P. Naumann
Brenk Systemplanung GmbH, Germany

ABSTRACT

Major air pollutants due to opencast mining are total suspended particulate matter
and respirable particulate matter whereas concentration of SO2 and NOX is negligible. The
primary source of fugitive dust at fully operational surface mine may include overburden
removal, blasting, mineral and coal haulage, mechanical handling operations, mineral and
coal stockpiles, and wind erosion.

The location and extension of each major dust source was included in this project in
the numerical dust dispersion model LASAT (Lagrangian Simulation of Aerosol-
Transport). For each of the dust sources, emission factors are used to characterize time
depending dust emissions. These factors are based on own experimental investigations and
values from literature. Meteorological data for the model were measured directly at the
open pit area over a period of more than one year.

The highly variable morphological structure of the open pit mine was included into
the model by a 10 m discretization. An analytic model run was done to simulate dust
dispersion over a one year period and compared with measured dust concentrations on
certain places. With prognostic model runs, various dust mitigation methods have been
analyzed and dust reduction potentials have been estimated.


SD03

NEW REGULATION FOR REDUCING AIRBORNE EMISSIONS FROM COPPER
FOUNDRIES IN CHILE

Carmen Gloria Contreras F., Priscilla Ulloa M., Pedro Santic C.
1

ABSTRACT

Copper foundries have been regulated since the 1990s, with controls affecting
airborne emissions of particulate matter (PM), arsenic (As) and Sulphur Dioxide (SO
2
).
Nevertheless, in 2010 priority was given to a new emissions standard for three main
reasons: 1) emissions limits have been complied with since 2003; 2) copper foundries
remain the principal source of contaminant emissions of SO
2
and As; and 3) social and
environmental conflicts persist in the locations where they are sited.

The focus and the challenge of the new regulation was to design an effective
standard while maintaining the fusion and conversion technologies currently used by the
foundries, although these processes produce the greatest proportion of air contaminants.
The assessment showed that there is great potential for reducing emissions, by introducing
technological improvements and good operating practices which will indirectly reduce
fugitive emissions from fusion and conversion. Specifically, decision-makers were
recommended to include annual emissions limits for each establishment; and chimney
emissions limits for unit operations which produce the contaminants assessed in significant
quantity and toxicity, for example concentrate driers, slag cleaning furnaces, fire refining
furnaces and acid plants.

In consideration of all the information available in the preparation of this standard,
such as technical visits to foundries, survey of the sector to be regulated, meetings with
distributors of process and control technologies, social assessment and public consultation
concerning the new standard, etc., it is concluded that the implementation in Chile of a


regulation such as that proposed is technically and economically feasible, as well as
socially beneficial.


SD04

INFLUENCE OF MINING PROJECTS IN SIERRA GORDA

Gina Roman,
Master of Business Administration & Bachelor of Biology

ABSTRACT

How is the transition from the evaluation of environmental impacts by project to a
holistic approach on the impacts achieved?

In the Region of Antofagasta, 263 projects have been submitted during the last 15
years to the Government Agencies for environmental approval. Twenty significant mining
project applications are located in the Sierra Gorda.
Sierra Gorda is one of the most vulnerable of the nine districts in the Region, with a
population of 3,700 habitants. It is a rural community with basic health and education
services, characterized by high population in transit searching for employment
opportunities.
This investigation will discuss the relationship of three projects in the area with the
governments development of community plans, in order to seek synergies that mitigate or
compensate the most sensitive socio environmental issues in the area.
The preliminary analysis of the information reveals that: i) sensitive socio
environmental issues are properly identified, ii) similar mitigations are proposed for
material emissions and management of water resources that can affect the community, and
iii) the government development of community plans are addressed descriptively but still
without action plans or programs that could promote sustainable development of the
community.


SD05

BREAKABLE GROUND SUPPORT, A VERIFICATION OF MECHANICAL
PROPERTIES TO DIMINSH FERROUS SOLID WASTE IN UNDERGROUND
MINING

V. Barrera and P. Lara
Instituto de Innovacin en Minera y Metalurgia, IM2 CODELCO
Ahumada #341, 7
th
Floor
Santiago, Chile
plara001@im2.codelco.cl

G. Pinilla and E. Arancibia
GTI- CODELCO
Hurfanos #1270
Santiago, Chile

ABSTRACT

The current elements used to support rock mass in underground mining are made
from ferrous alloys. They serve their purpose in order to help the rock mass self-supporting
but they also cause unwanted interruptions due to its high ductility, becoming in solid
wastes (SW). In Codelco underground mines, unscheduled downtime is caused in crushing
and transport in straps; due to this, the mineral gets stuck. For this reason, IM2s
Geomining Area is conducting a research on possible alternatives for the replacement of
ferrous elements with a technical point of view, thus making the system supports not
further considered SW. At least 3 support technologies have been found with the potential
to be breakable: fiber reinforced polymers, synthetic fibers and thin spray on liner. These
elements are subjected to various statics tests to study its technical feasibility (to the
reinforcement support: tensile, shear and pull out tests were performed; to containment
support, energy absorption test were made). This paper presents a review of these tests and
their results.


SD07

THE COMMERCIAL OPERATION OF ARSENIC FIXATION BY DMSPV

Naoki Hashimoto, Kazuyuki Matsumoto

ABSTRACT

Dowa Metals and Mining Co. Ltd. has developed and proposed a unique scorodite
synthesis technology (DMSPV) for arsenic fixation to solve the problems originating in
consistency increasing of impurities, especially arsenic, in copper concentrates. This
scorodite is well crystallized and least soluble, so it is easy to dispose of or store the
scorodite. There is a DIVISP plant at Kosaka Smelter for forming crystalline scorodite from
non-ferrous intermediate materials. The plant has started its commercial operation since
December 2011. The process management has been fairly good: fixing 30-50 arsenic-
MT/month, recovering copper, good disposal and effluent treatment allocation with existing
system.
The scorodite generated in the plant has excellent dissolution stability, which is
almost as same as that of one in laboratory examination. This means that we succeed in the
commercial application of DMSP. It is expected that more and. more arsenic is contained in
copper concentrate, then it is concerned that many non-ferrous smelters in the world do not
have enough ability of extracting arsenic in near future. We are convinced that DMSP
would have an important role in efficient use of resources and safe control of harmful
elements.


SD08

RISK UNDER STUDY APPROACH ISO 31000/2009, PLANT AREA, DIVISION
TALCUNA MINING SAN GERONIMO, COQUIMBO REGION

Torres Gonzalez, Fernando
Contreras Daz, Frank
Corvetto Zambra, Jonathan
Opazo Olivares, Alexis

ABSTRACT
The evolution of the processes, technologies and cultural changes, makes us reflect
on methodologies of analysis and risk assessment. The level of uncertainty in these new
complex scenarios posed the challenge of creating new tools. In this paper, we propose the
design of a risk management tool based on ISO 31000/2009, for Plant Talcuna of Mining
San Geronimo, located in the Region of Coquimbo, Chile. It develops a comprehensive tool
from selection of different methodologies to contextualize, analyze, evaluate and treat risk
as ISO 31000, for the area of plant concentrate Talcuna Division, generating a systematic
view of risk, reducing uncertainty and an important contribution to decision making.


SD09

PROPOSED DYNAMIC MODEL OF ENVIRONMENTAL AND OCCUPATIONAL
HAZARDS

Torres, Fernando.
Corts, Ernesto.

ABSTRACT
The evolution of the processes, technologies and cultural changes, makes us reflect
on methodologies of analysis and risk assessment. The level of uncertainty in these new
complex scenarios posed the challenge of creating new tools. In this paper, we propose the
design of a risk management tool based on a dynamic model of risk, through a
mathematical formulation to understand the issues facing companies today, is created
considering the state of the art , establishing the principles, variables and factors that
constitute it. The Dynamic Model mathematically integrates Risk factors influencing
variables Probability, Consequences and Risk Control to set the state of a system risk. The
design of the risk management tool is based on the development of an algorithm that
defines risk, provides data entry, processing and analysis results. The model provides an
innovative vision regarding the interrelation of operational variables, organizational, social
and environmental consideration in decision making for risk management.


SD11

SUSTAINTABILITY, A MINERALS SECTOR OPPORTUNITY

Patricio Leyton Lawyer
Alejandro Labb Engineer.

ABSTRACT

Meetings the needs of today without diminishing the capacity of future generations
to meet their needs.
The last years mining industry sustainable development program have advanced,
despite the efforts, miners and their activity has fallen into increasing public unfavorable
acceptance. Today society perception in the mining sector is that industry is incompatible
with sustainable development. Additionally, by historical reasons, mining is plenty of a
poor reputation and still remains as hostile and suspicious sector.
The authors compile today sustainable initiatives available for the mining industry
and where are the key aspects to take sustainability as an opportunity for mining acceptance
and where are the pending and forgotten issues still affecting.


SD12

FLEXIBLE MINING CLOSURE PLANS:
DEALING WITH ENVIRONMENTAL REGULATION UNCERTAINTY

Miguel Paredes Sadler
Department of Urban Studies and Planning
290 Massachusetts Avenue Apt. E6
Cambridge, MA, USA
mparedes@mit.edu

ABSTRACT

The future is inherently uncertain. This reality has large implications for the mining
industry, especially for the mining closure phase, which requires making many assumptions
about future conditions. However, some aspects are vastly ignored in closure plans, placing
mining companies in a disadvantageous and risky situation under certain unexpected
scenarios.

The environmental and social spheres are where this ignorability seems more
prevalent. Given the inability to precisely forecast what set of social or environmental
regulations will be in play after the extraction and processing life of the mine, mining
companys closure plans fail to intervene strategically in an effort to manage future
uncertainty.

Drawing from the social and environmental regulatory body of Peru, we highlight
how some crucial social and environmental issues are currently not being addressed by
mining companies, largely due to the Governments regulatory silence on these topics,
leaving mining companies vulnerable to future scenarios of more stringent social and
environmental regulation. The Peruvian example used is relevant to the mining industry as
a whole due to the prevalence of these problems.

Through a combination of Monte Carlo simulations, Real Options, Scenario
Planning, and Machine Learning techniques, we demonstrate how a more rigorous
representation of future social and environmental uncertainties could warrant strategic
investments today social and environmental real options - granting mining companies the
flexibility to manage future uncertainty.


SD13

CHILEAN REGULATION OF WORKING AT 3000-5500 METERS ALTITUDE:
UNIQUENESS AND CHALLENGES

Daniel Jimnez-Espinoza

ABSTRACT

The Ministry of Health of Chile, by DS-28-2012 recognizes that altitude diseases,
Acute Mountain Sickness, Pulmonary and Cerebral edema, hypoxic Sleep Disorders or
Polycythemia are Occupational Hazards if they occur while workers are laboring between
3000 and 5500 meters altitude. These diseases cause physical disability and commitment to
safe behavior, which are reversible to descend to low altitude. This occupational risk must
be controlled by identification and education of workers exposed, a Prevention Program,
a Surveillance System of altitude diseases and Mitigation measures in Camps above 3000
meters, considering oxygenation, humidification or other technologies. The health
professionals staff of altitude Polyclinics is defined by four evaluation criteria.
The uniqueness of this standard is a pioneer in the world, incorporating hypobaric
hypoxia between environmental risk factors, integrating concepts of Mountain Medicine
and Occupational Health regarding acute exposure, the possibilities of Acclimatization and
the implementation of effective mitigation measures.
Among the challenges is improving pre-occupational medical examination,
acclimatization clinical criteria defining for each altitude according oxygen saturation
levels, blood pressure, hemoglobin, quality of sleep, signs of mountain sickness, etc. Also
imposes Mountain Medicine training to medical examiners and health professionals of
altitude mine-site polyclinics.
This rule will help improve the interest of sea level natives to work in high altitude
mining, and protect them during occupational exposure in intermittent hypobaria.


SD14

PROCESS INNOVATION BY WORKING MINERS
A CASE OF USER INNOVATION IN COPPER MINING INDUSTRY

Juan Giuliano
CODELCO Divisin Andina
Avda. Santa Teresa 513
Los Andes, Chile
Juagiul@codelco.cl

Sergio Burdiles O.
Sloan School of Management
50 Memorial Dr.
Cambridge, MA, USA
sburdile@sloan.mit.edu

ABSTRACT

Employees are known to develop and use key process improvements. In this work,
we explore innovation by mining employees working in Codelco, a Chilean mining
company. The data on these innovations come from a contest sponsored by mine
management at the Andina division of Codelco. This contest encourages workers to come
forward and reveal the improvements they have made.

The research method used for this case study is based on data and information
collected from interviews with managers, workers and members of the contest organizing
committee. In addition, a survey was given to more than 50 workers involved in the current
version of the contest, to evaluate and analyze their interests and motivation drivers to
participate in the contest.

One of the main findings is that more than 10% of total workers do behave as user
innovators, and 85% of the surveys participants have created at least two innovations at
Andina. For the workers, the main reasons to participate in the contest are making a

contribution to the company, to develop a deeper knowledge in a specific topic, and also to
be recognized by family, colleagues and managers.

The key lessons of this work are that user innovations in the copper mining industry
do happen, and creating the right incentives for workers to innovate and share their
innovations, can increase their safety, the environmental impact, their motivation,
performance evaluation and add value to their company and the industry.

SD15

ENERGY BENEFITS OF IMPLEMENTING DRILL-TO-MILL STRATEGIES IN
OPEN-PIT COPPER MINES

S. Nadolski, B. Klein and M. Scoble
NBK Institute of Mining Engineering
The University of British Columbia
5
th
Floor, 6350 Stores Road,
Vancouver, Canada V6T 1Z4
snadolski@bcmr.ca

ABSTRACT

Over the last 10 years the benefits of optimizing both blast design and operation of
crushing and grinding processes, also known as drill-to-mill optimization, have been shown
at a number of mining operations. Significant reductions in energy intensity and operating
cost, as well as increased production potential, are typically associated with the successful
implementation of drill-to-mill strategies. However, it has been found that due to
operational and cultural challenges, drill-to-mill practices are rarely maintained after their
introduction. The typical management structure of a mining operation, where mining and
concentrator engineers are managed in separate teams and assessed against different
performance criteria, is one example of a cultural hurdle to optimizing overall comminution
on a continual basis.

Addressing the technical challenges of implementing drill-to-mill strategies, the
results of a study for a Canadian open-pit copper mine are presented in this paper. In
addition to quantifying improvements in energy intensity and operational costs, the
potential for increasing production through optimization of blast design and mill
comminution processes is also determined. An approach to ingraining drill-to-mill practices
within the culture of an operation is proposed and discussed with reference to the outcome
of a survey of upper level mine managers.


SD16

WATER, ENERGY AND LABOR: KEY CRITICS TO COMPETITIVENESS OF
THE CHILEAN COPPER INDUSTRY

Patricio Rojas Alfaro Patricio Prez Oportus
Ingeniero Civil Industrial Economista

Universidad de Valparaso
prperez@puc.cl

ABSTRACT

Mining is important for Chile, is the main productive sector of our economy, which
contributes more in terms of tax revenue, and which leads the flow of direct investment
received from abroad. On average, the mining activity will provide during 2013 more than
37 million pesos per minute, which translates into a contribution close to 55 billion pesos
per day.

However, mining is not without challenges. Three critical themes for their
competitiveness in the long run, are the costs of energy, labor and availability of water.

This document analyzes and quantifies the participation of these 3 - critical inputs in
the sector-level cash costs (C1) and net costs (C3), see the impact that have these elements
in operating costs and impact on the competitive position of the Chilean copper industry.
Finally, it makes policy recommendations to address and move forward on these
challenges.


SD20

THE USE OF MICROWAVES IN THE SMELTING INDUSTRYS THERMO
PROCESS TECHNOLOGY

Dirk Hannemann

ABSTRACT

Microwaves have gained acceptance as a technical application for warming up
materials in many industrial sectors. However, there have not been any applications in the
smelting industry yet. There are nevertheless several applications that seem that they could
benefit from the use of microwaves, in particular in situations where smelter materials have
to be heated to remove moisture or to dry them or where volatile components have to be
removed from critical materials.

Initial trials have shown that microwaves are well suited to warming moist metal-
bearing materials. This discovery led to the preparation of an overview of the potential
applications of microwaves to treat smelter materials. Furthermore, microwaves were
compared to established heating and drying processes in order to illustrate the benefits of
microwave dryers. The generation and properties of microwaves demonstrate the
differences from established thermo process technologies and provide indications for
designing microwave heating equipment.

This article presents the results of treating valuable raw materials and slimes with
microwaves. In addition, it provides an indication for drying moist concentrates and
treating critical intermediate products.
The conclusion addresses practical implementation with regards to installation engineering,
required space, environmental protection and occupational safety and discusses obstacles
that still stand in the way of using microwaves in the smelting industry.


SD21

ELECTRICAL POWER QUALITY IN BIG COPPER MINES

Marcelo Hormazabal
m.hormazabal@eecol.cl

ABSTRACT

There can be completely different definitions for power quality, depending on ones
frame of reference. For example, a utility may define power quality as reliability and
criteria established by regulatory agencies are usually in this vein, like the Norma Tcnica
de Seguridad y Calidad de Servicio [NT_de_SyCS]. Utilities and Big Copper Mines are
currently complying with these normative at the PCC (Point of Common Coupling).

Power quality has therefore becoming ultimately a consumer-driven issue, and the
end users point of reference takes precedence. Therefore, the following definition of a
power quality problem inside the electrical system of the Copper Mines could be defined
as:
Any power problem manifested in voltage, current, or frequency deviations that
result in failure or misoperation of the Copper Mine equipment.
Power quality, like quality in other goods and services, is difficult to quantify. There
is no single accepted definition of quality power. There are standards for voltage and other
technical criteria that may be measured, but the ultimate measure of power quality is
determined by the performance and productivity of end-user equipment. If the electric
power is inadequate for those needs, then the quality is lacking.
The economics involved in solving a power quality problem must also be included
in the analysis. It is not always economical to eliminate power quality variations on the
supply side. In many cases, the optimal solution to a problem may involve making a
particular piece of sensitive equipment less sensitive to power quality variations. The level
of power quality required is that level which will result in proper operation of the
equipment at a particular facility.

In summary, these users must accept that the quality problems of energy in their
systems are caused by their own processes and equipment and proceed accordingly.

SD22

COFELY TRMIKA TO ESCO MODEL: NEW ENVIRONMENTAL SOLUTIONS

David Mounissens,
Gerente General en Chile
Mail: Dmounissens@Cofely-Termika.Cl
COFELY GDF SUEZ

ABSTRACT

COFELY Trmika is responsible for improving the efficiency of the entire
production of utility (heat, steam, cold) of a client through a comprehensive offering:
Solution design optimized production Central
Financing and ownership of equipment
Equipment installation and commissioning
Operation and maintenance of long-term:
Engagement of savings on the production process Utility
Warranty lifecycle of equipment (repair and renovation)
Transfer of ownership of the exchange to the customer at the end of the
contract
Approach of energy efficiency (savings versus investment)
1st Source: maintenance and operation
2nd source: demand control
3tra: Renewal of more efficient equipment, investment in technology, re-
engineering of the utility.

COFELY invests and guarantees savings,
CCL: major source of savings come from the operation and maintenance
Guaranteed energy savings over the time of the contract
Applications for mining
All industrial processes that require
leaching
flotation
All applications for the camps:
Water production

Casino
Pools ...
A concrete example of clean production applications
Cogeneration
Solar Thermal Energy

SD23

DRASTIC ENERGY AND WATER REDUCTION IN LARGE METALLURGICAL
COMPLEXES

Osvaldo A. Bascur, Curt Hertler, OSIsoft, LCC, USA
Nelver Benavides, Southern Peru Cuajone, Peru
Michael Halhead, Anglo American Platinum, South Africa

ABSTRACT
One of the most vigorous of the continuous improvement methodologies is Six
Sigma. While usually associated with improving manufacturing and product quality,
leading manufacturers are using it to improve their extended supply chain and logistics
capabilities. At the same time they are improving reliability, some companies have cut
hundreds of millions of dollars of fat out of their supply chain.
Mine to Mill optimization is a transformation of culture from processing tons to
processing a quality feed size distribution which reduces the overall operational costs and
add the highest value to the mine. This is not a constant endeavor. As such, a dynamic
performance monitoring and diagnosis is necessary. We will review a systemic way to
performance improvements and avoiding metal losses from the blast to the metals.
We show three industrials cases where the requirements of using raw data for
analysis and for define operational maps. These cases provide assistance to run the mine
and mill operations, enterprise metal complexes. The first case study provides with the
mine and mill data integrating process control and quality information resulting in
reductions of water and energy consumption while improving the overall value of the mine.
The results of reengineering the current system with this innovative SIX SIGMA strategy
had the following results: an increase of ore milling: 4.6% decrease of mil power: 3.9%,
decrease of fresh water consumption: 6.8%, with a total of net profits: US$ 31.8 million,
the PI System infrastructure contribution: US$ 7.95 million.
A very similar case study summarizes the work by AngloAmerican Platinum
towards their goals of 15% specific energy reduction. We finish by provide a third case
study of CAP Acero. The result of this strategic implementation reduces 10% of the electric
power bill, reduces environmental emissions and enables to implement a gas cogeneration

plant using the gas savings. All these achievements with one common denominator: the
implementation of a dynamic operational continuous improvement and innovation strategy
enabled by a real time information infrastructure.


SD24

ENERGY EFFECTIVENESS AND SUSTAINABILITY MANAGEMENT AT
ANGLO AMERICAN PLATINUM

Osvaldo A. Bascur
OSIsoft, LLC, Houston, TX, USA.
Osvaldo@osisoft.com

Michael Halhead
Anglo American Platinum,
Johannesburg, RSA.

ABSTRACT
Large Metallurgical Complexes are large users of Energy, Water and
Assets. There are 1000 thousands of meters to manage the information at the local
and enterprise level. To improve the effectiveness of energy and assets the quality
of the data and events becomes a paramount for real time operational management.
The lack of resources at the local operations and at the enterprise to process the sea
of information becomes impossible and many projects have failed. As such, a novel
approach for implementation of continuous improvements at the local level and
innovations at the strategic level was implemented at all operating plants at
AngloPlats. The new capability of an enterprise real time monitoring and diagnosis
software infrastructure was available to implement many business strategies in
tandem.
A manufacturing services strategy was built to support operations and
reduce operational costs at the local and at the enterprise level. This paper will
highlight the required data hierarchies approaches for adaptive reporting, condition
based event management and proactive notifications. The results based on the
integrated and collaborative team efforts will be presented for a targeted reduction
in energy consumption of 15% by 2014.


SD27

ENVIRONMENTAL HAZARD CLASSIFICATION OF COPPER
CONCENTRATES

P.H. Rodriguez , J.J. Arbildua, P.F. Urrestarazu, M.R. Opazo and G. Villavicencio
Center for Ecotoxicology and Chemistry of Metals
Universidad Adolfo Ibaez
Av. Diagonal Las Torres 2700
Santiago, Chile
patricio.rodriguez@uai.cl

K. Delbeke
European Copper Institute
Avenue de Tervueren 168 b10, B-1150
Brussels, Belgium
katrien.delbeke@copperalliance.eu

J. Liipo
Outotec Research Center
P.O Box 69 Kuparitie 10, FIN-28101
PORI, Finland
Jussi.liipo@outotec.com

T. Brouwers
ECTX-Consult bvba
Havenstraat 46/0.01, B-3500
Hasselt, Belgium
Tony.Brouwers@ectxconsult.be

ABSTRACT

Copper concentrates are complex metal bearing substances, whose composition
varies depending on the geology of the ore body. The environmental hazard classification
of such substances presents particular difficulties and depends, among other things, on the
bioavailability of copper, arsenic, cadmium, cobalt, lead, molybdenum, nickel and zinc;
metals which are relevant from a regulatory standpoint and are frequently found in the
concentrates. A read across procedure was developed to classify copper concentrates using

transformation / dissolution (T/D) test results of pure minerals, and their elemental and
mineralogical composition. Validation of the procedure for copper involved contrasting
T/D results of 12 copper concentrates against the predicted bioavailability values for the
metal contained in the pure minerals. A correlation coefficient of (R
2
) 0.73 was found for
these 12 concentrates. Then, a sample of 119 copper concentrates with known elemental
and mineralogical composition was assessed, representing most of the product transported
globally, following the United Nation Globally Harmonized Classification and Labeling
System of Chemicals (GHS).


SD29

COPPER MINING, GENERATING INNOVATION IN CHILE.

Horacio VERGARA ARANCI BI A
Master and Innovation and MBA International
And Mining Engineer
Innovation Challenge Latam.
Nueva York 53, office 61.
Santiago of Chile
hvergara@ichallenge.cl

Enric Barba
Telecommunications PhD and
Master in business management and organization
University Polytechnic of Catalonia /Barcelona Spain

Carlos Baradello
PhD, Electrical Engineering, Carnegie Mellon University,
MSc, Electronic Engineering , Eindhoven University of Technology, Holand
Electrical Electronic Engineering Degree University Catholic of Crdoba, Argentina

ABSTRACT

The Chilean mining has been marked by many milestones in the development of it.
In this descriptive character study, we analyzed three moments that we considered relevant,
of which we have partnered for character technological innovation in technology and
management, deliver it from a series of data of relevance to the international mining
industry, that can serve as a guide and catalyst to advance in a contemporary world where
connectivity has taken a major role.

We have concluded and believe that Chilean society must use the knowledge
Generat ed by industry, mining in general and from them advance value creation. They
should think about transforming the country and its economy, in another direction, but
moving forward with the information and knowledge generated in and by the mining
industry in Chile, as at the time was made by gold mining in the United States during gold
Rush.

SD30

FROM THE SMOKE TRAGEDY TO THE SAN JOSE MINE ENTRAPMENT. 68
YEARS OF OCCUPATIONAL HEALTH AND SAFETY MANAGEMENT IN
CHILE

Alex Morales (amorales@mutual.cl)
Mutual de Seguridad CChC - Chile
Quebec 424 Providencia
Santiago, Chile

ABSTRACT

In June 1945 a fire inside El Teniente mine, the world largest underground copper mine in
the world killed 355 miners. This event changed the way Occupational Health and Safety
(OHS) in mining was managed in our country. It also brought changes in our OHS
legislation. At El Teniente the accident lead to a shift towards a preventive approach that
has persisted over time and has generated a OHS risk management model in mining that
has been trend setting in our country. Not surprisingly, when a new mining accident struck
our country in 2010 leaving 33 miners trapped in the San Jose mine in northern Chile, a
rescue team from El Teniente was convened to bring them back to the surface alive. This
paper describes the evolution in Chile and worldwide of the strategies to control risk in
mining, from the classic pyramid of Heinrich-Bird to Risk Management Systems, to the new
perspectives from behavior based safety and from leadership and safety culture.


SD31

INCREMENTAL VS. DISRUPTIVE INNOVATION,
SENSE OF OPPORTUNITY AND A PATH TO DEVELOP DISRUPTIVE AND
SUSTAINABLE TECHNOLOGICAL INNOVATION FOR THE COPPER INDUSTRY
INTEGRATED OBJECTIVES MODEL (IOM)
COPPER 2013 CONFERENCE

A. Zolezzi
AIC- CHILE
Calle Limache 3405 Of 63
Via del Mar, Chile
alfredo.zolezzi@aicchile.com
@AlfredoZolezzi
ABSTRACT

The working and operating context of large corporations during the next decades will
develop under high-complexity economic, social and environmental scenarios. This entails
combining a large number of external variables, hence increasing conflicts. We coincide that
currently these processes have not considered enough in the regular space for decisions that
must be faced by such corporations, resulting in successive crises that cause high mass media
impact and unsuspected economic consequences.

Lately, Barrick Golds Pascua Lama Project with an investment of about US$ 8.5
billion has announced its temporary shutdown. Will we lose this investment? The Latin
American Mining Conflicts Observatory (OCMAL) claims that there are 196 conflicts at
Latin American level involving 205 projects and affecting some 295 communities. These
figures include 34 conflicts in Peru, 33 in Chile, 28 in Mexico and 26 conflicts in Argentina,
representing 62% of that total. These figures make us understand that its necessary to
progress in developing new capabilities to successfully face the challenges imposed by the
presence of such variables in the productive, economic, social and environmental landscapes.
This happens because different from what happened in the past the progress in the
operations of large mining projects doesnt happen and wont happen due to the exclusive
control of the corporations. This makes us look to the future with a perspective that is totally
different to the current one. For the first time, the key decision elements wont be the capital,
the technology or the business profitability; actually, they will be the capacity to operate with
all these factors simultaneously. In fact, in the Chilean Mining Industry Competitiveness
Diagnosis (Mc Kinsey, 2012), high risk factors are the following: energy costs in Chile, lack
of water resources in the north of the country, on-going increase in salaries and a complex and
uncertain environmental regulations system.


In that sense, mining projects and projects based on the natural resources exploitation
will face huge challenges in addition to the common economic issues, a reality that we are
starting to see today. Currently, one fifth of the worlds population lives in water scarcity
areas. It has been forecasted that in 2025, two third of the worlds population could face water
stress conditions. In face of this, the natural resources management and transformation has
gained a critical value for society, which will require better quality responses, with innovation
and commitment, from the corporations. Can we continue using water in mining in the
manner we do today?

Currently, the innovative look on the mining business technical and inherent problems
has resulted in relevant results. They effectively show that responses have been developed
mostly based on incremental development, with a permanent focus on the industrys
productive processes. However, todays challenges require responses associated to
environmental and social issues; and the restrictive regulations that will be put in force, and
the deposits low grades make the model to be increasingly and inevitably more complex.
Today those variables are not only visualized in the near future, but they will also have a
higher relative weight. In this scenario, forecasts establish that this incremental innovation
developed by the industry wont be able to give an answer to those challenges, bringing with
it, consequences such as the ones reviewed before, resulting in project delays or cancellation.

Hence, we must wonder, is incremental innovation the key to face these new
challenges? Which is its cost? In an environment of multiple variables, constantly changing
and with a high demand for transformation, the capacity to think out of the box to find new
paths becomes the tool that can be used by organizations, because it allows having an open
and evolutionary look with the capability to face the unforeseen.
To ensure the highly demanded global sustainability, it is necessary to decouple the
corporations growth from the intensive use of resources. This is only possible through the
addition of disruptive innovation lines oriented to the development of distributed value
(corporations, environment and community). AIC Chile appropriates these principles by
defining its Integrated Objectives Model (IOM). This model merges community and
corporate interests based on the principle that the main hurdles for the development and
adoption of innovations in the future wont be the technical problems. Instead, the major
hurdles will be the environmental, social and cultural problems that require creating new
structures that go beyond the boundaries of the corporations and that allow aligning their
objectives with the communities objectives. This condition is the one that has allowed us to
develop sustainable technologies that can change the rate in which we fight against poverty in
industries as diverse as the oil and water purification industries.
In that sense, we are convinced that it is possible to harmonize the private and public
value creation without affecting corporate development, working in anticipating disruptive
innovation programs that search for the feasibility not only of these projects, but also ensuring
the environmental, human and talent sustainability of the stakeholder communities.


SD32

REGULATORY CHALLENGES FOR THE MINING INDUSTRY IN CHILE.

Alejandro Canut de Bon

ABSTRACT
Sustainable development and Mining Industry is going through different
tensions among new regulatory standards, communities engagement and environmental
requirements; then, the companies must be aware of how these changes may affect their
activities and the projects development. The panel will review main regulations under
review, not only those related to operational matters (safe & health) but also to social
and environmental frameworks. Moreover, some international soft-law standards will be
analyzed by the panel, such as those referring to transparency and accountability in the
extractive sector. Few words, as introduction, regarding sustainable development and
mining, will be part of this presentation.
Process Control and Optimization

SYMPOSIUM: 07 PROCESS CONTROL AND OPTIMIZATION

PC01 Rodrigo De
Carvalho
PREDICTING SAG GRINDING USING A
MECHANISTIC MODEL
PC02 S Mohsler MAXIMIZING POWER GENERATION IN
METALLURGICAL SULPHURIC ACID
PLANTS
PC03 Michel Ruel DO YOU NEED ADVANCED CONTROL?
PC04 Michel Masse SMARTEXEC OPTIMIZED MINE
VENTILATION CONTROL AT GOLDCORP
OPINACA MINES, ELENORE PROJECT,
NORTHERN QUEBEC
PC05 Ewa Kolcsyk IMPLEMENTATION OF NUMERICAL
MODELING FOR EFFICIENCY INCREASE IN
FIRING OF ROTARY ANODE FURNACE
PC06 P.Poks ANALYZING ELECTROREFINING PROCESS
DATA
PC07 Raul Zuiga MODELLING THE EARLY SUPPLY CHAIN
PROCESSES IN THE MINERAL RAW
MATERIALS INDUSTRY
PC08 Abbas
Tabatabaei
PROCESS OPTIMIZATION AND CONTROL OF
OXIDE COPPER MINERALS FLOTATION
USING IMAGE ANALYSIS AND FUZZY
CONTROL SYSTEM
PC09 Luc Lachance COPING WITH THE CHALLENGES OF METAL
ACCOUNTING IN COPPER HEAP LEACH
OPERATIONS
PC10 Jose Misle INNOVATION IN ADVANCED CONTROL AT
MINERA LOS PELAMBRES
PC11 Juan Solis
Castro
MINERA ESPERANZA WAY TO STOP THE
BREAKAGE OF SAG MILL'S LINERS
PC12 Luis Bergh HYBRID LABS FOR EDUCATING AND
RESEARCH ON FLOTATION CONTROL
PC13 Jorge
Echeverria
SMART TECHNOLOGY FOR MINING
REPORTABILITY A DECISION-MAKING
SUPPORT APPLICATION BASED ON THE
TIBCO SPOTFIRE TECHNOLOGY

PC14 Jonhatan
Barriga
MOISTURE MONITORING IN HEAP
LEACHING, THROUGH ELETROMAGNETIC
METHOD
PC15 A.Warczok CONTINUOUS PROCESS OF COPPER
CONCENTRATE SMELTING, CONVERTING
AND REFINING
PC16 Jesus Cruces
Herrera
OPTIMIZATION OF SERVICE TIME AT GAS
STATION WITH THE IMPLEMENTATION OF
FAST SYSTEMS
PC17 Tim
Krusmark
PROCESS CONTROL TRAINING-
SIMULATORS ARE ONLY HALF THE STORY
PC18 Shangyang
Zhang
OUTDOOR INTEGRATED GREEN ENERGY-
SAVING HIGH POWER RECTIFIER SYSTEM
FOR COPPER SMELTER


PC01

PREDICTING SAG GRINDING USING A MECHANISTIC MODEL

Rodrigo M. de Carvalho, Vladmir K. Alves, Lus Marcelo Tavares

ABSTRACT

The accurate prediction of the outcomes in SAG grinding has been a great
challenge to researchers and process operators. The use of Discrete Element Methods
for modeling charge motion in tumbling mills allowed for extraction of not only visual
data, such as the position of the charge, but also the energy transfer in terms of the
energy dissipated in the collisions. One of the advantages of DEM technique is its
scalability to different mill sizes and some operational conditions such as speed and
mill filling.

Recently the Authors proposed the coupling between DEM outputs and
modified Population Balance Models which with proper dedicated ore characterization
tests allows the prediction of the outcomes of an energy transfer example. This
modeling framework is called the Multi-scale Mechanistic Modeling. This paper
shows the application of the Multi-scale Mechanistic Model to a set of several pilot
plant tests ran at different operational conditions which include different operation
type (AG/SAG), different mill speeds and mill fillings for a Brazilian copper ore.
Detailed results from ore characterization for modeling are presented, which enabled
calibration of the mechanistic mill model.


PC02

MAXIMIZING POWER GENERATION IN METALLURGICAL SULPHURIC
ACID PLANTS

S. Mohsler

ABSTRACT

Metallurgical processes which generate very concentrated SO
2
off-gas, such as the
Outotec Flash Smelter and flash converter in combination with Outotec sulphuric acid plant
technology allow the production of high pressure steam to be used for power generation.
Outotec combines well proven technology from sulphur burning plants for this purpose in
metallurgical plants.

The application of Outotecs proven LUREC
TM
process enables processing of SO
2

gas of up to 18 vol.-%. This process maximizes the energy recovery from the SO
2
oxidation
at a reasonable high temperature level which can be turned into high pressure steam.

The application of the Outotec HEROS
TM
heat recovery system enables the
generation of low pressure steam from the absorption energy released at the intermediate
absorption step. Additionally, energy is also recovered in the acid coolers for boiler feed
water pre-heating.

The concept of integration of high and low pressure steam in combination with the
pressurized operation of the boiler feedwater deaerator, thus heating up the boiler feed
water to temperatures around 160170C, enables indirect transfer of low pressure steam
(for deaerator operation) into more valuable high pressure steam and hence better overall
thermal efficiency, which improves the degree of heat recovery. This is the characteristic of
Outotecs HIPROS
TM
process.

The thus increased generation of high pressure steam will in turn enable the
generation of more electricity when compared to a standard traditional sulphuric acid
process.


PC03

DO YOU NEED ADVANCED CONTROL?

Michel Ruel P.Eng.
Department head, Optimization and Advanced Control, BBA Inc. Qubec City, Canada

ABSTRACT
This paper describes advanced control choices when difficult processes need
improvement.
How to determine the best approach? How to decide between ruled based
approaches and model based approaches? How to balance advantages and disadvantages,
complexity and simplicity, investment and results?
How to decide which approach should be preferred?
This paper will present briefly each solution and define vocabulary for most
common solutions: basic control (single loop), advanced regulatory control, model
predictive control and expert systems such as fuzzy logic controller and neural network.
Then, a decision tree to select the most appropriate approach will be suggested. The
decision tree will include a list of questions, a series of tests to validate models, a series of
question to interview operators. The possible solutions and approaches will be organized in
a simple schematic by hierarchy and type. Examples for each solution will be presented and
commented. A table will compare usage, development, commissioning, maintenance and
lifecycle costs for each approach.
Conclusions and suggestions will summarize the methodology.


PC04

SMARTEXEC OPTIMIZED MINE VENTILATION CONTROL AT GOLDCORP
OPINACA MINES, ELENORE PROJECT, NORTHERN QUEBEC

Michel Mass y Edinson Claros

ABSTRACT
In 2012, Simsmarts SmartEXEC (Smart Expandable Energy Control) was selected
at the planning stage of the Elenore Project of Goldcorp located in, Quebec, Canada to
contribute to the overall optimum profitability of the Opinaca mine. With objectives of
reducing development capital costs, production operating costs, and energy consumption,
Simsmart Tecnologies was selected to engineer and implement its unique, 3-D modeling
and optimized ventilation control technology.
This paper will report on the current status and results to date of the SmartEXEC
turnkey solution. It will detail the SmartEXEC five level implementation process and the
adaptation of SmartEXEC to the selected and installed automation control technology
operating at the Elenore project. In particular, discussion will include:
How SmartEXEC was used during ventilation planning to reduce CAPEX
expenditures
How SmartEXEC was commissioned during mine construction to reduce
power consumption.
How SmartEXEC calculates the required aggregate air requirement for each
work zone and how it controls the zone air flow as a function of personnel presence and
machinery movement.
How SmartEXEC is the only ventilation control system that can provide real
time simulation and control from a 3D model.


En el ao de 2012, el sistema SmartEXEC (Smart Expandable Energy Control) de
Simsmart fue seleccionado para contribuir en la etapa de planeamiento del proyecto
Eleonore de Goldcorp en Quebec Canad, con el fin de optimizar la rentabilidad global
operacional de la mina Opinaca. Teniendo como objetivos reducir el costo capital de
desarrollo, el costo operacional de produccin y el consumo de energa, Simsmart
Technologies ha sido seleccionada para realizar la ingeniera e implementacin a travs de
su sistema de modelizacin y control optimizado de ventilacin 3-D.
Este artculo tiene como objetivo presentar los resultados alcanzados con la solucin tipo
llave en mano(turnkey) implementada por SmartEXEC, adems se explicarn los cinco
diferentes niveles de implementacin y adaptacin con la tecnologa de automatizacin
existente en el proyecto Eleonore. El informe va a incluir Principalmente los siguientes
aspectos:
La estrategia utilizada por el sistema SmartEXEC para reducir los gastos (CAPEX)
durante la etapa de planeacin del sistema de ventilacin.
La tcnica implementada por el sistema para reducir el consumo de energa durante
las preparaciones.
El mtodo utilizado por el sistema SmartEXEC para calcular los requerimientos de
aire en cada zona de trabajo y controlar el caudal de aire en funcin del movimiento del
personal y de la maquinaria.
Las ventajas de SmartEXEC a travs de la implementacin del nico sistema de
control de ventilacin que utiliza la tecnologa 3-D en tiempo real para la optimizacin y el
control del sistema de ventilacin.


PC05

IMPLEMENTATION OF NUMERICAL MODELING FOR EFFICIENCY
INCREASE IN FIRING OF ROTARY ANODE FURNACE

E. Kolczyk, Z. Miczkowski and G. Krawiec
Institute of Non-Ferrous Metals
Sowiskiego 5
44-100 Gliwice, Poland
Ewa.Kolczyk@imn.gliwice.pl

ABSTRACT
The paper presents analysis of variants of rotary anode furnace firing for
minimization of fuel consumption by application of a burner and tuyeres. A mathematical
model of heat exchange in the rotary anode furnace was developed. The model was used for
determination of average copper charge temperature and uniformity of thermal field in the
anode furnace which was fired by traditional method and with application of tuyeres. Based
on the performed calculations and analyses it was established that the rotary anode furnace
fired with application of a burner only requires higher volume of the fuel to provide
appropriate temperature of the bath. Implementation of the submerged tuyeres beside the
gas burner in the firing of the anode furnace provides possibilities to reduce fuel
consumption and improves uniformity of thermal field in the bath. The highest firing
efficiency was produced with application of the burner and tuyeres supplied with gas in the
amount of 100 + 50 + 50 Nm
3
/h, where the average temperature of liquid copper of 1219C
with standard deviation of 18.2C was reached.


PC06

MANAGEMENT AND ANALYZING ELECTROREFINING PROCESS DATA

P. Poks and Z. Gostyski
KGHM PM S.A.
O/HM Gogw
ul. ukowicka 1
67-200 Gogw
Poland
p.poks@kghm.pl

C. Poks
Pharmaceutical Production Company Hasco-Lek S.A.
ul. migrodzka 242E
51-131 Wrocaw
Poland

M. Czaplicka
Instytut Metali Nieelaznych
ul. Sowiskiego 5
44-100 Gliwice
Poland

ABSTRACT

Nowadays, industrial installations are based on advanced automatic systems
generating a huge amount of process data. Online measurements and process parameters let
operators keep processes in optimal technological limits. Collected process data from
technological software is not very useful for direct use in long-term analysis (for example
annual) without some transformation which helps to analyze it in connection with data from
other sources (for example anode and cathode quality control data). In this paper we would
like to present an attempt at analysis of electrorefining data stored in a data warehouse.
Initial results are very promising, and thanks to having input data (anodes), processing data
(electrorefining parameters) and output data (quality analysis) we can build models for

statistical analysis. For now we have created an algorithm of predicting cathode
composition basing on historical processing data.


PC07

MODELLING THE EARLY SUPPLY CHAIN PROCESSES IN THE MINERAL
RAW MATERIALS INDUSTRY

Raul Zuiga
1,2,3
, Marcus Seifert
1
, Klaus-Dieter Thoben
1

1
Bremer Institut fr Produktion und Logistik GmbH an der Universitt Bremen,
Hochschulring 20, 28359 Bremen, Germany
2
Faculty of Engineering and Architecture, Arturo Prat University, Arturo Prat 2120 Av.,
Iquique, Chile
3
International Graduate School for Dynamics in Logistics, University of Bremen,
Hochschulring 20, 28359 Bremen, Germany
{zun, sf, tho}@biba.uni-bremen.de

ABSTRACT
Supply chain integration in the mineral raw material industry can help to optimise
total supply chain performance rather than optimising its components parts, resulting in a
better outcome overall. A standard framework to supply chain that allows modelling the
early supply chain processes can contribute to the integration in the chain and the success
of improvement for this industry. This paper examines how the processes of this industry:
exploration, development, extraction, processing, and distribution, are represented in
todays supply chains. These processes are described by using the existing models, Design
Chain Operations Reference (DCOR) model and Supply Chain Operations Reference
(SCOR) model. These models describe a supply chain simple or complex, using their own
standard main processes. This work nds that DCOR and SCOR models can be adapted
and extended to model the processes of this industry. Furthermore, it demonstrates the
possibility to extend these models to include the Key Performance Indicators and Best
Practices that are more suitable in the context of this industry. The results show that an
improvement in the early part of the supply chain in the mineral raw materials industry
influences the entire supply chain performance.

PC08

PROCESS OPTIMIZATION AND CONTROL OF OXIDE COPPER MINERALS
FLOTATION USING IMAGE ANALYSIS AND FUZZY CONTROL SYSTEM

Abbas Tabatabaei
1
, Edgar Canta
2
, Pedro Mamani Hauman
3

Kamoto Concentrator, Kamoto Copper Comapy SARL, Democratic Republic of Congo

ABSTRACT
Flotation of copper oxide minerals using NaSH/Collector system with addition of
some modifier reagents have been experienced for decades in Kamoto copper concentrator
located in DR Congo. But the copper recovery and product grade is not always desirable
tends to loss of copper in tailing or reported high acid consumable gangue minerals in final
concentrate. It is well known that the dosage of NaSH and collector must be controlled
carefully, however, there are some other key parameters such as slurry density, particle
size, dosages of booster and modifier reagents, froth level, etc, affecting the flotation which
make the current control facilities non efficient.
After some primary testwork in laboratory and plant circuit, it was found that the
shape and color of froths could be defined as a consequence of all the main parameters.
Basically the skilled plant operators are well familiar with this procedure. Based on this
primary studies, a knowledge based control system has been designed by using image
analysis methods in conjunction with fuzzy control system. The system is able to adjust the
optimum dosage of reagents and/or inform the operator on-time to set other key parameters
manually.


PC09

COPING WITH THE CHALLENGES OF METAL ACCOUNTING IN COPPER
HEAP LEACH OPERATIONS

Luc Lachance
(1)
, Simon Garipy
(1)
, Donald Leroux
(1)
, Frdric Flament
(1)

(1)
Triple Point Technology (Canada)

ABSTRACT

Copper heap leaching is an extractive metallurgy process mostly applied to recover
copper from low-grade ores. It is amongst the simplest processes often involving no more
material preparation than crushing and agglomeration. The ore stockpile, built upon a
specifically-designed pad, is typically sprinkled for many weeks with a sulfuric acid
solution.

Best operating and management practices can only be applied when reliable
information, including an accurate metallurgical performance of the heap leaching
operation, is readily available. Copper balances between the heap and metal production
must therefore be rigorously determined and reported against production objectives on a
regular basis.

Even though apparently simple, establishing a reliable copper balance for a given
heap leaching operation can be challenging. The presence of huge and spatially
heterogeneous copper inventories is surely one of them. However, severe metal accounting
as well as operational challenges could arise when the heap construction and the design of
the PLS solution management system have not been done in accordance with state of the art
metal accounting principles. This paper shows that such challenges can be avoided when
best practices are considered at the heap layout design phase.


PC10

INNOVATION IN ADVANCED CONTROL AT MINERA LOS PELAMBRES

Jorge Misle and Daniel Silva
Gerencia Plantas Minera Los Pelambres
Apoquindo 4001, piso 18
Santiago, Chile
jmisle@pelambres.cl
dsilva@pelambres.cl

ABSTRACT

This paper addresses the need for advanced control technologies and strategies in the
mining industry, its potential and actual impact on mining processes and the best practices
for their implementation, operation, and long term sustainability.

It is well known that advanced process control (APC) can be a very good source for
incremental process improvement for the mining industry, yielding to higher production
rates or helping maintain consistent production rates despite ore changes. The application
and integration of new technology, process knowledge and innovation are key elements in
building such a supporting structure. More specifically, and this cannot be emphasized
enough, the correct application and assembly of control tools, the in-time presentation of
key data to decision makers and the development of relevant statistics and KPIs (key
performance indicators) can and will make a difference not only in terms of production, but
also in plant stability, availability and production costs. In deploying such ideas and aiming
at the long-term goal of Operational Excellence, Minera Los Pelambres (MLP) has
developed a number of successful control strategies, best practices and technologies, which
are not only the application of state-of-the-art automation and computing tools, but rather
the assembly of the above presented structuring factors. This work discusses some of the
key tools and ideas implemented for SAG & Ball milling and Flotation areas, their
performance results and the roadmap taken for the integration of process knowledge and
control tools. Also, cases studies are presented and discussed further to not only show the
main areas of improvement, but also to highlight the benefits of such strategy that for the
most part, deviate from the traditional mining industry control approach. Also, a word is
given on the need for innovating in the design of control strategies and leveraging best
practices and process knowledge that ultimately, will contribute to long-term reliable

operations, improved mineral processing and, although unmeasured, lead to a superior
overall performance and productivity of all mining personnel involved.


PC11

MINERA ESPERANZA WAY TO STOP THE BREAKAGE OF SAG MILLS
LINERS.

J. Sols, E. Martnez, R. Martnez, S. Allendes and M. Flores
Minera Esperanza Antofagasta Minerals
Av. Apoquindo 4001 piso 13
Las Condes, Santiago, Chile
jsolis@mineraesperanza.cl

ABSTRACT

This document sets out the efforts made by Minera Esperanza to develop a no breaks
strategy in the SAG mills shield. The results are presented to show how reliability and
maintenance, operational, metallurgical and process control are working hard and
coordinated in this strategy.

The big size SAG mills operational control, defined by a concurrent work between
metallurgical, operational and control disciplines, has been an important key to success in
the improvement of operational results. Another key to success has been the coordination
between metallurgical and maintenance engineers to develop a well-coordinated strategy to
achieve a very good performance of the equipment.

The strategy is based in teams experience achieved through the analysis of the liners
campaign and operational variables related to the liners breakage phenomena. This
document shows best practices and lessons learned in this process and how this
coordinated work is projecting an achievement of the goal imposed in near future.


PC12

HYBRID LABS FOR EDUCATING AND RESEARCH ON FLOTATION
CONTROL

Luis Bergh, Juan Yianatos
*CASIM, Automation and Supervision Centre for Mineral Industry,
Chemical Engineering Department,
Santa Maria University, Valparaiso, Chile, (e-mail: luis.bergh@usm.cl)

ABSTRACT
The wide plant control integration of mineral processes poses many challenges.
Flotation plants consist of complex interacting circuits where minerals are processed in
different stages with recycling. Today, a common arrange are the RCS circuits, where a
rougher circuit is combined with a cleaning circuit and a scavenger circuit. The global
objectives of a flotation plant are to maximize the valuable metal recovery while the grade
of the final concentrate is kept inside a narrow band. To achieve this, for any time variant
feed attributes (flow rate, solid percent, grade, particle size distribution, pH, and
chemicals), a capability of modifying the operation of each circuit, in order to achieve some
local objectives, is demanded.
Testing strategies for process monitoring, diagnosis and control is expensive, and
usually requires either complex pilot plant facilities or to deal with the hard constraints
posed by experimentation in real plants. The experience developing hybrid systems is
discussed and its application to flotation processes is presented. The main idea is that the
essential phenomena underlying a process can be divided in two aspects: the
hydrodynamics (mixing and separation) and the physicochemical changes. The first can be
experimentally implemented in pilot plants where the main streams are mixed and
separated, at a low cost. However, to follow the process changes, mainly metal grades on
each stream, it will require expensive instrumentation, store facilities and chemical reagent
consumption. The use of physics and chemical models, fed with time variant feed attributes
and real on-line measured variables, describing the process hydrodynamics, are proposed as

an economical convenient substitute of experimentation in real processes. These facilities
are implemented in the Process Control Lab at the Chemical Engineering Department,
Santa Maria University. Examples of the application of control strategies on flotation
column and a three cell circuit are presented.

PC13

SMART TECHNOLOGY FOR MINING REPORTABILITY
A DECISION-MAKING SUPPORT APPLICATION BASED ON THE TIBCO
SPOTFIRE TECHNOLOGY

Jorge Echeverra V.
Gerente General
Intermedia Ingeniera S.A.
jecheverria@intermediaingenieria.com

ABSTRACT

Intermedia designed an analogue model similar to a
Command/Control/Communication panel C3 based on a Causal Tree method that
allows confronting processes/events rigorously, facilitating decision-making, in order to
optimize operational performance, reducing risks, establishing collective work practices.

The C3Panel model is based on TIBCO Spotfire technology. It integrates
operational issues through Key Performance Indicators (KPI) within order structures
(Taxonomies) typical of classification process, and implemented within each customers
sector/department.

With C3Panel Model and TIBCO Spotfire its possible to:

Mirror an operational network involved in the client's industry, associates value
metrics in order to manage total/partial capacities and functionalities.
Model how senior management "thinks" about the business, through a dynamic
application capable of supporting relational analysis, generating results with real
effectiveness metrics.
Ensure interoperability between process areas, delivering consolidated reports for
managements decisions.
Standardize reporting/monitoring of indicators performance.
Publish indicators report automatically, directed to management and/or process
managers areas.
Integrate C3Panel application to other company applications/databases.
Allow monitoring report through a user interface designed for the critical related
process.

PC14

MOISTURE MONITORING IN HEAP LEACHING, THROUGH
ELETROMAGNETIC METHOD

J. Barriga; E. Rodrguez
Instituto de Innovacin en Minera y Metalurgia IM2

ABSTRACT

Heap leaching is an alternative for processing copper ore. In this process it is
important to know how the leaching solutions are distributed through the mineral bed,
because a homogeneous wetting of the stacked materials allows the maximization of copper
recovery. Keeping in mind the previous challenge, the present article describes a technique
that allows the moisture monitoring on a quick and precise way.
On the first place, the state of art of the moisture measurement on heap leaching was
determined, allowing the selection of an electromagnetic technique based on the frequency
domain as the most suitable for this kind of application. Later, the electromagnetic
characteristics of several mineral layers under study were determined by the resolution of
the data inversion problem, which have as entries the frequencies measurements that were
carried out. Then, a 3D map absolute humidity of the heap was obtained, based on the
electromagnetic parameters 3D map of itself, by using Archies law.
Finally, with this technique heap leaching from different divisions of CODELCO
were prospected, what allowed a quick and precise way of moisture monitoring.


PC15

CONTINUOUS PROCESS OF COPPER CONCENTRATE SMELTING,
CONVERTING AND REFINING

A.Warczok and G. Riveros
UNIVERSIDAD DE CHILE
Av. Tupper 2069
Santiago, Chile
awarczok@bell.net

D. Smith, A. Balocchi, and H. Rojas

ENAMI
Hernan Videla Lira Smelter,
Paipote, Chile

S. Botto

BUILTEK S.A.
9180 Quilicura
Santiago, Chile

ABSTRACT
Processes of continuous copper matte converting and fire refining, developed by
Universidad de Chile and ENAMI, permit for projection and analysis of feasibility of the
totally continuous process of copper concentrate smelting up anodes of fire refined copper.
Concentrate smelting in Teniente Converter, flash smelter or other type of smelting
units is continuous. Continuously tapped out copper matte is directed to packed bed
continuous converter, producing over-oxidized blister (8000 ppm [O]), directed to
continuous packed bed refining furnace, where is reduced and casted continuously in twin
type of anode casting wheels. The slag from the smelting furnace is tapped out
continuously into electric furnace for slag cleaning and tapped out as waste slag into a ladle

or granulation installation. The slag from converting furnace with high copper content is
recycled into smelting unit or a slag cleaning furnace in a solid or liquid form.
The projection of the dream, totally continuous process, points out the potential
advantages of the processes of continuous converting and refining being under
development.
The results of laboratory and industrial scale tests, together with mass and heat
balances, permit to initiate the discussion and feasibility analysis of totally continuous
copper smelters in their pyrometallurgical part.


PC16

OPTIMIZATION OF SERVICE TIME AT GAS STATION WITH THE
IMPLEMENTATION OF FAST SYSTEMS

J. Cruces and R. Cotrado
SOUTHERN PERU COPPER CORPORATION
Av. Caminos del Inca 171 Santiago de Surco
Lima, Per
jcruces@southernperu.com.pe
rcotrado@southernperu.com.pe

ABSTRACT
Within our operations, the haulage represents 56% of the total cost, which is
possible decrease increasing productivity and reducing delays.
With the current resources, we need between 8 and 10 minutes to refill the fuel to tanks of
the trucks, considering review and doing other works us a, filling levels of coolants,
lubricants, inspection of tires. The stayed of truck in the gas station is within the range of
15 - 20 minutes, which includes the time waiting.

The optimization of gas stations it aims to reduce the service time, take as a
principal idea in filling speed of the trucks, fuel and lubricants.

To achieve the reduction of these times, it proposed to change the conventional
filling system for the new rapid systems for fuel fill in 3 gas stations supplying any tank in
less than 3.5 minutes, thus reducing the time of in gas station to 8 minutes.

With the implementation of the fast systems, the time of service will be shortest, it
will be removed the lost time by queues and there will be no restrictions by flow pumps,
generating more productive time for the fleet of trucks.

According to the simulation, with the reduction of the time at fueling station is
achieved an increase of 151.931 tons per month, reduction of operating cost in 0.48 %
which equates to an annual savings of US$ 696.631


PC17

PROCESS CONTROL TRAININGSIMULATORS ARE ONLY HALF THE
STORY

Stephen R. Brown,
Timothy Krusmark,
Kenneth Slack, and
Rion Westfall
Performance Associates International, Inc.
December 2013

ABSTRACT
With reference to greenfield plant projects, using process simulators similar to the
designed plant front-end HMI or DCS has become common practice. These simulators
represent a virtual plant based on process modeling of the circuit chemistry and
thermodynamics, and on the physical nature of the plant, including equipment, valves,
piping, etc. The virtual plant allows trainees to troubleshoot problems, optimize process
variables, react to alarms, etc., all based on the process simulation model. Performance
Associates experience is that this complex simulator training is valuable, but only after
more in-depth training on the process and control logic. To truly optimize a process plant,
prior to simulator training, the control room operators must have detailed knowledge of
the:
Process objective of each process system, comprising a group of unit
operations.
Process objective of each unit operation.
Process chemistry and the variables affecting it.
Important characteristics of each unit operation, the variables affecting it,
and the impact on downstream unit operations.
Plant control loops and interlocks.
Safety issues related to the process and control schemes.
Operating procedures for start-up and shutdown under various scenarios, as
well as important operator tasks.

Additionally, trainees must be intimately familiar with the applicable fundamental
scientific concepts such as pressure, temperature, heat exchangers, electricity, PID control
logic, combustion, etc. With this fundamental and plantspecific foundation, the process
simulator can be fully exploited for training.

PC18

OUTDOOR INTEGRATED GREEN ENERGY-SAVING HIGH POWER
RECTIFIER SYSTEM FOR COPPER SMELTER

Shangyang Zhang and Denggai Zhou
Zhuzhou Kori Convertors Co. Ltd.
629,Heilongjiang rd.,Zhuzhou,Hunan,China
frankding@kori.cn

ABSTRACT

This paper introduces a type of outdoor integrated green energy-saving high power
rectifier system for copper smelter, analyze the construction layout and electric
characteristics.

Downstream Fabrication and Applications

SYMPOSIUM: 08 DOWNSTREAM FABRICATION AND
APPLICATIONS

DA02 J. Aufrecht CORROSION AND ANTIFOULING PROPERTIES OF COPPER
ALLOYS IN SEAWATER APPLICATIONS
DA03 Achim
Kuhn
MICROSTRUCTURE AND MECHANICAL PROPERTIES OF
ULTRA FINE GRAINED HIGH PERFORMANCE COPPER
ALLOYS
DA04 Marco De
Pilla
ELECTRICAL COPPER BUSBAR PRODUCTION: FROM
CATHODES TO FINAL PRODUCTS IN 24 HOURS BY
CONVENTIONAL TECHNOLOGY AND CONFORM PROCESS
DA05 Beata
Smyrak
ANNEALING SUSCEPTIBILITY OF COPPER WIRES VS
CATHODE'S CHEMICAL COMPOSITION
DA06 Tadeusz
Knych
FAILURE CAUSES AND MECHANISMS OF CONTINUOUS
CASTING MOULDS ELEMENTS
DA07 A. Moya AN INVESTIGATION BY SCANNING DIFFERENTIAL
CALORIMETRY (DSC) OF THE RECRYSTALLIZATION OF
DIFFERENT COPPERS AND THE ELECTRON BACK
SCATTERING DIFFRACTION (EBSD) ANALYSIS
ASSOCIATED TO THEIR MICROSTRUCTURAL
EVOLUTIONS
DA08 M.Ignat MECHANICAL CHARACTERIZATION AND RELIABILITY OF
REFINED COPPER AND DERIVED PRODUCTS, A
PERMANENT CHALLENGE IN COPPER APPLICATIONS
DA09 M.Ignat TENSILE EXPERIMENTS TO ANALYZE THE DUCTILITY OF
DIFFERENT COPPERS
DA10 Ncolas
Amigo
AN ATOMISTIC APPROACH OF THE MECHANICAL
RESPONSE OF SINGLE AND POLY CRYSTALS OF COPPER
DA11 Y.
Navarrete
BAYESIAN INFERENCE OF MECHANICAL PARAMETERS OF
COPPER PRODUCTS
DA12 Claudio
Aguilar
OBTENTION OF CU-MO ALLOYS BY MEANS OF
MECHANICAL ALLOYING
DA13 Scott
Kotvis
VCI (VOLATILE CORROSION INHIBITING) TREATED
PACKAGING FOR PROTECTING COPPER FROM CORROSION
DURING STORAGE AND TRANSPORT
DA14 Hal
Stillman
MICROGROOVE: SMALL TUBE COPPER IS ECONOMICAL
AND ECO-FRIENDLY

DA15 Claudio
Aguilar
REVIEW OF NEW COPPER ALLOYS FOR ADVANCED
APPLICATIONS
DA16 Hal
Stillman
ULTRACONDUCTIVE COPPER
DA17 Freitas, M.
C. S
ELASTOPLASTIC FINIT ELEMENT ANALYSIS FOR POROUS
METALS


DA02

CORROSION AND ANTIFOULING PROPERTIES OF COPPER ALLOYS
IN SEAWATER APPLICATIONS

J. Aufrecht 1), A. Grohbauer 1), U. Hofmann 1), A.Drach 2), I.Tsukrov 2), J. DeCew 2)
1) Wieland-Werke AG, Ulm, Germany; 2) University of New Hampshire, Durham, NH,
USA

ABSTRACT

Copper alloys are widely-used in marine applications because of their very good
resistance to corrosion and biofouling. An upcoming application is the use as wire material
for aquaculture cages. The corrosion resistance of different copper alloys in seawater was
evaluated in a combined laboratory and field study. Most alloys showed a very good
corrosion resistance. The uniform corrosion rate decreases to values significantly lower
than 50 m / year already after a 3-4 month exposure to natural or synthetic seawater,
corresponding to a copper release rate of less than 5 g/cmd.

Selective corrosion and dealloying have not been observed in the field tests. Results
from laboratory tests indicate, however, that the use of alloys is recommended, which are
not prone to dealloying. The resistance against biofouling of most tested alloys is excellent.
However, some alloying elements like aluminum can significantly reduce the antifouling
effect of copper alloys. Testing devices for mechanical characterization of copper alloy
wires in seawater were developed and results on fatigue and wear properties are presented.
The study confirmed that copper alloys are excellent and trendsetting materials for
aquaculture constructions. Relating technical properties to economical considerations, the
use of alloys based on admiralty brass is especially recommended.

DA03

MICROSTRUCTURE AND MECHANICAL PROPERTIES OF ULTRA FINE
GRAINED HIGH PERFORMANCE COPPER ALLOYS

H.-A. Kuhn, I.Altenberger, J. Riedle, H. Hlzl (Wieland-Werke AG, Ulm, Germany)

ABSTRACT

Ultra fine grained (UFG) pure copper has been thoroughly investigated in the last
two decades, however ultra fine grained high-strength copper alloys have scarcely been
characterized so far.

This contribution puts focus on UFG copper alloys, more specifically, cu-Ni-Si-
alloys, being well known as ideal materials for electromechanical connectors, springs and
leadframes. Characterization of these materials after severe plastic deformation and
subsequent aging was carried out using SEM, EBSD, conductivity, hardness and tensile test
measurements. The result show that UFG low alloyed copper alloys exhibit impressive
combinations of properties such as strength + conductivity + high ductility + acceptable
thermal stability at low and medium temperatures.

DA04

ELECTRICAL COPPER BUSBAR PRODUCTION: FROM CATHODES TO
FINAL PRODUCTS IN 24 HOURS BY CONVENTIONAL TECHNOLOGY AND
CONFORM PROCESS.

Mr. Ugo Angelucci and Mr. Marco Di Pilla

ABSTRACT

Over the last years, copper busbars have gained an important market share in
electrical and electronic applications, especially in the Asia-Pacific region.
Typically, the busbars are made of Cu-ETP, but depending on the application,
materials like Cu-OF or Cu-FRHC are an interesting alternative. However, these alternative
materials also imply an alternative production route, which has to be optimized regarding
feeding material and process technology in order to guarantee not only the required product
quality, but also low process costs and competitive product prices.
The conventional busbar production route uses cathodes as raw material and allows
the production of Cu-ETP busbars in any required dimension. By using state-of-the-art
machinery, supported by highly automated and computerized control systems, and
integrated processes in the conventional production process, ATECO IMPIANTI could
realize a modern and cost-competitive production line that allows the production of busbars
of any shape, size, and batch size in a minimum time, typically 24 hours.
Two further approaches are presented: firstly, the production of Cu-FRHC busbars
from copper scrap, and secondly the production of Cu-OF busbars from Cu cathodes using
the continuous rotating extrusion process (CONFORM Process).


DA05

ANNEALING SUSCEPTIBILITY OF COPPER WIRES VS CATHODES
CHEMICAL COMPOSITION

Beata Smyrak, Tadeusz Knych, Andrzej Mamala, Monika Walkowicz
AGH University of Science and Technology
Faculty of Nonferrous Metals
30 Mickiewicza Av
30-059 Krakow
POLAND
e-mail: smyrak@agh.edu.pl, Tel.+48 12 6172653

ABSTRACT
A highly annealability of copper rod should ensure full recrystallization of wires
during drawing with a multi-wire drawing machine. Nowadays, a typical drawing speed
achieved by manufacturers is approximately 30 m/s. This means we are dealing with less
and less favourable conditions for annealing that needs to be completed within a fraction of
a second. That is why the ideal material for annealing should offer such annealing kinetics
so as to be able to carry out the transition between the solid state and the ductile state in the
shortest possible time. As a result, manufacturers face new challenges with regard to rod
properties. Furthermore, chemical composition needs to be taken into consideration as early
as when defining requirements for cathode manufacturers.

The traditional method of estimating copper rod annealability is the Spiral Elongation
Test. For many years, this method used to suffice when classifying rods and thereby
cathodes. However, with the enhanced chemical purity of cathodes, the Spiral Elongation
Test lost its practicability, especially for cathodes of the highest quality. The new approach
for classifying rods consists in introducing more stringent criteria by reducing the
propelling force and temperature, i.e. the parameters that influence the recrystallization
process, where the basis of rod (cathode) classification is the time in which the structure is
restored (represented macroscopically by an elongation in a single-axis tension test). This
new approach is known world-wide as the Rapid Tensile Test.

This paper presents the analysis of the theoretical and experimental results of the
complex research program on influence of chemical composition of cathode on annealing
susceptibility of copper wire. The comparative research on the recrystallization temperature
proved to be the most interesting at this point.

DA06

FAILURE CAUSES AND MECHANISMS OF CONTINUOUS CASTING MOULDS
ELEMENTS

Tadeusz Knych, Beata Smyrak, Andrzej Mamala, Pawe Kwaniewski, Artur Kawecki,
Grzegorz Kiesiewicz
AGH University of Science and Technology
Faculty of Non-Ferrous Metals
Department of Metal Working and Physical Metallurgy of Non-Ferrous Metals
30 Mickiewicza Av.
30-059 Krakow
POLAND
e-mail smyrak@agh.edu.pl

ABSTRACT

The subject matter of the article are results of the research regarding wear-out of the
elements of copper continuous casting mold materials. During the research special attention
was paid to dam blocks used in the process of copper continuous casting in the copper
casting machine Hazelett. The research was carried out on the three blocks made of
multicomponent copper alloys and namely of CuNiSiCr, CuNiSiCrZr and CuNiBe alloys.
The aforementioned alloy additions were to give the material an appropriate level of a
whole set of usage properties, and in particular high and stable in time mechanical and
abrasion resistance, high fatigue strength, appropriately high thermal conductivity and
corrosion resistance.
The aim of the study is to tell a few words about mechanisms of dam blocks wear in
exploitative conditions. Presented mechanisms are related to the quality of copper alloys
that are used for dam blocks production and especially related to their structure (size and
homogeneity of grain), type, morphology and separations distribution which decides about
possible possibilities of thermo-mechanical treatment and related level of resistance
properties, electrical conductivity, thermal and corrosion resistance.

DA07

AN INVESTIGATION BY SCANNING DIFFERENTIAL CALORIMETRY (DSC)
OF THE RECRYSTALLIZATION OF DIFFERENT COPPERS AND THE
ELECTRON BACK SCATTERING DIFFRACTION (EBSD) ANALYSIS
ASSOCIATED TO THEIR MICROSTRUCTURAL EVOLUTIONS.

A. Moya
1
, T. Jil
1
, A.L. Helbert
2
, M. Andrieux
2
, M.Ignat
3
.
1: Codelco, DIMEC ,FCFM U.de Chile.2: Facultad de Ciencias Orsay.U. Paris Sud.
3:IM2-Codelco, DIMEC, FCFM U. de Chile.

ABSTRACT

The kinetics of recrystallization of a metal is an important aspect to consider, before
any process of transformation. Indeed, depending on the stored energy in the metal, of the
impurities or alloying elements content, the activation of a recrystallization process will
restore partially or completely the ability of the material to be deformed.
By DSC, we analyzed four different deformed and undeformed Coppers,
containing precipitates or different elements in solid solution. The evolution of their grain
microstructure was investigated by Electron Back Scattering Diffraction (EBSD) and the
recrystallization kinetics were determined after 60% cold-rolling using micro hardness
measurements .
The Copper samples were extracted from anodes, cathodes and wire rods.
Elements in solid solution as well as precipitates directly influence the recrystallization
ability of the samples as they decrease the grain boundary mobility.


DA08

MECHANICAL CHARACTERIZATION AND RELIABILITY OF REFINED
COPPER AND DERIVED PRODUCTS, A PERMANENT CHALLENGE IN
COPPER APPLICATIONS.

M.Ignat
1
,A.Moya
2
,T.Jil
2
, S.Davis
3
,G.Gutierrez
3
,A.Valencia
4
,L.Contreras
5

IM2-Codelco, DIMEC, FCFM U. de Chile. 2: Codelco, DIMEC ,FCFM U.de Chile.3:
Facultad de Ciencias,U.de Chile.4:DIMEC.FCFM U.de Chile. 5: Codelco Chile.

ABSTRACT

Because nowadays technological advances in key industries widely extended from
aeronautics to biomedical applications, need Copper and Copper alloys, and because in
most of these applications, the Coppers must satisfy specific requirements; their study and
analysis from the earlier stage of refinery to the later stages of transformation to products,
remains a fundamental aspect which bridges research and industry.
With the objective to consider the reliability of Coppers, an attempt to study their
traceability, from anodes to cathodes and Copper products as rods and thin wires is
presented.
The study is developed in terms of mechanical behavior and microstructural
evolution. Deformed and fractured specimens are analyzed to a better understanding how
the impurities which are present in the earlier steps of anode casting and refinery, or those
added during further processes could affect the mechanical properties and/or the restoration
processes during manufacturing for technological applications.
The validity of current industrial qualifying mechanical tests with respect to
Coppers coming out from continuous casting and rod obtention is discussed.


DA09

TENSILE EXPERIMENTS TO ANALYZE THE DUCTILITY OF DIFFERENT
COPPERS.

M.Ignat
1
,Alvaro Valencia
2
,Carlos Quintanilla
2
.
IM2-Codelco, DIMEC, FCFM U. de Chile.2: DIMEC.FCFM U.de Chile.

ASBTRACT
The ductility of metals depend on extrinsic as intrinsic factors, sometimes both
combined. As extrinsic factors, we may remind for instance: complex loading conditions,
high loading rates, low temperaturesAs intrinsic ones, the most common causes of loss of
ductility are related to the effect of impurities. Indeed, depending on their concentration ,
impurities can segregate at grain boundaries causing embrittlement and/or precipitate, then
forming incoherent brittle particles in a ductile material.
We compared the mechanical behavior of Copper samples, with different
concentrations of impurities, which were submitted to tensile tests. For these tests, we
designed the samples geometry by considering the shape of notched samples of existing
ASTM standards. The stress redistribution at the notched zones was simulated by FEM,
while the microstructural analysis, in particular at the rupture surfaces was analyzed by
SEM.


DA10

AN ATOMISTIC APPROACH OF THE MECHANICAL RESPONSE OF SINGLE
AND POLY CRYSTALS OF COPPER.

Nicols Amigo
1
, Gonzalo Gutirrez
1
, Miguel Ignat
2
, Sergio Davis
1
, Alvaro Valencia
3

1: Facultad de Ciencias,U.de Chile. 2: IM2-Codelco, DIMEC, FCFM U. de Chile.
3:DIMEC.FCFM U.de Chile.

ABSTRACT

The mechanical behavior of high purity copper (99.99%) in mono and poly-
crystalline state is studied by atomic level computer simulation technique. In particular, our
aim is to estimate the changes in the stress-strain curve due to the presence of defects and
impurities in relation to the atomic structure, which is possible to track by means of the
atomic simulations. As is well known, in copper like in others ductile metals, the presence
of structural defects as well as impurities can change the mechanical properties, including
the elastic constants, yield and tensile strengths, among others.

Here we present molecular dynamics simulations using a state of the art interatomic
potential for copper, on systems up to one million of atoms, for mono-crystalline and
polycrystalline samples. The former ones are composed by a number of grains ranged from
20 to 200. It is observed that while the number and disorientation among grains increase,
the elastic behavior (modulus and yield strength) tend to usual values, also increasing the
plasticity; in agreement to experimental results. The mechanism of these effects will be
discussed in detail.


DA11

BAYESIAN INFERENCE OF MECHANICAL PARAMETERS OF COPPER
PRODUCTS

Y. Navarrete
1
, S. Davis
2
, M. Ignat
3
.
1:Codelco, Facultad de Ciencias. 2: Facultad de Ciencias,U.de Chile.3: IM2-Codelco,
DIMEC, FCFM U. de Chile.

ABSTRACT

In this work we present a Bayesian methodology for the characterization of high-
purity Chilean copper products (from anodes to cathodes and the derived wire rods).
The method, applies a Weibull distribution, which considers the homogeneous
tensile deformation, deduced from the engineering stress-strain curves, which describe the
ductility of the material. Based on previous data, we designed an informative, semi-
empirical prior distribution for the Weibull scale and shape parameters. The data base was
established from the results of tensile experiments on coppers of cathodes and their
corresponding wire rods.
This Bayesian procedure allows a more efficient use of the information contained
in a few mechanical tests, and therefore reduces the amount of individual tests needed
for the characterization coppers (cathodes and corresponding wire rods).


DA12

OBTENTION OF CU-MO ALLOYS BY MEANS OF MECHANICAL ALLOYING

C. Aguilar, T. Muthiah, K. Tello
Departamento de Ingeniera Metalrgica y Materiales
Avenida Espaa 1680
Valparaso, Chile
claudio.aguilar@usm.cl

D. Guzmn
Departamento de Metalurgia
Universidad de Atacama
Avenida Copayapu 485
Copiap, Chile

ABSTRACT

Interesting alloys are Cu-Mo alloys, which are used in applications of heat sink
material, vacuum technology and electronic packing devices due to their physical and
electronic properties. In most of the applications, high-density Cu-Mo materials with
homogeneous microstructures are required for high performance. The disadvantage of Cu-
Mo systems is that they present a positive mixing enthalpy at solid state, thus the solubility of
Mo in Cu at room temperature is negligible. But it is known that by using a non-
equilibrium process, such as mechanical alloying, the range of solubility of many systems
can be extended. Cu-5wt.% Mo and Cu-8wt.%Mo were obtained in this work. Cu-Mo form solid
solution after 50 h of milling which was determined by X-ray diffraction. The energy resulting
from the MA process increases the crystalline defect density. Thus the stored energy is
sufficient to increase the solubility of Mo in Cu. For this milling time, smaller crystallites sizes
around of 10 nm at 50 of milling were found, which shows that Cu-Mo alloys are nanocrystallines.
The HV values measured show an increment with milling time and amount of Mo in the alloys, up
values between 240-260 HV.


DA13

VCI (VOLATILE CORROSION INHIBITING) TREATED PACKAGING FOR
PROTECTING COPPER FROM CORROSION DURING STORAGE AND
TRANSPORT

Scott Kotvis, Director Global Business Development, Daubert Cromwell

ABSTRACT

Author: Problem: Corrosion costs affect copper manufactures profits and reputation.
Approach: For decades, Daubert Cromwell has provided to metals manufacturers and
processors their VCI coated papers and treated polyethylene packaging products.
Results: Learn the basic concepts corrosion and how packaging materials treated with VCI
uniquely improves corrosion protection. Understand the cost benefits and why leading
manufactures prefer VCI over traditional barrier and desiccant or rust preventive liquid
approaches to corrosion protection.
Conclusion: See how the VCI concepts and products are used to protect copper
manufacturers products and how they are also used to protect mining equipment during
transport and storage including decommissioning periods.
Bio: Scott Kotvis has sold materials to industry since 1985. For the last 15 years has

DA14

MICROGROOVE: SMALL TUBE COPPER IS ECONOMICAL AND ECO-
FRIENDLY

Hal Stillman

ABSTRACT

Room air conditioner manufacturers are under pressure to improve energy
efficiency, change the type and amount refrigerants used in systems, reduce costs, and
improve indoor air quality.
Through industry/academic research and development organized by the
International Copper Association, air conditioner manufacturers are meeting these
objectives by transitioning to MicroGroove technology. MicroGroove technology is based
on small diameter copper tubes, 5mm or less, engineered with thin walls and internal
features to enhance heat transfer. This technology packs all the advantages of copper into
more compact, more efficient heat exchanger coils, reducing the cost of high efficiency air
conditioners.
Using proven, cost effective copper fabrication processes and familiar assembly
techniques, suppliers and manufacturers are already producing new commercial and
residential air conditioning and refrigeration products based on small diameter
MicroGroove copper tube.
This presentation will describe the key elements of the MicroGroove technology
platform: tube configuration for increased heat transfer, heat exchanger and system design
software for optimized energy efficiency, adaptability to alternative refrigerants, high
volume manufacturing processes, and the use of copper fins for antimicrobial performance
and sustained energy efficiency. It will also touch on how the technology can be extended
into new applications in thermal energy storage and refrigeration systems.


DA15

REVIEW OF NEW COPPER ALLOYS FOR ADVANCED APPLICATIONS

C. Aguilar, K. Tello, T. Muthiah
Departamento de Ingeniera Metalrgica y Materiales
Avenida Espaa 1680
Valparaso, Chile
claudio.aguilar@usm.cl

D. Guzmn
Departamento de Metalurgia
Universidad de Atacama
Avenida Copayapu 485
Copiap, Chile

ABSTRACT

Copper and copper alloys are widely used in engineering due to its electrical
thermal properties and corrosion behavior. The rapid technological development demands
materials stronger, capable to use at higher temperature, more corrosion resistant and less
expensive. The improvement in properties of copper based alloys are complicated by
traditional methods of synthesis, but the non-equilibrium methods of synthesis shows
substantial improvement in mechanical, thermal and physical properties. The ability of non-
equilibrium method is to produce the new materials beyond the equilibrium solubility limit
on attained (maximal energy that can be stored in excess of that of the equilibrium/stable
structure). The most common non-equilibrium methods are rapid solidification, mechanical
alloying, condensation from vapor, laser processing, plasma processing and ion-mixing.
This paper focus mainly, the development of new copper-based alloys and discuss its
mechanical, thermal and physical properties. In addition to that, this paper also discuss in
detail about the various non-equilibrium process for synthesis of copper-based alloys. This
paper has been good effort to expose the current scenario of copper based alloys for
engineering applications.


DA16

ULTRACONDUCTIVE COPPER

Hal Stillman
Director, Technology Development and Transfer

ABSTRACT

Progress is being made in incorporating carbon nanotubes into copper to improve
the ambient temperature electrical conductivity of copper by 40% or more. We call this
nanocomposite material UltraConductive copper (UC copper).

Carbon nanotubes conduct electricity differently than copper and optimizing the
way electrons move in a copper-carbon nanocomposite requires careful engineering on a
nanoscale. The International Copper Association (ICA) started exploratory research on this
topic in 2005.

UC copper has been produced at laboratory scale via electrolytic co-deposition of
carbon nanotubes and copper. This process is similar to the way copper cathodes are
produced. In 2011, the first validated sample of UC copper with 30% higher electrical
conductivity than pure copper was produced using this method.

Samples of UC copper with >200% IACS over short distances have been made
using modified die casting and hot extrusion processes. These processes are used to form
carbon nanotube filaments within copper. This is similar to the way superconducting wires
have been produced.

Over 60% of copper is used in electrical applications. By reducing electrical losses,
various types of UC copper would have a transformative effect on electrical and electronic
devices and would immensely benefit society. Much work needs to be done to make UC
copper a widely available engineering material for use in electrical components and
systems.

Studies and trials are underway on the scale-up of production from grams to
thousands of tonnes of UC copper wire. The presentation will provide an overview of
worldwide research towards the development of ultraconductive copper wire.


DA17

ELASTOPLASTIC FINIT ELEMENT ANALYSIS FOR POROUS METALS

Freitas, M. C. S, Castro, J. A., Pessanha, L. M

ABSTRACT

Powder forming involves fabrication of a preform by conventional press-and-sinter
processing, followed by various forming processes, citing as examples, rolling, compaction,
forging, extrusion, among others, of the porous preform into a final shape through
substantial densification. This work makes a finite element analysis for porous metals. The
finite element model was applied to simulating the case of cold compaction of
nanocristalline copper under uniaxial compression conditions in order investigate the
densification behavior.

The model was simulated using explicit integration method as applied to the
evolution variation of the relative density and the dislocation density of the compact. Finite
element analysis program used was Abaqus. Finite element calculations were compared
with literature experimental data. The agreements between finite element model and
literature results for densification of nanocristalline copper were good.
Keywords: copper, finit element, nanocristalline, powder forming
Recycling and Waste Management

SYMPOSIUM: 09 RECYCLING AND WASTE MANAGEMENT

RW01 Etsuro Shibata BEHAVIORS OF ANTIMONY OXIDE, COPPER AND
SILVER DURING THE THERMAL DECOMPOSITION OF
BROMINATED FLAME RETARDANTS
RW02 Andrew Hall SULPHIDE PRECIPITATION AS A NOVEL APPROACH
TO REMOVE ARSENIC FROM COPPER SMELTER
SCRUBBER EFFLUENT
RW03 T. Fujita REMOVAL AND RECOVERY OF COPPER FROM ACID
MINE DRAINAGE
RW04 Kyoungkeun Yoo THE RECOVERY OF SN, CU, AG FROM WASTE PB-
FREE SOLDER USING FERRIC CHLORIDE SOLUTION
RW05 Milorad Cirkovic TEST RESULTS OF COMPLEX VALORIZATION THE
METAL AND NON-METAL COMPONENTS OF THE
WASTE REFRACTORY BRICKS FROM
METALLURGICAL FURNACES IN RTB BOR
RW06 Rene Rumpold ZINC IN THE COPPER SECONDARY PRODUCTION
AND POTENTIAL RECYCLING TECHNOLOGIES
RW07 Dairo Chaverra COPPER EXTRACTION FROM WASTE PRINTED
CIRCUIT BOARDS
RW08 M. Suburdy -M.
Sanchez
A THEORETICAL STUDY OF FLUID BED BASED
TECHNIQUES FOR RECOVERING NICKEL, COPPER,
COBALT AND/OR MOLYBDENUM FROM COPPER
SMELTER SLAG VIA OXIDATION IN A FLUIDIZED
BED REACTOR
RW10 Eduardo O.
Berger
TAKING ADVANTAGE OF USED OILS FOR
MANUFACTURING "IN SITU" BLASTING AGENTS -
THE CHILEAN EXPERIENCE
RW11 Mark Coleman RECYCLING OF METAL ASHES AND ELECTRONIC
SCRAPS IN VARIOUS FURNACES USING PNEUMATIC
INJECTED FEED DELIVERY
RW12 Ryszard Prajsnar RECOVERY OF LEAD IN COPPER SMELTERS OF
KGHM POLSKA MIED? S.A.
RW13 Jens Skei SEA DISPOSAL OF MINE TAILINGS FROM COPPER
MINING - AN ALTERNATIVE TO LAND DISPOSAL
RW14 Amir Mohammad
Nazari
COPPER ION REMOVAL BY BSA SOLUTION AND
ULTRASONICALLY SYNTHESISED AIR BUBBLES
RW15 A. Valenzuela -
Jan Smit
WASTE MANAGEMENT AND METAL RECOVERY IN
THE CHILEAN COPPER INDUSTRY

RW16 Roberto Mallea ECONOMIC POTENTIAL OF MINING TAILING
RW17 Paula Gonzalez C. IMMOBILIZING ARSENIC WITH HIGH RATE
BIOPRECIPITATION TECHNOLOGY FOR
SUSTAINABLE MINING
RW18 P. Rodenas Motos BIOELECTROCHEMICAL SYSTEMS FOR METAL
RECOVERY
RW19 I. Valenzuela AN INNOVATIVE TECHNOLOGY FOR ARSENIC AND
ANTIMONY ABATEMENT FROM MINING EFFLUENTS
DEVELOPED BY ECOMETALES LIMITED
RW20 Szczypiorski,
Wojtek
THE USE OF CONTIROD TECHNOLOGY FOR
CASTING RECYCLED COPPER
RW21 P Kamath SMELTING OF COPPER SECONDARY MATERIAL IN
TBRC - KALDO
RW22 Bruce Huffman REFRACTORY USE SPECTRUM FOR COPPER
MELTING IN RECYCLING
RW23 John Hugens FUTURE DIRECTIONS FOR SCRAP MELTING IN
COPPER SHAFT FURNACES
RW24 R. Cayumil RECOVERY OF COPPER FROM PRINTED CIRCUIT
BOARDS AT 1150C
RW25 Yao Suping - Liu
Qinghua
PROCESS FEATURES AND OPERATION PRACTICES
OF NGL FURNACE IN SECONDARY COPPER
SMELTER
RW26 Nickolas J.
Themelis And
Jennifer M.
Namias
THE CASE FOR METAL RECOVERY FROM
ELECTRONIC WASTE


RW01

BEHAVIORS OF ANTIMONY OXIDE, COPPER AND SILVER DURING THE
THERMAL DECOMPOSITION OF BROMINATED FLAME RETARDANTS

Etsuro Shibata1, Sylwia Oleszek1,2, Mariusz Grabda1,2, Micha Rzyman1, Takashi
Nakamura1
1 Institute of Multidisciplinary Research for Advanced Materials (IMRAM), Tohoku
University, Sendai, Japan
2 Institute of Environmental Engineering of the Polish Academy of Sciences, Zabrze,
Poland

ABSTRACT
One of the most effective methods for treatment and the recycling of waste electric
and electronic equipment (WEEE) is thermal technique such as direct combustion, co-
combustion with plastic wastes, pyrolysis and gasification. Nowadays, this kind of waste is
mainly thermally treated in incinerators (e.g. rotary kilns) to decompose plastics, and to
concentrate metals in the bottom and fly ashes. The concentrated metals (e.g. copper) can
be supplied as a secondary raw material to metal smelters, while pyrolysis of plastics
allows the recovery of energy as fuel gases. However, WEEE such as a printed circuit
boards (PCBs) usually contain brominated flame retardant (BFR) plastics/resins. For these
materials, hydrobromic acid (HBr) is known to be formed as a product of their thermal
decomposition.
In the present work, bromination of antimony oxide (Sb2O3), copper (Cu), and
silver (Ag) by HBr, originated from BFRs such as Tetrabromobisphenol A (TBBPA) and
Tetrabromobisphenol A-Tetrabromobisophenol A diglycidyl ether (TTDE) polymer, and
possible volatilization of the formed bromides were studied using mixtures of Sb2O3, Cu
or Ag with BFRs heated under inert atmosphere at wide temperatures range by thermo-
gravimetric analyzer (TGA) and laboratory-scale furnace.

RW02

SULPHIDE PRECIPITATION AS A NOVEL APPROACH TO REMOVE
ARSENIC FROM COPPER SMELTER SCRUBBER EFFLUENT

Andrew Hall, David Kratochvil and Oscar Lopez

ABSTRACT

Many new copper deposits being developed contain elevated levels of arsenic,
leading to a trend of increasing arsenic content in copper concentrates traded and processed
globally. Smelting of these high arsenic concentrates generate high levels of dissolved
arsenic in smelter scrubber effluent, which must be removed before the wastewater can be
discharged or re-used. Typical lime neutralization processes, sometimes augmented by
ferric iron addition, used to treat scrubber effluent produce large quantities of low-density
calcium/ferric arsenate and gypsum sludge which must be stabilized prior to final disposal,
increasing treatment costs. This paper provides an overview of sulphide precipitation as an
alternate process for selective removal of arsenic and dissolved metals from scrubber
effluent at copper smelters.

Results from recent test work completed using BioteQs BioSulphide
process
technology to treat two scrubber effluent streams are presented. Scrubber purge streams
containing arsenic concentrations of > 7 g/L were effectively treated to < 0.3 mg/L final
arsenic content, producing arsenic free weak acid for recycle and re-use in the smelter
process while reducing the quantity of waste solids generated. Process options for
concurrent recovery of dissolved copper and other valuable metals from scrubber effluent
were also found to be possible with sulphide precipitation.


RW03

REMOVAL AND RECOVERY OF COPPER FROM ACID MINE DRAINAGE

T. Fujita
1
, L.P.Wang
1
and G. Dodbiba
1
, T.Nasuka
2
,
1
The University of Tokyo, Department of Systems Innovation, 7-3-1, Hongo, Bunkyo-ku,
Tokyo 113-8656 JAPAN
2
Furukawa Co., Ltd.

ABSTRACT
The most commonly used commercial process for acid mine drainage (AMD)
treatment today is lime neutralization. However, it is accompanied by the treatment of
produced metal hydroxide precipitate. Owing to the decrease of new landfill disposal site,
as well as the remarkable price raise of base metals such as copper (Cu) in the recent years,
it is considered not only to treat but also to recover these base metals from AMD. For the
succeeding smelting process, the major subject is how to separate the Cu and zinc (Zn) over
iron (Fe) from AMD individually as well as possible. Also the removal of arsenic and so
on is discussed.


RW04

THE RECOVERY OF SN, CU, AG FROM WASTE PB-FREE SOLDER USING
FERRIC CHLORIDE SOLUTION

Kyoungkeun Yoo
1*
, Younghun Lim
1
, Jae-chun Lee
2

1 Department of Energy and Resources Engineering, Korea Maritime University
2 Mineral Resources Research Division, Korea Institute of Geoscience & Mineral
Resources

ABSTRACT
The Pb/Sn solder has been used as interconnecting materials, but the solder has been
substituted by Pb-free solder due to toxicity of Pb. There is an increasing concern about
treating the Pb-free solder generated in electric home appliance industry. The recycling
process of Pb-free solder containing Sn-Ag-Cu as main components was developed using
ferric chloride solution. The leaching behaviors of Sn, Ag, Cu were investigated under the
leaching conditions; ferric ion concentration, 0.5 mol/L; stirring speed, 400 rpm; pulp
density, 0.5 % - 1.5 %; temperature, 30 C 90 C. HCl concentration, 1 mol/L. Tin and
copper were dissolved within 15 min whereas silver was not leached in the leaching test
because ferric ion could oxidize tin and copper but not silver.
Therefore, silver could be separately recovered from tin and copper. The
cementation process was applied to recover tin from the leach solution. The tin powder was
added to the leach solution with 144.6 mg/L Cu at 30 C and 400 rpm. Copper could be
precipitated soon and separated from the leach solution. Consequently, these results
indicate that Sn, Ag, and Cu were successfully recovered as individual metal.


RW05

TEST RESULTS OF COMPLEX VALORIZATION THE METAL AND NON-
METAL COMPONENTS OF THE WASTE REFRACTORY BRICKS FROM
METALLURGICAL FURNACES IN RTB BOR

Milorad IRKOVI
1
, eljko KAMBEROVI
2
,

Vlastimir TRUJI
1
, Mile BUGARIN
1
,
Milane MITOVSKI
3

1
Mining and Metallurgy Institute Bor, Zeleni bulevar 35, Bor, Serbia
E-mail: milorad.cirkovic@irmbor.co.rs
2
University of Belgrade, Faculty of Technology and Metallurgy, Belgrade, Serbia

3
RTB-BOR Group, Djordja Vajferta 20, Bor, Serbia

ABSTRACT

The condition of ore reserves in RTB Bor (Serbia) is characterized by as much as
lower content of useful components, and any effort to valorize the off balance mineral and
secondary raw materials from the pyrometallurgical processes in terms of economy is
viable. One of such raw materials is a refractory brick from smelter plants of RTB Bor that
in replacement of lining from converters, flame and anode furnaces, enriched with copper,
gold and silver, is rejected at hald as useless.

Quantity of waste refractory bricks from pyrometallurgical furnaces for production
of copper in RTB Bor-TIR, as well as the content of useful components in them, copper,
precious metals and non-metallic magnesite component, indicates that it can present an
interesting secondary raw material. Test results show that the waste brick from flame
furnace, converters and anode furnaces contain 8-10% copper, 2-3 g/t gold and 25-30 g/t
silver, and also in these bricks the presence of other useful components should be expected,
such as platinum, palladium, germanium, etc. The useful magnesite component of these
bricks can be also be valorized.

Processing of waste refractory bricks from the smelting aggregates has resulted into
concentrate containing 20% copper, 6 g/t Au and 56 g/t Ag. Technological recovery of
metal component from these materials is 93%. At the annual level, the waste of refractory
bricks can produce 500 t of copper concentrate, containing 100 tons of Cu, 2.5-3 kg Au and
17-20 kg Ag.


RW06

ZINC IN THE COPPER SECONDARY PRODUCTION AND POTENTIAL
RECYCLING TECHNOLOGIES

Rene Rumpold
1
, Jrgen Antrekowitsch
1
1
Christian Doppler Laboratory for Optimization and Biomass Utilization in Heavy Metal
Recycling University of Leoben, Chair of Nonferrous-Metallurgy

ABSTRACT

Zinc enters the copper production cycles as an appreciable amount of raw materials
contain zinc, especially the secondary ones. Based on its characteristics and the process
parameters during the copper production, the zinc is evaporated and concentrated in the flue
dust. The content of that metal in such dusts can be up to 45 %, therefore they represent a
valuable secondary zinc source. Unfortunately it is not possible to use them directly in the
primary zinc metallurgy, because of high halogen concentrations, which are disturbing the
electrowinning process of zinc. Moreover the presence of high lead-, tin- and copper-
concentrations results in higher efforts to recycle them by that process route.
Therefore separate recycling technologies have to be used to extract the valuable
metal fraction from those residues. The variety of potential processes is quite high as
hydrometallurgical and pyrometallurgical principles can be used as well as both combined.
This work gives an overview about the behavior of zinc in the copper secondary metallurgy
and it shows strategies to recycle the valuable fraction from evolving dusts.


RW07

COPPER EXTRACTION FROM WASTE PRINTED CIRCUIT BOARDS

Dairo E. Chaverra, Oscar J. Restrepo
Universidad Nacional de Colombia Sede Medelln
Calle 59A No 63 - 20 Medelln, Colombia
dechaverraa@unal.edu.co, ojrestre@unal.edu.co

ABSTRACT
The waste stream of electrical and electronic equipment (EEE) is growing, because
the market is far from saturated and time of use of EEEs is decreasing as a result of
technological innovation. The printed circuit boards (PCB) are the basis for the electronics
industry, being an essential part of almost all EEE.
They are a material of growing interest, not only for its metal content, about 20 %
of copper, but also by the complications during recovery of metals due to its complex
composition and lack of established methods.
A method for the recovery of copper and byproducts of copper from waste PCBs of
computers, as a first contribution to a process of complete recycling of electronic is
proposed. The process consists on a size reduction and classification, magnetic and
electrostatical separation, electroleaching and final obtaining process. The methodology is
developed at laboratory level achieving a concentrate containing about 60 % of copper for
leaching process.

RW08

A THEORETICAL STUDY OF FLUID BED BASED TECHNIQUES FOR
RECOVERING NICKEL, COPPER, COBALT AND/OR MOLYBDENUM FROM
COPPER SMELTER SLAG VIA OXIDATION IN A FLUIDIZED BED REACTOR.

Michael Sudbury
Private consultant, Oakville, Toronto, Canada
Mario Sanchez
Universidad Andres Bello, Santiago, Chile

ABSTRACT

Small scale tests have shown it is possible to oxidize fayalite slag at a relatively
modest temperature (700
o
C) and to recover copper and molybdenum from the resulting
hematite/silica calcine by leaching in dilute sulphuric acid. This paper addresses the
considerations that need to be included in the design of a commercial scale fluidized bed
operation and also discusses the potential application of fayalite slag oxidation to the
recovery of base metals from copper-cobalt, copper-nickel-pgm-chrome and nickel-cobalt
slags. The additional challenge of separating the hematite and silica from the leached
calcine to provide products with commercial potential is also examined.
An extensal literature review, including their own experimental results are shown by
the authors. It is considered as an important support for application in reutilization of
wastes in the mining industry.


RW10

TAKING ADVANTAGE OF USED OILS FOR MANUFACTURING IN SITU
BLASTING AGENTS THE CHILEAN EXPERIENCE.

Eduardo O. Berger
Head of Mining & Metallurgy Department
Universidad Andrs Bello Via del Mar.
eduardo.berger@unab.cl

ABSTRACT

To face a more demanding environmental regulations for mining activities in Chile,
a significant number of open pit mines have decided to take advantage of recycled used oil
generated by different types of mining equipment for manufacturing in situ blasting
agents, in a similar way that some other mining operations in USA and Canada do. Those
blasting agents manufactured with some percentage of recycled used oil (usually 50%),
allow same results in rock fragmentation and heave as compared to regular blasting agents
manufactured using fuel oil only. Some mining companies in Chile which have already
implemented this practice are: Escondida, Spence, Cerro Colorado (BHP); Los Bronces, El
Soldado, Mantos Blancos (Angloamerican); Radomiro Tomic, Gaby (Codelco); Los
Pelambres, El Tesoro (Antofagasta Minerals); Candelaria, El Abra (Freeport Mac Moran).
Main steps to carry out a project like this are as follows: a) Sampling of collected
used oil at maintenance workshop; b) Physical and chemical analysis of representative
samples of used oils, c) A set of lab and field trials; d) Analysis of the scheme used in the
maintenance workshop for collecting and storage used oil; e) Analysis to define the
expected used oil consumption in accordance to the corresponding blasting agents
consumption for the complete life of mine; f) Definition of a basic plant design likewise
project feasibility; g) Government allowance or authority permission affairs.

RW11

RECYCLING OF METAL ASHES AND ELECTRONIC SCRAPS IN VARIOUS
FURNACES USING PNEUMATIC INJECTED FEED DELIVERY

Mark Coleman
Sales and Applications Engineer Clyde Process Brand of Schenck Process Limited

ABSTRACT

Clyde Process an established customer-driven solutions provider, utilising its
knowledge, expertise and technologies to transform production processes, operating in the
ferrous and non-ferrous metals industries joined the Schenck Process Group of Darmstadt
Germany bringing the Brand into their focused Process Team.
Clyde Process solutions have delivered transformed operation to many of their
global clients, enabling them to generate sustainable economic benefit and maintain
positions as leaders in their markets.
Clyde Process has delivered a number of solutions in the secondary copper industry
to enable metal ashes produced as process arising to be safely recycled. In the lead industry
Clyde have enabling producers to recycle lead dross, control accurately TSL and QSL
Furnaces and to accurately fume the slag recovering the zinc. In the tin and copper industry
delivering material dusts and recycling chips to furnaces. Enabling EAF dusts to be
recycled in Fumers and delivery to Plasma torches. Electronic Scrap as a free fuel or
Reductant, while delivering the full PGM value.
These solutions have delivered improved environmental performance, tighter
control of the furnaces and enabled the producer to improve economic performance.
This paper discusses some of the solutions delivered showing the truth of Schenck
Process Solutions claim that we make processes work


RW12

RECOVERY OF LEAD IN COPPER SMELTERS OF KGHM POLSKA MIED
S.A.

Ryszard Prajsnar, Jzef Czernecki, Zdzisaw Miczkowski
Institute of Non-Ferrous Metals
44-100 Gliwice, ul. Sowiskiego 5
Poland

ABSTRACT

The paper presents a technology for recovery of lead at KGHM Polska Mied S.A.
with special consideration of lead behavior in the processes of copper production, smelting
of lead-bearing materials in rotary-rocking furnaces and fire lead refining.

In the technological processes of copper production from sulfide materials lead
concentrates in dusts and slimes from dedusting of furnace gases. The generated lead-
bearing by-products present diversified physicochemical properties, as they form
polymetallic concentrates of lead, zinc and copper, significantly polluted with toxic metals,
such as arsenic, cadmium and thallium and in some cases (slime from shaft furnaces)
containing also large volumes of bituminous substances and chlorine.

The lead-bearing materials are smelted into crude lead in rotary-rocking furnaces at
HM Gogw copper smelter. The complex chemical composition of the treated lead-bearing
materials poses important problems with respect to the crude lead purity, smelting
efficiency, treatment of toxic metals, especially arsenic, and during post combustion and
purification of gases.

Presence of the wide spectrum of impurities in the crude lead, such as Cu, Zn, Cd,
Ag, Sn, Sb, As, Bi, Tl, Te in the total amount up to 2 % requires application of a multi
stage fire refining process for production of refined lead of 99.985% Pb purity.


RW13

SEA DISPOSAL OF MINE TAILINGS FROM COPPER MINING AN
ALTERNATIVE TO LAND DISPOSAL.

Professor Jens Skei,
Skei Mining Consultant (SMC), Norway.
jens@skeimining.com

ABSTRACT
Mineral production generates tailings and waste rock in large quantities and due to
lack of beneficial use, the mineral residues are considered as waste material which has to be
disposed. Management of large amounts of solid waste is an environmental challenge and
the permits for mining are dependent on what is considered as environmental acceptable.
The definition of what is acceptable has been unclear and the consequence is that the
mining companies experience a considerable unpredictability in terms of waste handling
and permissions. Mines located not far from the sea should consider deep sea disposal
(DSTP) of tailings and waste rock as an alternative to land disposal. Many coastal states,
Norway included, have either applied or planned sea disposal of tailings. Lack of suitable
land disposal sites due to conflicting interests of land use has increased the need of
exploring the possibility of DSTP.
However, sea disposal is a political sensitive issue and among environmentalists
strong opposition has been expressed. Alternative disposal sites should be evaluated and
decisions should be based on an overall impact assessment where land areas and the marine
environment are compared. Site specific conditions will influence environmental risk and
user conflicts. Consequently, environmental acceptance criteria and criteria for
classification of suitability for disposal sites are needed.


RW14

COPPER ION REMOVAL BY BSA SOLUTION AND ULTRASONICALLY
SYNTHESISED AIR BUBBLES

Amir Mohammad Nazari
a
, Philip W. Cox
b
, Kristian E. Waters
a

a
Department of Mining and Materials Engineering, McGill University
3610 University, Montreal, Quebec H3A 0C5, Canada
b
School of Chemical Engineering, University of Birmingham
Edgbaston, Birmingham, B15 2TT, United Kingdom

ABSTRACT
This paper investigates copper ion uptake using innovative technique named air-
filled emulsion. This method is based on the generation of microscopic bubbles enclosed by
a thin film of bovine serum albumin (BSA), and is the combination of air-assisted solvent
extraction (AASX) and biosorption methods. XPS analysis was employed to probe the
chemical interaction between functional groups present on the surface of BSA and adsorbed
copper ions. It was observed that manipulation of experimental conditions such as copper
solution pH, temperature, copper and bisorbent concentration has a significant impact on
copper ion uptake.


RW15

WASTE MANAGEMENT AND METAL RECOVERY IN THE CHILEAN COPPER
INDUSTRY

A. Valenzuela (1), M. Snchez (2), P. Reyes (3)
(1) AL Prospecta Consultores, Chile
(2) University Andrs Bello, Chile
(3) Chagres Division, Angloamerican Chile

ABSTRACT

Chilean copper is produced by two processes: Concentrators, including mining,
crushing, milling, flotation, obtaining concentrates (30-35% Cu), and hydrometallurgical
plants, including mining, crushing, heap leaching, solvent extraction and electro winning,
obtaining copper cathodes (99.99% Cu). A portion of concentrates are treated in smelters
and electro-refineries, obtaining copper cathodes (99.99% Cu), while other portion is
exported to be treated in international smelting and refining plants.

Typical wastes generated during these processes are acid drainage, flotation tailings,
copper slag, smelters flue dust, acid effluent, etc.

In the last decades, the local copper industry has implemented several technologies
and carried out research to manage these wastes and recover metals contained, mainly
copper, molybdenum, and iron, among other.

This paper reviews the present situation of the waste management in the Chilean
copper industry in terms of generation and characterization, as well as the operations and
research carried out to recover metals from these waste. Some suggestions are proposed
regarding waste management and metal recovery guidelines and regulations to increase the
chain value in the mining and metallurgical copper process.


RW16

ECONOMIC POTENTIAL OF MINING TAILING

Dr. Roberto MaIlea C. Jefe de Proyectos
Elena Blanco N" 1070 Providencia, Santiago CHILE

ABSTRACT

Copper production in Chile is associated with the generation of large quantities of
massive wastes, such as gravel, slags, and tailings. For example, the copper industry has
generated in the last ten years (2002 to 2011) about 2,156 million tons of tailings. The
future trend is an increasing production of tailings per ton of copper concentrate produced.
These massive mine wastes, particularly tailings generated by flotation plants, may
still have interesting concentrations of several elements such as Iron, Aluminum, lead,
Selenium, Tellurium, Tungsten, Rhenium, and Rare Earth, among others.
Identification (Characterization) and recovery of a fraction of these elements confer
commercial value to these residues, with an important business potential due to their global
growing demand, particularly in industrialized countries. They are key components and
strategic raw materials for the maintenance and development of new and advanced
technologies that enable or facilitate the economic welfare of industrialized countries. Most
industrialized countries belonging to the European Union, besides EE.UU and Japan, have
explicitly recognized that the lack of certain elements that are mainly being produced by
China, Russia, the Democratic Republic of Congo and Brazil, represents a great challenge
for running their economies.
The presentation will address the identification of some of these elements in
massive mine wastes, their possibilities of recovery and the type of commercial product
which may be generated.

RW17

IMMOBILIZING ARSENIC WITH HIGH RATE BIOPRECIPITATION
TECHNOLOGY FOR SUSTAINABLE MINING

Paula Gonzlez Contreras, Martijn Olde Weghuis
Paques B.V., T. de Boerstraat 24, 8561 EL Balk, P.O. Box 52, 8560 AB Balk, The
Netherlands

ABSTRACT
An undesirable scenario is predicted with the production of 11 million tons of
arsenic from copper and lead extraction for the coming years. Paques B.V. has previously
introduced the Thioteq-orpiment (As
2
S
3
) sulphide process, leading to effluents with arsenic
concentrations below 0.2 mg/L. However, only scorodite (FeAsO
4
2H
2
O) precipitation
would provide a time-stable discard product to reduce the risk of arsenic leach to the
environment. Scorodite precipitates contain up to 30%wt arsenic, when precipitated in the
absence of gypsum. Paques B.V. has recently introduced a new arsenic immobilization
process based on biocrystallisation in airlift bioreactors: Thioteq-scorodite. In this process,
arsenic oxidation, iron oxidation and crystallization are mediated by microorganisms.
Currently Paques B.V. foresees two main applications in the copper industry:
treating diluted arsenic bleed streams and processing of arsenic trioxide dust. In the
Thioteq-scorodite process, a single thermophilic (70C) bioreactor can be used if low
arsenite oxidation rates are required. However, if high arsenite oxidation rates are desired, a
mesophilic (35C) bioreactor can be used as pre-treatment of the Thioteq-scorodite. Iron
and neutralizing reagents can be chosen to minimize gypsum production, depending of the
geographical location of the mine site, leading the arsenic immobilization process to a new
sustainable concept.


RW18

BIOELECTROCHEMICAL SYSTEMS FOR METAL RECOVERY.

P. Rodenas Motos, R.J.W. Meulepas, T.H.J.A. Sleutels, M. Saakes and A. ter Heijne
Wetsus, centre of excellence for sustainable water technology
Agora 1, 8934 CJ Leeuwarden, the Netherlands
roel.meulepas@wetsus.nl

ABSTRACT

Metals are commonly removed from wastewater by precipitation, e.g. with slaked lime,
resulting in the production of large amounts of with metal contaminated waste. The annual
global production of mine wastes has been estimated at approximately 15,000-20,000
million tons.

This paper presents a novel process to recover metals from metallurgical wastewaters
or mine drainage. The process is driven by the chemical energy present in waste streams
that contain reduced compounds, like organics or sulphide. The process comprises an
electrochemical cell in which the anode and cathode are separated by a membrane. At the
anode, electrochemically-active microorganisms oxidise the organic matter or reduced
sulphur compounds. At the cathode, dissolved metals are reduced to their elemental form,
similar to electrowinning. Because the potential for organic matter or sulphide oxidation is
lower than the potential for copper reduction the reaction is spontaneous.

Anode:
HS
-
S + H
+
+ 2e
-
E
0
= -0.06 V
C
2
H
3
O
2
-
+ 4 H
2
O 2 HCO
3
-
+ 9 H
+
+ 8 e
-
E
0
= 0.19 V

Cathode:
Cu
2+
+ 2e
-
Cu
(s)
E
0
= 0.34 V

Bioelectrochemical metal recovery has the potential to reduce waste production and
increase the metal yield without additional energy costs.


RW19

AN INNOVATIVE TECHNOLOGY FOR ARSENIC AND ANTIMONY
ABATEMENT FROM MINING EFFLUENTS DEVELOPED BY ECOMETALES
LIMITED

I. Valenzuela, M. Acua, M.P. Merino and J. Smit
EcoMetales Limited
Nueva de Lyon 072, of 1701
Santiago, Chile
mmeri004@ecometales.cl

ABSTRACT

EcoMetales Limited (ECL) is a leading company in environmental solutions and
metal recovery from mining waste. ECL operates a dust leaching plant located in Calama,
which generates a PLS with a high content of Cu, Mo and impurities such as As and Sb.
This PLS is treated through the Arsenic and Antimony Abatement Process (AAA), an
innovative technology developed by ECL.

Through an optimal combination of pressure, temperature and pH, this technology
permits the removal of the impurities from the solution, generating scorodite, a stable solid
residue, allowing at the same time the recovery of the value species contained. With the
development of AAA process, EcoMetales became the first company in the world to
stabilize As and Sb on an industrial scale as a non-hazardous waste.

This document describes the AAA process, as applied to the treatment of smelter dust
and refinery effluent, as well as its industrial validation based on the characterization of the
obtained residue and the stability tests developed.


RW20

THE USE OF CONTIROD TECHNOLOGY FOR CASTING RECYCLED
COPPER

Szczypiorski, Wojtek (wojteksz@hazelett.com)

ABSTRACT

Contirod technology for producing wire rod was first commercialized in the
70s. Though in the beginning, it was used only for casting cathode-grade copper, some saw
the potential that the straight mold of the Hazelett twin-belt caster could be a good way to
cast copper with a higher impurity level. Soon, Contirod technology was successfully used
for producing copper rod based on recycled material.


RW21

SMELTING OF COPPER SECONDARY MATERIAL IN TBRC - KALDO

B P Kamath and Dr S Tandon
Balapkamath@gmail.com

ABSTRACT

For the past 10 years, there has been considerable interest to recover copper from
non scrap secondary material with relatively low copper content.
Smelting of secondary materials like Reverts, Oxide Concentrates with high
insoluble content, Flue Dusts, Copper Cake, Copper Cement, Copper Dust, Concentrate
etc. Besides, it can process Cables, Shredded Armatures, and Medium & High Grade
Copper Scraps hin Kaldo- TBRC furnace as been discussed in this report The plant can
treat, using Bolidens shock quench technology, copper bearing materials like druid,
cables, electronic scrap etc without damaging the environment.
Some modifications were carried out after modeling studies on Kaldo furnace by
Tata Research Design & Development Centre, Pune (India) which are also highlighted in
this paper.
The paper attempts to signify the versatility of TBRCKaldo in treating different
types of secondary material with experience in operating the Kaldo furnace.

RW22

REFRACTORY USE SPECTRUM FOR COPPER MELTING IN RECYCLING

Bruce Huffman,
Atlantic Refractory Technologies and John Hugens, Fives North American Combustion

ABSTRACT

Pyrometallurgical copper recycling requires close attention to refractory selection.
The refractory selection influences both the life of the furnace vessel and the quality of the
end product. The participation of oxygen in the copper refining process is the major
determinant of the refractory.

The next most important parameter is the level and type of impurities in the recycle
stream.

The range of optimum refractory choices for different recycle streams varies from
Silicon Carbide brick to Basic brick with several special uses for other compounds. Since
refractory wear is rapid in many recycling melting operations, the economics of refractory
choice are discussed. Performance in several scrap melting applications is compared.


RW23

FUTURE DIRECTIONS FOR SCRAP MELTING IN COPPER SHAFT FURNACES

John Hugens

ABSTRACT

Although the copper melting shaft furnace was developed primarily for the melting
of copper cathodes, its use for the melting of copper scrap started immediately, due to the
need to recycle scrap copper tube in tube mills. The scrap melting techniques developed in
the tube mills eventually spread to wire and rod making plants as well.
Today the favorable economics of melting scrap have induced many users to
maximize the introduction of copper scrap in their shaft furnaces. The use of different
grades of copper scrap affects the design, operation and quality of production of the
furnaces in many different ways.


RW24

RECOVERY OF COPPER FROM PRINTED CIRCUIT BOARDS AT 1150C

R. Cayumil, R. Khanna, A. Hill
1
, V. Sahajwalla
Centre for Sustainable Materials Research and Technology (SMaRT@UNSW)
School of Materials Science and Engineering
Room 116, Building E8
The University of New South Wales, NSW 2052, Sydney, Australia
r.cayumilmontecino@student.unsw.edu.au
1
CSIRO Process Science & Engineering
Bayview Avenue, Clayton VIC 3168, Melbourne,
Australia

ABSTRACT

The recovery of materials from urban waste has become progressively important
with wastes providing a variety of resources, whose processing can lead to an
environmentally sustainable solution to metal availability. Recycling of metals such as
copper makes the recovery attractive from technical and economical points of view, as
copper content in several discarded products can be much higher than the corresponding
concentration of copper from various ores. This article provides an overview on the
recovery of copper from several waste streams and reports an experimental investigation on
the recovery of copper from end-of-life electric and electronic equipment (e-waste).

In-depth investigations have been carried out to recover copper from printed circuit
boards. Experimental results have shown that a heat treatment at 1150C over a period of
time generated two types of solid residues: A metal phase and a carbonaceous material.
Copper and copper alloys were recovered in the metallic residue achieving a high recovery
after the heat treatment.


RW25

PROCESS FEATURES AND OPERATION PRACTICES OF NGL FURNACE IN
SECONDARY COPPER SMELTER

Yao Suping and Liu Qinghua
CHINA NERIN ENGINEERING CO. LTD.
888 Qianhu Avenue, Hongjiaozhou District,
Nanchang, Jiangxi, China,
yaosuping@nerin.com

ABSTRACT

Secondary smelters with pyro-processing are always challenged with the facts of
time consuming during feeding and melting, complicated and unpredictable materials,
difficulty of refining and large volume of slag, possible Dioxin in gases from organics
burning and consequently high demanding of gases cleaning. NGL furnace with complete
process and equipment has developed by CHINA NERIN ENGINEERING CO. LTD
especially cope with those challenges in pro-processing in secondary smelter. The structure
of NGL furnace together with its combustion, nitrogen stirring and gas cleaning system are
introduced in this paper. Operation practices in several secondary smelters in China with
complete NGL furnace process are summarized with major operation parameters, technical
and economical results and the monitoring of Dioxin in gas emissions.
The operation practices NGL furnace process shows it with significant advantages in
high production efficiency, low energy consumption and efficient reductant utilization as well
as high level of automation and operation safety. With closed vessel and proper gas cleaning
system of NGL furnace process, black smoke and hazardous gas emissions are significantly
eliminated and CO
2
/NO
x
emissions are significantly reduced. NGL furnace process has been
recommended by Chinese government as a priority selection in secondary smelter in China.
The further development of NGL furnace process and its equipment is also discussed in this
paper.


RW26

THE CASE FOR METAL RECOVERY FROM ELECTRONIC WASTE

Nickolas J. Themelis and Jennifer M. Namias
Earth Engineering Center,
Columbia University,
500 West 120
th
Street, #926
New York, New York, 10027;

ABSTRACT

Rapid growth and technological advances in the use of electronic products have led
to the generation of millions of tons of used electronics, commonly called e-waste. In
fact, e-waste is the fastest growing component of the municipal solid waste stream
worldwide. Globally, over 50 million tons of e-waste were discarded in 2009 and this
amount is es expected to increase to 72 million tons by 2014. E-waste contains precious and
special metals, including gold, silver, palladium and platinum, as well as toxic and
hazardous substances such as lead, mercury, cadmium and beryllium. Therefore,
responsible end-of-life management of e-waste results in the recovery of valuable metals
and, also, reduces the effects of hazardous and toxic components in the environment. It is
estimated that 50 to 80 percent of the e-waste collected in the U.S. is exported to
developing countries for end-of-life management, due to cheap labor and lenient
environmental regulations.
The remainder is treated pyrometalurgically in copper smelters in Canada and
Western Europe. Therefore there is a need for increasing e-waste processing capacity in the
U.S. and also ensuring that e-waste treated in China, India, and other developing nations
does not result in environmental pollution and associated public health impacts. There are
some ongoing efforts on hydrometallurgical processing of e-waste but have not as yet
reached large industrial scale.

SYMPOSIUM: 10 GEOMETALLURGICAL CHALLENGES IN MINING
PROJECTS

GM01 David Meadows TESTWORK PROGRAMS AND PLANNING - TOO LITTLE,
TOO LATE
GM02 Peter Naumann GEOCHEMICAL MODELING OF A MINE WASTE DUMP IN
NE VIETNAM
GM03 Wolfgang Baum PROCESS MINERALOGY SURVEYS FOR COPPER
CONCENTRATOR OPTIMIZATION, DE-BOTTLENECKING
AND THROUGHPUT INCREASE
GM04 Dan Mcgraw FRACTAL COPPER MINING
GM05 L.L. Kuhar NOVEL DIAGNOSTIC AND SELECTIVE LEACHING
CHARACTERISATION OF COPPER SAMPLES WITH
ROBUST STATISTICAL MINERALOGICAL VALIDATION
GM06 Heresi N. INFLUENCE OF GEOLOGICAL VARIABILITY ON THE
RHEOLOGY OF ROUGHER TAILINGS SAMPLES
GM07 Kiyoto Yamaguchi DEVELOPMENT OF CASERONES PROJECT IN CHILE
GM08 Y. Ichii MOLYBDENUM-COPPER EXPLORATION ACTIVITY IN
THE PHNOM BASSET AREA,KANDAL PROVINCE,
KINGDOM OF CAMBODIA
GM09 T. Tanaka COPPER EXPLORATION ACTIVITY IN THE MOUNE
AREA, MOUNE DISTRICT, VIENTIANE PROVINCE, LAO
PEOPLE'S DEMOCRATIC REPUBLIC
GM10 Roberto Freraut GEO-MINER METALLURGICAL PLANNING AT DMH
"ROCK TO CATHODE"
GM11 Roberto Freraut MINERALES COMPLEJOS SULFURADOS DE DMH: UNA
SOLUCIN TECNOLGICA INTEGRAL
GM12 Roussos
Dimitrakopoulos
MINE PLANNING OPTIMIZATION WITH UNCERTAINTY:
A REVIEW OF CONCEPTS AND APPLICATIONS FROM
SINGLE MINES TO MINNING COMPLEX
GM13 Marcelo Navarrete MINE PLANNING FOR AUTONOMOUS TRUCKS
GM14 Osmar Morgado MODELLING OF GRINDING PARAMETERS TO
DETERMINE THE TREATMENT FOR THE MINING
PLANNING OF COMPAA MINERA DOA INES DE
COLLAHUASI
GM15 N. Mora GEOMETALLURGICAL MODELLING OF THE
COLLAHUASI GRINDING CIRCUIT FOR SHORT-MID AND
LONG TERM MINING PLANNING
GM16 Luis Serrano CASERONES PROJECT GEOMETALLURGICAL MODEL -
LUMINA COPPER
GM18 Sandy Prieto CASE STUDY OF GEOMETALLURGICAL DOMAIN
DEFINITION FOR SAMPLE SELECTION USING
MULTIVARIATE ANALYSIS OF DATA FROM THE
GRAMALOTE PROJECT, COLOMBIA

GM19 C. J. Suazo THE COLLAHUASIS FLOTATION GEOMETALLURGICAL
MODELLING FOR PROCESS OPTIMIZAION AND MINING
PLANNING
GM20 Javier Vargas GEOMETALLURGICAL MODEL OF SAG MILLING AT
MINERA ESPERANZA
GM21 Sandra Gonzalez GEOMETALLURGY STANDARDIZATION WITHIN AMSA
GM22 R. Castro FUNDAMENTALS OF IN SITU UNDERGROUND MINING
GM23 Edmundo Martinez TOWARDS A STANDARDIZATION OF THE SULFURIC
ACID SOLUBLE COPPER ASSAY
GM24 X. Rubio P. METHODOLOGY OF DEVELOPMENT OF CONCEPTUAL
GEOMETALLURGICAL MODELS FOR CU MINING
PROJECTS, IN EARLY STAGES
GM25 Pia Lois WATER/ROCK INTERACTIONS AND PHYSICOCHEMICAL
CONTROLS ON MINERAL PROCESSING IN FLOTATION
CELLS: BEING PREDICTIVE BASED ON GEOLOGY
GM26 Jose Aldana ANTUCOYA PROJECT: LOW GRADE COPPER ORE
TREATMENT
GM27 D.C. Curry OPPORTUNITIES FOR AN INDUSTRY CONSTRAINED BY
INFRASTRUCTURE
GM28 Veronica Escobar GEOMETALURGICAL MODEL FOR OXIDE HEAP
LEACHING
GM29 Veronica Escobar GEOMETALLURGICAL MODEL AND METALLURGICAL
TESTING FOR A SOUND CONCENTRATION PLANT
DESIGN
GM30 J. M. Delgado Vega APPLICATION OF A GEOMETALLURGICAL MODEL TO A
STRATA-BOUND DEPOSIT
GM31 Edgardo Madariaga G REDUCING PRODUCTION VARIABILITY IN SHORT TERM
SCHEDULING - A PRACTICAL APPROACH

Geometallurgical Challenges in Mining Projects

GM01

TESTWORK PROGRAMS AND PLANNING TOO LITTLE, TOO LATE

David Meadows, Vice President Process Technology Group, FLSmidth
David Jensen, Director Process Technology Group, FLSmidth
Samuel Yu, Senior Metallurgical Engineer, FLSmidth

ABSTRACT

Testwork programs are essential to effective process design, accurate equipment
sizing, and timely startups for Greenfield projects. Adequate testwork is even more
imperative as mined ore bodies have more complex mineralogy, and larger ore variation.
Further, these changing ore bodies do not always fit within the framework of currently
available testwork databases and installations. The effects of inadequate testwork are
evident in some of the mill sizing errors made in recent years; many non-optimum
flowsheet design and underperforming plants can be traced back to the quality of testwork
planning at the beginning of project. .

It is recognized that achieving adequate testwork is challenging. The ramifications
of inadequate testwork and lack of mineralogical ore characterization on equipment sizing
and process design will be discussed to emphasize the importance of testwork programs
and planning. Two important aspects of the testwork planning, ore sampling and choosing
the right type of testwork will be addressed. Explanations, examples, interpretation, and
cost estimates of testwork programs will be presented. Finally, recommendations will be
made for the planning, execution and utilization of a testwork program.


GM02

GEOCHEMICAL MODELING OF A MINE WASTE DUMP IN NE-VIETNAM

A. Filby, K. Haneke, J.B. Pateiro Fernndez, P. Naumann
Brenk Systemplanung GmbH, Germany

ABSTRACT

The oxidation of pyrite in the Chinh Bac mine waste dump (Vietnam) leads to the
release of heavy metals, salts and acidity into the environment. Brenk Systemplanung
(Germany) undertook a long-term water and rock sampling campaign of the waste dump
and its surrounding open-cast mines. The derived information was used as input data for a
geochemical modeling study by means of the proprietary software TAILINGS. In this case,
the 1-D reactive transport in the unsaturated zone of the waste rock dump was simulated
considering the following processes: diffusive gas transport, advective-dispersive solute
transport and chemical interactions (e.g. sulfide oxidation, sorption,
dissolution/precipitation etc.) between dissolved species, primary and secondary mineral
phases and the gas phase. Thus, all processes relevant for acid mine drainage prediction are
modeled.
Additionally, the annual rainy and dry seasons are also regarded. This aspect is
important for simulating the subtropical conditions of NE-Vietnam, where drastic seasonal
differences regarding the precipitation and consequently percolation exist. As a result of
these geochemical calculations, the contaminant loads released into the ground and surface
water are determined and the impact of different remediation options on the pyrite
oxidation rate and acid mine drainage generation is investigated.


GM03

PROCESS MINERALOGY SURVEYS FOR COPPER CONCENTRATOR
OPTIMIZATION, DE-BOTTLENECKING AND THROUGHPUT INCREASE

Wolfgang Baum*, Randy Zahn, Phil Thompson, & Dariusz Lelinski
FLSmidth Salt Lake City, Inc.
7158 S. FLSmidth Drive
Midvale, UT 84047-5559 USA

ABSTRACT

Optimization of copper concentrators has, traditionally, been hampered by lack of
quantitative mineralogical data. The implementation of Automated Mineral Analyzers (e.g.
QEMSCAN, MLA, TIMA, EVO MA 15 etc.), the use of XRD Rietveld and NIR analysis
have enabled plant operations to continuously material-balance their mineralogy and
metallurgy. Yet, a considerable application potential for a robust Process Mineralogy
remains untapped as these surveys too often are used sporadically and/or for circuit
troubleshooting only. The integrated use of process mineralogy for geo-metallurgical
modeling, daily/weekly ore profiling, and daily analysis of key concentrator streams is
considered one of the most cost-effective tools for improving equipment performance,
reagent schemes, and flotation recovery.

The continuous mineralogical characterization of ore types, ore boundaries,
alteration zones and mine planning samples ahead of production, is pivotal to minimizing
variances which impact grinding, flotation and metals recovery. Particularly for
molybdenite by-product metallurgy, a routine monitoring of the gangue in regard to
minerals detrimental to moly flotation (such as talc, pyrophyllite, Ca-minerals) is
imperative. This paper will outline the planning, sampling, sample preparation,
mineralogical and metallurgical analysis of baseline (end-member) ore types and
concentrator samples for integrated Process Mineralogy Surveys. It will also illustrate the
economic benefits obtained after process and/or equipment changes were implemented.


GM04

FRACTAL COPPER MINING

Dan McGraw
Senior Research Engineer
Group Research & Product Review
FLSmidth Minerals Salt Lake City

ABSTRACT
Increasing global copper demand and tightening energy, water, and environmental
constraints in the face of continuously declining copper grades create an increasing pressure
for innovation in copper mining. Highly disseminated, inhomogeneous, and refractive ores
give copper mining the most challenging, diverse, and fluctuating feeds in any process
industry. Our geometallurgical modeling must accurately reflect the geology and
geochemistry to faithfully guide and constrain our process innovation to best fit our ore
bodies.
Historical ore-tonnage relations indicate that a fractal distribution accurately
describes the spatial distribution of copper in most large copper deposits. This has
implications and places constraints on the degree and means of pre-concentration
enrichment. Quantitative differences in the measured fractal dimension describing different
deposits are seen to create qualitatively different requirements for their efficient mining and
processing. We look at copper pre-concentration processes with an eye to constraints and
opportunities for improved process efficiency created by the fractal nature of the ore grade
distribution. We review trends in on-line process sensing in light of a fractal description of
process fluctuations described as Fractional Brownian Motion. A fractal model gives
insight into copper geometallurgy, allowing a geo-mimicry and integration in our process
innovation.


GM05

NOVEL DIAGNOSTIC AND SELECTIVE LEACHING CHARACTERISATION
OF COPPER SAMPLES WITH ROBUST STATISTICAL MINERALOGICAL
VALIDATION

L.L. Kuhar, N.M. Chapman, R.L. Meakin, R. Martin, N.L. Turner and D.J. Robinson
CSIRO Minerals Down Under Flagship, CSIRO Process Science and Engineering
P.O. Box 7229
laura.kuhar@csiro.au

A.J. McFarlane
CSIRO Minerals Down Under Flagship, CSIRO Earth Science and Resource Engineering
P.O. Box 1130
Bentley, Western Australia, 6102

ABSTRACT

Characterisation of copper samples by leaching tests is conducted frequently by a
number of commercial laboratories. These leach tests not only have the potential to provide
more sample information than is gathered routinely but furthermore, in investigations into
these traditional laboratory leach analyses, it was found that the determination of copper
mineralogical deportment is not as selective as is claimed. New leach protocols have
therefore been developed by Commonwealth Scientific and Industrial Research
Organisation (CSIRO) researchers to improve the accuracy of calculated copper mineralogy
(oxides, chrysocolla, chalcocite, covellite, bornite and chalcopyrite). The validation of
results from leach tests, using quantitative mineralogical analysis, is essential for quality
control. An accurate, robust statistical method for QEMSCAN (Quantitative Evaluation of
Minerals by SCANning electron microscopy) data analysis and validation of the new
proposed selective leaching approach was therefore developed. The development and
improved accuracy of these diagnostic and selective leach tests, including the use of the
QEMSCAN for validation, will be highlighted with examples of applications to real
samples from three different operations.


GM06

INFLUENCE OF GEOLOGICAL VARIABILITY ON THE RHEOLOGY OF
ROUGHER TAILINGS SAMPLES

Heresi N.*, Castillo C., Fuentes R.

ABSTRACT

The relationship between geological unit characteristics and rheological behavior of
tailings is of great interest due to its impact on thickening, transport and deposition. In
order to understand this relationship, it is necessary to study the rheological behavior of
tailings produced from ores with known mineralogical characteristics and different
combinations of lithology and alterations of the hypogene mineralization zone of a deposit.
Two hundred laboratory rougher tailings samples were characterized. Measuring
included solids density, particle size distribution and rheograms obtained with a Searle-type
coaxial cylinder rheometer.
The rheograms were determined at different concentrations of solids and the results
were assimilated to the Bingham plastic model, which has turned out to be convenient and
practical for this type of suspensions. The parameters obtained were successfully
interpreted employing Krieger and Dougherty equations for plastic viscosity, and Heymann
et al for shear stress.
An explicit relationship between different tailings with their own geological
properties and rheological characteristics, was reached. These results enable us to be
provided with more solid design bases for thickening, transport and deposition.


GM07

DEVELOPMENT OF CASERONES PROJECT IN CHILE

Kiyoto Yamaguchi, Masashi Kikuchi, Susumu Kubo and Nelson Pizarro
JX Nippon Mining & Metals Corporation

ABSTRACT

Caserones Project is the Copper and Molybdenum mining project in Chile managed
by SCM Minera Lumina Copper Chile (MLCC), This project is owned 100% by Japanese
companies, Pan Pacific Copper Co., Ltd. a joint venture between JX Nippon Mining &
Metals Corporation and Mitsui Mining & Smelting Co., Ltd., and Mitsui & Co., Ltd. The
deposits are located 162km southeast of the city of Copiapo, the capital of Region Blof
Chile, at an altitude of approximately 4,200-4,600 m above sea level.
The ore is mined from an open pit and processed at concentrator plant or SX-EW
plant depending on its characteristic. Copper and Molybdenum concentrate is produced
with sulfide ore (1.05 billion tons, average CuT 0.34%) by flotation and refined copper
with oxide and low grade sulfide ore (0.3 billion tons, average CuT 0.25%) by SX-EW.
The production plan considers geometallurgy model developed by the metallurgical
tests and the geological information. By introducing technology of improving water
recovery in the operation, Caserones Project plans to achieve lowest level of water
consumption per ton ore processed, in Chilean copper mine operation. The construction
began in March 2010. In 2013, the leaching operation commences and afterwards the
concentrator starts.


GM08

MOLYBDENUM-COPPER EXPLORATION ACTIVITY IN THE PHNOM
BASSET AREA, KANDAL PROVINCE, KINGDOM OF CAMBODIA

Y. Ichii, T. Tanaka, S.Machida Nittetsit Mitring Co., Ltd. Yusen Building, 3-2, Marunouchi
2-Chome, Chiyoda-ku, Tokyo, 100-8377, Japan
H. Takahata, K. Yasunaga, K. Watanabe Nittetsu Mining Consultants Co., Ltd NOF
Building, 2-3, Shiba 4-Chome, Minato-ku, Tokyo, 108-0014, Japan

ABSTRACT

Nittetsu Mining Co., Ltd. obtained an exploration license in the Phnom Basset Area,
Kandal Province, Kingdom of Cambodia in 2012. The area is located about 20 km north
west of Phnom Penh, the capital city of Cambodia. This area has been recognized as a
molybdenum prospecting area for more than 30 years and Nittetsu Mining Co., Ltd. has
conducted geological, geochemical and geophysical survey.
As a result of these surface surveys, it was revealed that the mineralization of the
area was recognized as of the porphyry molybdenum-copper type and the mineralization
was mainly associated with quartz veins cutting quartz porphyry, monzonite porphyry and
potassium-feldspar porphyritic monzonite. The intensity of the mineralization was strongly
related to the quartz vein frequency and, as a result of the geophysical survey, high IP
anomalies also implied the existence of the mineralized zone which was supposed to
contain sulfides. On the basis of the results of these surface surveys, some drillings were
planned to identify the mineralized zones and the drilling survey was commenced in 2012.
In the presentation and article, the results of these exploration activities and the
characteristics of the molybdenum-copper mineralization of this area will be reported.


GM09

COPPER EXPLORATION ACTIVITY IN THE MOUNE AREA, MOUNE
DISTRICT, VIENTIANE PROVINCE, LAO PEOPLE'S DEMOCRATIC
REPUBLIC

T. Tanaka,
Nittetsu Mining Co., Ltd. Yusen Building, 3-2, Marunouchi 2-Chome, Chiyoda-ku, Tokyo,
100-8377 Japan

Y. Hosokawa
Sojitz Corporation 1-1, Uchisaiwaicho 2-chorne, Chiyoda-ku, Tokyo, 100-8691 Japan

T. Kabashinia
Japan Oil, Gas and Metals National Corporation 10-1, Toranomon 2-chome, Minaio-ku,
Tokyo, 105-0001 Japan

H.Takahara
NOF Building 2-3, Shiba 4-Chome, Minato-ku. Tokyo, 108-0014 Japan

ABSTRACT

Sojitz Corporation and Nittetsu Mining Co., Ltd. have obtained a prospecting
license in the Moline Area, Moune District, Vientiane province, Lao People's Democratic
Republic and started exploration activity in 2009. The Moline area locates in the Loei fold
belt and possesses a high potential of mineral resources. Several campaigns of field works
have been conducted from December 2009 to March 2011 by Japan Oil, Gas and Metals
National Corporation (JOGMEC), Sojitz Corporation and Nittetsu Mining Co., Ltd. In the
first phase of the exploration activity, geochemical survey and preliminary geological
survey were carried out for the whole area of the prospecting license (226.25 km2) and,
after these surface surveys, three encouraging zones (in total 7.12 km') were picked up
based on the data of overlapping of copper occurrences and strong geocheinical anomalies.


For these three encouraging zones, grid soil geochernical survey, trench survey and
geophysical survey (IP method) were conducted and detailed feature of geochemical
anomaly overlapped by geophysical anomaly was disclosed. Based on the data of these
surface surveys, some prospecting areas for drilling survey were selected and the drilling
survey was commenced in 2011. In the presentation and article, the results of these
exploration activities and the characteristics of the copper mineralization of this area will be
reported.

GM10

PLANIFICACIN GEO-MINERA-METALRGICA DMH DE ROCA A CTODO

Roberto Frraut C, Ruben Osorio P, Manuel Alfaro C.

ABSTRACT
En la Divisin Ministro Hales, el recurso geolgico tiene caractersticas
particulares, tales como: la gnesis de este prfido, la razn lastre-mineral, la variabilidad
mineralgica y leyes de Cu, el alto contenido de arsnico, la complejidad del proceso de
tostacin dentro de la cadena del negocio y su ubicacin cercana a la comunidad. Estas
caractersticas especiales, nos desafan a desarrollar proactivamente una planificacin geo-
minero-metalrgica, dado que debemos absorber la coyuntura tcnico-econmica,
capturando las oportunidades de mejora y mitigando los riesgos propios del negocio
minero. Adems generamos escenarios de uso eficiente de los activos y recursos,
integrando principalmente la seguridad, el cuidado del medio ambiente y las comunidades.

El planificador Geo-minero-metalrgico de Divisin Ministro Hales, est
convencido de que incorporar la informacin geo-minera-metalrgica en el modelo de
bloques para generar los planes mineros de largo plazo, permite agregar mayor valor al
negocio, lo que impacta finalmente a todos los chilenos.

Daremos una mirada del proceso de planificacin y las consideraciones claves en la
obtencin de los planes de produccin de Divisin Ministro Hales de Codelco. En
particular se revisar tpicos como la valorizacin del modelo, secuenciamiento,
incorporacin de variables geometalrgicas en la confeccin del plan minero, y su impacto
en los procesos aguas abajo.


GM11

MINERALES SULFURADOS COMPLEJOS DE DMH: UNA SOLUCIN
TECNLOGICA INTEGRAL.

Roberto Frraut C, Victorino Moyano E, Heidy Miranda Z, Andrs Reghezza I.

ABSTRACT
Divisin Ministro Hales de CODELCO, DMH, tiene programado iniciar sus
operaciones productivas a comienzos del segundo semestre del 2013. Esta nueva Divisin
est situada en la Segunda Regin de Antofagasta y con un recurso de 1.100,5 Mton con
una ley promedio de 0,93% de cobre. El depsito es del tipo prfido cuprfero con
mineralizacin temprana de cobre molibdeno.
La mineralizacin principal y de mayor valor econmico se encuentra en el sector
central y se caracteriza por una alta cantidad de enargita, calcosina y covelina. Esto infiere
una alta presencia de las impurezas en el sistema, principalmente de arsnico y antimonio,
que supera los niveles de todas las operaciones en Chile. El proceso definido para la
recuperacin de las especies de valor Cu, Mo y Ag contempla etapas de molienda, flotacin
y tostacin de los concentrados de cobre, a un ritmo de 50.000 t/d en la alimentacin. El
producto de la lnea de sulfuros, Calcinas de Tostacin, se canaliza al Horno Flash de la
Divisin Chuquicamata para la obtencin de ctodos electrorefinados en base a tecnologa
convencional.
Para enfrentar la complejidad del recurso tcnica y ambientalmente, se hace
necesario un riguroso control y seguimiento de las impurezas en el sistema, el cual es el
objetivo del presente trabajo. En este, se detalla como controlar la disposicin de relaves, el
tratamiento de gases y precipitacin de impurezas voltiles y la calidad de los productos:
concentrados y calcinas.


GM12

MINE PLANNING OPTIMIZATION WITH UNCERTAINTY: A REVIEW OF
CONCEPTS AND APPLICATIONS FROM SINGLE MINES TO MINING
COMPLEXES

Roussos Dimitrakopoulos
COSMO - Stochastic Mine Planning Laboratory
McGill University, Canada

ABSTRACT

Conventional approaches optimizing mine design and planning, production
forecasting and valuation result in single, and often biased, forecasts. This is largely due to
the non-linear propagation of errors in understanding orebodies being mined throughout the
chain of mining to products, and is well documented and appreciated. A new stochastic
mine planning paradigm is reviewed herein, integrating two broad elements: stochastic
simulation and stochastic optimization. These elements provide an extended mathematical
framework that allows modeling and direct integration of uncertainty in metal supply to
mine design, production planning, and valuation of mining projects and operations.
Several approaches and intricacies are overviewed along with applications in
producing mines and are then extended to global optimization of mining complexes as a
specific form of a supply chain. The stochastic framework is shown to increase the value of
production schedules by about 25% and ore production is substantially increased when
compared to deterministic approaches and industry standards to suggest a contribution to
the sustainable utilization of natural resources.


GM13

MINE PLANNING FOR AUTONOMOUS TRUCKS

Marcelo A. Navarrete (*)
Codelco Chile Divisin Gabriela Mistral, Calama, Chile, Mine Planning Superintendent,
77676582, mnava017@codelco.cl
Chang Ja Kim
Codelco Chile Divisin Gabriela Mistral, Calama, Chile, Mine Planner Engineer,
62267780,
ckim@codelco.cl

ABSTRACT

Minera Gaby, a different way of mining, has operated with the biggest
autonomous truck fleet on the world since 2007 to date. This has allowed developing a
planning model that suits the conditions and operating parameters of autonomous haulage
system (AHS) technology. This technology consists of a haulage system where the trucks
are operated from a central, through software, which delivers instructions to operate the
trucks in different mining circuits with mineral haulage and mine development. The trucks
are equipped with a wireless navigation system that allows a wireless communication, and
service teams equipped with a truck interactive system, that perform support in the mine.
Those form the AHS.

The mine planning in Minera Gaby has developed a planning method to incorporate
the following variables: design of operating width for loading and haulage equipments
inside of the mine; tread width; stochastic models (simulations) for the cycle time and
performance for loading and haulage equipments; develop of survey (haulage route) with
mine software that allows improvements for the haulage performance, ramps and dump
design. All of these, with a continuous KPI evaluation of AHS and considering the mine
business variables such as ore feed rates, mine development rates and drilling-blasting
requirements allows a mine planning method for autonomous haulage system.


GM14

MODELLING OF GRINDING PARAMETERS TO DETERMINE THE
TREATMENT FOR THE MINING PLANNING OF COMPAA MINERA DOA
INES DE COLLAHUASI SCM

Osmar Morgado T.
1
, Alejandro Hofmann N.
1
, Cristin Sprohnle
1
, Luis Aedo S.
1

1. Ca. Minera Doa Ins de Collahuasi SCM.

ABSTRACT

A Geometallurgical Grinding Model (GGM) has been developed in Compaa
Minera Doa Ins de Collahuasi SCM, located in high Cordillera, North of Chile. The
GGM allows to obtain the treatment values for each block into the Block Model. This
model is required for the long term mining plan and to support new business cases of the
company.

Through geostatistics tools, the GGM considers the estimate for each grinding
parameters contained in the treatment equation (TPH), permitting evaluate the spatial
hardness variability into the Block Model and the generation of a continuous distribution of
TPH. This estimate process of the grinding parameters allowed also to obtain continuous
models for the Specific Consumption of Energy and Steels for each block.

Consequently, the planning team can perform different production plans considering
both the geological and treatment models at the same time.

This is an absolutely objective methodology, supporting the planning process,
whose final consequence is meeting the plan that delivers the best net present value for the
company.


GM15

GEOMETALLURGICAL MODELLING OF THE COLLAHUASI GRINDING
CIRCUIT FOR SHORT-MID AND LONG TERM MINING PLANNING

N. Mora
a
, C.J. Suazo
a
, C.Muoz
a
, A. Hofmann
a

Compaia Minera Doa Ins de Collahuasi SCM
nfmora@collahuasi.cl

ABSTRACT
Compaa Minera Doa Ins de Collahuasi SCM initiated the development of its
geometallurgical modelling in 2007. The objective was to characterize the Rosario deposit
in terms of treatment capacity performance. The grinding model allows predicting the
treatment capacity, specific power and liners-balls consumption for mid and long term
planning.

The model uses a combination of simulation and power-based approaches to relate
ore hardness and flotation feed size to grinding circuit throughput. Ore hardness values are
provided by Collahuasis block model which has been populated with ore characterisation
data derived from Bond ball work index tests, JK drop-weight tests and SMC Tests
on
diamond drill cores. The influences of planned and unplanned maintenance downtime are
taken into account both in terms of frequency and duration. The model allows detecting the
constraints of the grinding circuits and prioritizes these restrictions to define projects to
release them.

Additionally, a Collahuasis grinding test is also presented to bring the
geometallurgical model from mid and long term to short term planning. The Collahuasis
grinding test uses either the production blast holes or infill geological drill holes.


The grinding model has been successfully used in mining planning and the accuracy of the
model is demonstrated using weekly production data taken from the period September 2007
December 2012, showing an average relative error of 4.6% and an R
2
value of 0.94.


GM16

CASERONES PROJECT GEOMETALLURGICAL MODEL - LUMINA COPPER

Luis Serrano

ABSTRACT

Caserones Project is located in the III Region of Chile, 162 km north-east of
Copiap city and corresponds to a porphyry copper - low grade molybdenum. Because of
the present mineralogy and metallurgical test results, it was decided to build two mineral
processing plants, a leaching plant and a concentration plant.
A geological characterization of the ore body and metallurgic units prevailing in the
mining plan were used for the design of these plants. With this information, representative
samples were taken from the ore body to test comminution and concentration through
drilling samples and samples of tunnels constructed for this purpose. Gabions were
constructed to make leaching pilot tests.
Also WI, ICC, CI and flotation tests were performed to determine treatment,
recovery and concentrate laws. Many of these variables were modeled and came to
constitute part of the block model, the results of which were designed with plants, defining
production rates and economic indicators of the project.

GM18

CASE STUDY OF GEOMETALLURGICAL DOMAIN DEFINITION FOR
SAMPLE SELECTION USING MULTIVARIATE ANALYSIS OF DATA FROM
THE GRAMALOTE PROJECT, COLOMBIA

Mauricio Romero, Luis Valencia & Sandy Prieto
SGS Minerals S.A., Chile

Juan Velez & Juan Arbelez
SGS Colombia S.A.

Claudio Devaux, Pablo Noriega & Fernando Arredondo
Gramalote Colombia Ltd.

ABSTRACT

A multivariate analysis of several stages, using categorical and continuous data
from drillcore logging and chemical analyses, was conducted in aim of selecting samples
from the drillcore, to be sent to grindability, flotability and amenability for cyanidation
testwork, as part of the feasibility stage of the Gramalote Project in Antioquia, Colombia,
controlled by Anglo Gold Ashanti.

The objective of the metallurgical testwork is obtain mineral processing and
cyanidation results to provide information to upgrade the mine planning and scheduling for
the first 6 years of production.

The data analysis was performed over a database of 38,295 records and
encompassed a starting framework of univariate and bivariate statistical analysis, to honour
standard industry practice and to explore data variability and basic correlations. This was
followed by multivariate analysis developed progressively by using Factor Analysis by
Principal Components (controlled by Tests of Hypothesis and Table of communalities),
which yielded the variables to conduct Cluster Analysis. Overall, a total number of thirteen
categorical variables (including lithology, structure types, alteration, alteration occurrence
and intensity amongst others) and thirty three continuous variables (such as fire assays, ICP
and magnetic susceptibility) were used in the several phases of the analysis.

A resulting number of five Clusters were obtained after eleven iterations of the
abovementioned analysis. The key driving variables which define the five groups are

alteration occurrence, potassium, sodium, copper, gold and sulphur. These clusters only
come to constitute domains with geometallurgical validity if each of them present
robustness in terms of spatial continuity, which was checked after completing each of the
eleven iterations mentioned above.

The final stage was driven by the criteria of getting the subset of samples selected
from each domain, to represent the variability of the total population of samples for key
variables in addition of getting a number of samples of each domain to honour the tonnage
distribution per domain, as part of the total tonnage of the six year period of the mine plan.
A by-product type of result was obtained from the Principal Component analysis, in the
sense that there exists total consistency of the geological logging of the alteration in spite
the fact that there have been two companies owning the project while having had different
teams of geologists capturing data.

The follow up for this study allows the Gramalote team to incorporate new sources
of data, such as analytical mineralogical results, to update and upgrade the obtained results.


GM19

THE COLLAHUASIS FLOTATION GEOMETALLURGICAL MODELLING FOR
PROCESS OPTIMIZATION AND MINING PLANNING

C.J. Suazo
a
, C.Muoz
a
, N. Mora
a
, A. Hofmann
a

Compaia Minera Doa Ins de Collahuasi SCM
cjsuazo@collahuasi.cl

ABSTRACT

Compaa Minera Doa Ins de Collahuasi SCM has developed a geometallurgical
modelling to simulate and optimize a flotation circuit. The objective was to characterize the
Rosario deposit in terms of flotation performance. The flotation model allows predicting
the recoveries and concentrate grades of a flotation circuit and predicting the copper
production for short-mid and long term planning.
This work presents a novel approach to scaling up the flotation results from
laboratory to industrial scale using the air dispersion properties. The model is based on well
known works developed by several authors and allow predicting the flotation rate constant
at industrial scale as a function of air dispersion properties, the complete feed particle size
distribution and geometallurgical unit.
A Collahuasis simulation software that uses the flotation geometallurgical
modelling is also presented. The software allows simulating and optimizing a flotation
circuit.
The model was tested at laboratory scale achieving a quadratic correlation
coefficient equal to 0.94. In addition, it has been sucessfully test at industrial scale for
short-mid and long term mining planning.


GM20

GEOMETALLURGICAL MODEL OF SAG MILLING AT MINERA ESPERANZA

J. Vargas, C. Lozano and C. Bisso
MINERA ESPERANZA
Apoquindo 4001, piso 13, Las Condes.
Santiago, Chile
javier.vargas@mineraesperanza.cl
clozano@mineraesperanza.cl
cbisso@mineraesperanza.cl

ABSTRACT

This paper summarizes the activities performed to predict SAG milling throughput
at Minera Esperanza.
Having highly reliable geometallurgical models aided by the new computer tools
and specific metallurgical testing to rely on has become a major issue in recent times due to
their impact on the business.
Minera Esperanzas SAG throughput model was constructed by characterizing the
ore feed and operational parameters of the plant. Producing a robust model required
satisfying number of requirements for the parameters used for both the ore and the plant
as follow: 1) geologic and geometallurgical characterization parameters; and 2) parameters
of a plant running at the rated production under optimum operating conditions.
Obtaining these parameters required increasing the quantity of samples and metallurgical
testing through drilling campaigns, mapping the drill holes and putting samples through
various comminution tests while sampling all operational flows at the plant to obtain the
metallurgical information for the operational parameters.
The information was entered on the JKSimMet software to enable a throughput
model to be developed to output SAG mill throughput predictions that are very close to
actual throughput figures, i.e., accurate within a range of 2% on a monthly basis.


GM21

GEOMETALLURGY STANDARDIZATION WITHIN AMSA

S. Gonzlez C.
VPP. Antofagasta Minerals (AMSA)
4001 Apoquindo Av, Las Condes
Santiago, CHILE 7550162
sgonzalez@aminerals.cl

ABSTRACT

Large scale of operations and expansions to existing operations is the logical response
to optimizing the value of very large, low grade ore bodies. However, new projects and
mature existing operations frequently have increased geometallurgical complexity.
Therefore, improving the predictability of key mining and metallurgical variables is one of
the biggest challenges to maximizing the value of mining assets.

In that context, Antofagasta Minerals (AMSA) is in the process of standardizing the
mining base for its deposits. For this purpose, AMSA geo sciences related teams have
begun to standardize practices and protocols in terms of geo metallurgy, both for Projects
and Operations.

In the first stage, a Geometallurgy status evaluation has been performed in Operations
and Projects, findings gaps and identifying improvement opportunities.

In order to establish common standards, methodologies, procedures, protocols and
criteria have been proposed to align the mining base parameters and its characterization,
consistent with the state of the art facilitating the use of these common standards within
AMSA.

Later, it is going to be diffused bottom up and top down within the Organization.


GM22

FUNDAMENTALS OF IN SITU UNDERGROUND MINING

R. Castro, C.Bahamndez and T. Vargas
Advanced Mining Technology Center (AMTC) - Universidad de Chile
Tupper 2069
Santiago, Chile
rcastro@ing.uchile.cl

ABSTRACT

Traditional mining involves several processes including the removal and extraction
of blasted or caved rock, size reduction through comminution process and processing of the
ore and the subsequent storage of residues on the surface. On the other hand the in situ
leaching method involves the recovery of metals, such as copper, from a pregnant leach
solution, which is obtained after the contact between the leaching solution and the ore. In
situ leaching is the application of leaching solutions to unperturbed or fragmented rock. In
situ leaching of unperturbed rock has been successfully applied to the uranium mining
industry
(1)
. In the case of copper, attempts to leach remnants from the caved rock have been
relatively successful
(2)
.

This paper aims to illustrate a new mining method that integrates in situ leaching
and conventional underground mining in a novel way. Such a method allows for the
recovery of metals from deposits that could not otherwise be extracted using traditional
mining. The following research shows a framework for establishing the fundamentals of in
situ mining through an experimental program to determine copper recovery as a function of
mining variables using a physical model.


GM23

TOWARDS A STANDARDIZATION OF THE SULFURIC ACID SOLUBLE
COPPER ASSAY

Edmundo Martnez D.
VPRM Antofagasta Minerals S.A.
4001 Apoquindo Av. - Las Condes
emartinez@aminerals.cl

ABSTRACT

The sulfuric acid soluble copper assay corresponds to an analytical methodology
widely used in the mining industry for quantifying the grade of potentially leachable copper
ores.

However, does not exist a rigorous standardization of the technique regarding with
sample mass, acid concentration, stirring rate, temperature and leach time. This makes
difficult the comparison of analytical results for the same ore.

It is studied the kinetics of leaching in sulfuric acid for a number of common copper
minerals (krhnkite, atacamite, antlerite, brochantite, malachite, chrysocolla, copper pitch,
copper wad, chalcocite, covellite, bornite and chalcopyrite), as a function on the
aforementioned variables.

From this result, we propose a general standard methodology that minimizes the
variability of analytical results.


GM24

METHODOLOGY OF DEVELOPMENT OF CONCEPTUAL
GEOMETALLURGICAL MODELS FOR CU MINING PROJECTS, IN EARLY
STAGES

X. Rubio P.
VPRM. Antofagasta Minerals (AMSA)
4001 Apoquindo Av, Las Condes
xrubio@aminerals.cl

ABSTRACT

The development of conceptual geometallurgical models, based on the information
analysis and exploratory metallurgical testing laboratorys scale, add value to the geological
model and it is an important tool for geo-mining-metallurgical evaluation for projects in
early stages.

Hereby a works guide for the development of geometallurgical conceptual models
based on: geological models, chemical and geological drilling information and standard
metallurgical testing laboratorys scale.

The proposed methodology is applied on types sections, adding to the data of drilling,
chemical analysis and mineralogical studies, oriented to process. The collection of this
information is analyzed statistically to determine on site metallurgical response according
to: geological variables control, distribution in relation to geological units, sections and
projection on site.

The result is the definition of preliminary UGM, modeling in sections and, finally, a
program of exploratory metallurgical testing for validation of the UGM and quantification
of the metallurgical response. The extension of this process to other sections allows
generating 3D models of these units and application of averages by UGM to blocks model.


Additionally geological parameters, relevant to process necessary to incorporate to
the mapping, are recognized.


GM25

WATER/ROCK INTERACTIONS AND PHYSICOCHEMICAL CONTROLS ON
MINERAL PROCESSING IN FLOTATION CELLS: BEING PREDICTIVE BASED
ON GEOLOGY

Pia Lois, Brian Townley, Willy Kracht, Julian Ortiz

ABSTRACT

Rocks are formed by diverse geological processes, igneous, metamorphic,
sedimentary, and hydrothermal, among others, formed under specific thermodynamic and
physicochemical conditions. In hydrothermal ore deposits, different types of hydrothermal
environments are recognized, formed by specific mineral associations crystallized in
equilibrium from hydrothermal fluids. Hydrothermal mineral associations and minerals in
general, when in contact with water, tend to equilibrium, generating physicochemical
buffering conditions, in particular pH, Eh and chemical composition.
In mineral processing rocks are grinded in presence of water. Grinding elevates
temperature of rock enhancing water/rock reactions that affect physicochemical conditions
of process. In flotation cells the proper function of chemicals is much dependant on pH, Eh,
and chemical composition, as well as proportion of clay minerals, which inhibit proper
recovery of copper sulfides.
To understand the effects of gangue mineralogy on the flotation process, theoretical
reactive flow models have been applied to different mineral associations typical of
porphyry copper systems. The objectives of these initial studies are to determine how
detailed geological modeling of alteration and mineralization minerals in an ore deposit
may assist mineral behavior predictive models, in assistance of mine planning for
optimization of metallurgical processing.


GM26

ANTUCOYA PROJECT: LOW GRADE COPPER ORE TREATMENT

Jos Aldana F.
Minera Antucoya
Apoquindo4001, 18
th
Floor
7550162, Las Condes
Santiago, Chile
jaldana@antucoya.cl

Pablo Schmidt
Antofagasta Minerals S.A.
Apoquindo4001, 18
th
Floor
7550162, Las Condes
Santiago, Chile
pschmidt@aminerals.cl

ABSTRACT

This paper presents the development of the metallurgical process of the Antucoya
project, through the development of a set of column scale test, pilot plant and industrial test
using raw sea water.

The Antucoya mine is a porphyry copper deposit, with oxidized minerals at the top
and primary sulfides of low grade in depth. The project considers the extraction of ore
through a conventional open-pit operation. The deposit has reserves approximate 700
million tons of ore with an average copper grade of 0.35% at a cut-off grade of 0.2%. The
leach solution produced by the process of acid leaching is treated in a solvent extraction
and electro-winning plant to produce high purity copper cathodes at a rate of 80,000 t/year.
During the years 2010 2011 Antofagasta Minerals S.A. (AMSA) developed several
campaigns of metallurgical characterization and leach testing with Antucoya ore. The bulk
of the metallurgical information used in the feasibility study comes from columns test using
PQ drilling samples and "Industrial test" with a bulk sample from the deposit and processed
in the leaching facilities of Minera Michilla located 45 km away from Antucoya. From

those tests the copper recovery of and acid consumption parameters of the different
metallurgical units of the deposit were generated, which were subsequently used for the
mining blocks model for planning. In the year 2012, Minera Antucoya carried out
campaigns of complementary metallurgical testing using samples with high presence of
carbonate to support better the feasibility study.


GM27

OPPORTUNITIES FOR AN INDUSTRY CONSTRAINED BY INFRASTRUCTURE

D.C. Curry and A.C. Keith
Aurecon
Level 1, Septimus Roe Square, 256 Adelaide Tce
Perth, Western Australia, 6000, Australia
dan.curry@aurecongroup.com

D. Way and B. Wong
JKTech
40 Isles Road
Indooroopilly, Queensland, 4068, Australia

ABSTRACT

The South American copper industry is facing infrastructure constraints in two major
ways; the cost and lead time of new or expanded facilities and insufficient supply of
electrical power. Infrastructure now represents over 75% of a green field projects capital
cost having increased from around 50% a decade ago. The demand for electrical power
continues to increase in proportion to copper output; however investment in power
generation lags behind the potential copper production growth rate.

Opportunities exist to overcome local power constraints. Learnings from the
aggressive expansion of South Africas platinum industry last decade can be applied to the
South American copper industry. Platinum production in one company was doubled with
only a small increase in total power consumption by assessing the complete mine to metal
supply chain.

Now infrastructure is the largest project cost it seems logical to include it in the
geometallurgy design or optimisation phase. i-GeoMet
TM
does exactly this with the aim of
building smaller and staged infrastructure optimised to each specific mining project. An
Australian sulphide mining and processing case study illustrates the technical, financial and
schedule benefits of using this approach.


GM28

GEOMETALLURGICAL MODEL AND METALLURGICAL TESTING FOR A
SOUND CONCENTRATION PLANT DESIGN

Vernica Escobar*
Jacobs, Chile

Cristian Jara
MetricArts, Chile

ABSTRACT

The design of a copper concentration plant needs to have a sound geometallurgical
and metallurgical test program that includes laboratory and pilot plant test.
Geometallurgical models are important in the design of sulphide concentration plant in
greenfield and brownfield projects, as well as in the operation of the same ones.
The purpose of this paper is to explain and provide a methodology to develop a
geometallurgical model for copper concentration and have sound design parameters. This
modeling is based on the analysis of the geological information commonly acquire for the
geological model, metallurgical testing information, and statistical analysis. The stages to
carry out the modeling are as follows:
1. Geological information of ore
2. Laboratory and pilot plant tests
3. Exploratory data analysis
4. Geometallurgical model
5. block model of the deposit with the estimation of parameters
6. Incorporate these values and analysis in the plant design criteria
The end result of this process is a geometallurgical model incorporated in the three-
dimensional block model, allowing the estimate of the copper recovery and hardness with a
good precision. This geometallurgical model toghether with the metallurgical test program
will be the bases for the determination of the design parameters.

GM29

GEOMETALURGICAL MODEL FOR OXIDE HEAP LEACHING

Vernica Escobar*
Jacobs, Chile

Julio Escrate
Codelco Divisin RT, Chile

Cristian Jara
MetricArts, Chile

ABSTRACT

Heap leaching is a simple, low-cost method of recovering metals from low grade
ores, which has come into widespread application in the mining industry and widely used.
To estimate sound metallurgical parameters: recovery of copper and acid consumption, a
geometallurgical model is required to be developed. The best way is incorporate a large
amount of information with a wide spatial distribution in the resource as it is the chemical
analysis of drill and blast hole.
The aim of this paper is to present a methodology to develop a geometallurgical
model for heap leaching of copper oxides ores. This modeling is based on the geological
information and chemical analysis of core drilling and blast hole, laboratory and pilot plant
testing, exploratory data analysis for developing the copper extraction and acid
consumption geometallurgical models.
The end result is a geometallurgical model incorporated in the three-dimensional
block model, allowing estimating the copper recovery and acid consumption. The
validation of this methodology is carried out with the incorporation of operational
information of the processing of the ore. This modeling should be used in short, medium
and long term planning.


GM30

APPLICATION OF A GEOMETALLURGICAL MODEL TO A STRATA-BOUND
DEPOSIT

J. M. DELGADO VEGA
Professor, Mining Department,
University of Antofagasta
Jaime Guzmn Av., n/n, Antofagasta, Chile
jdelgado@uantof.cl

M. Jean-Alain FLEURISSON,
Maitre de Recherche, MINES ParisTech

ABSTRACT

The present work describes a methodology for the analysis and modeling of
geometallurgical units. The development of this study was based on exploration data
mainly collected in the course of reverse circulation campaigns and previously mined areas
found in strata-bound deposits located in northern Chile.

From a methodology perspective, this study has been designed in several stages.
The first of these stages points out where these units would be used in a long-term plan
scenario by seeking proximity to reality and focusing the efforts on the modelization of its
units to later on incorporate this modelization into a long-term planning. Each of the
selected variables has been determined by both linear and non-linear geostatistical methods.
(se busca una aproximacin a la realidad ,centrando el esfuerzo en la modelizacin de sus
unidades e incorporarla a una planificacin a largo plazo. Cada una de las variables
seleccionadas se han estimado por mtodos geoestadsticos lineales como no lineales.
Finally, the results have been merged into a spatial block model applicable to the
mine planning stage.

GM31

REDUCING PRODUCTION VARIABILITY IN SHORT TERM SCHEDULING A
PRACTICAL APPROACH

Edgardo Madariaga G., junior engineer, emadariaga@redcoglobal.com.
Mara Grigaliunas G., junior engineer, mcgrigaliunas@redcoglobal.com.
Sebastian Troncoso B., chief engineer, stroncoso@redcoglobal.com.
REDCO Mining Consultants.
Av. La Dehesa 181 of. 208, Lo Barnechea, Chile.
Phone: +56-2-23769840

ABSTRACT
One of the main task during the short-term scheduling process is to generate the
extraction sequence inside each bench. This sequence represent a feasible mining scenario
and when is combined with cut-off grades and mining and processing capacities, constitutes
a production schedule that represent the expected operational outcomes in terms of
tonnages and grades. Normally, this sequence is constructed over a deterministic block
model and is focused in to obtain the larger possible amount of copper fines, considering
that in a short-term scenario, mining and process capacities are fixed. Moreover, is not
unfrequented to see that short-terms schedule tries to reach metal production promised in
Budget, so the searching for the sequence that reach the desired metal production left little
room to face any kind of variability during the actual mining process. Despite the expertise
of the mine planner, that maybe could reduce to a minimum the chance that operations
cannot follow the timing of the mining sequence, the natural uncertainty of the ore body (in
terms of grades, hardness and any other relevant variable) still could jeopardize the
obtention of the desired outcomes.
This work proposes an empiric and practical approach to select a short-term mining
sequence balancing the expected fine metal production and its associated uncertainty, so the
mine planner can take a more informed decision about what mining sequence should be
follow in order to limit the outcomes variability.

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SYMPOSIUM: 01 ECONOMICS AND MARKETS

AUSMELT TSL COPPER

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