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First Extractive Metallurgy Proceedings Operators' Conference 7 - 8 November 2005 Brisbane, Australia O The Australasian lnstitute of Mining and Metallurgy 2005 All papers published in this volume were peer reviewed prior to publication. The lnstitute is not responsible as a body for the facts and opinions advanced in any of its publications. ISBN 1 920806 39 3 Desktop published by: Kristy Burt and Angie Spry for The Australasian lnstitute of Mining and Metallurgy Printed by: BPA Digital 11 Evons Street Burwood VIC 3125 Foreword On behalf of the Southern Queensland Branch of The AusIMM welcome to the First AusIMM Extractive Metallurgy Operators' Conference. The conference is intended to complement the highly successful and popular AusIMM Mill Operators' and Underground Operators' Conference series, and become a regular feature on the conference calendar. The intention of the Conference is to provide a forum for extractive metallurgy operators to discuss and present experiences in dealing with real processing issues and their solutions. The three main aims of the Conference are: to exchange practical information to assist operators in improving their plant's day to day performance; to introduce new processing concepts and stimulate debate about how to improve the industry generally; and to review past performance on the implementation of projects from an operator's perspective with the aim of identifying what was done well and what needs to be done better in the future. All papers have been peer reviewed in accordance with The AusIMM guidelines to ensure the presentation and technical content is maintained at a high standard. We are confident that the conference volume will serve as a valuable source of information for those seeking to understand and to further improve plant performance. On behalf of the organising committee I would like to thank everyone who has contributed to the conference, particularly the authors, reviewers, sponsors, exhibitors, venue hosts and The AusIMM conference team. We hope you find the conference both enjoyable and technically stimulating, and look forward to meeting you all at the second conference in this series. Peter Hayes and Conference Organising Committee Contents Keynote Addresses EducationandDevelopmentofExpertisefortheResourcesIndustry CSartain 3 DialogueWiththeDarkSide—GeologistsandMinersArePeopleToo TJNapier-Munn 5 Leaching and Solvent Extraction PilotStudiesoftheRavensthorpeNickelProject’sPressureAcidLeach DWhiteandMMiller 9 SlurryHeater DesignandCommissioningoftheSeponCopperPressureOxidation RSherrit,AGPavlidesand 21 Circuit BLWeekes HydroCopper®—ANewMethodforTreatingCopperConcentrates LHaavanlammi,OHyvärinen 29 andEYllö ImplementationofaNewLeachingApproachfortheTreatmentofKCGM GDeschênes,SEllis, 35 GoldFlotationConcentrate JMcMullenandMHabner AnalysisofAgitationLeachingData—MethodsandInterpretation GMMiller 41 UraniumRecoveryFromHighlySalineInSituLeachSolutionsbyIon KSoldenhoffandJDavidson 47 Exchange TheUseofAuRIX®100ResinfortheSelectiveRecoveryofGoldand AHGray,THughesand 53 SilverFromCopper,GoldandSilverSolutions JAbols ImprovingPlantOperationsUsingSynergisticSolventExtraction CYCheng,KBBarnardand 59 TechnologyandOrganicMonitoring MDUrbani DecreasingOperatingCostsandSolubleLossinCopper GMMillerandANisbett 67 HydrometallurgyWithUseofInnovativeSolventExtractionCircuits PreciousMetalRecoveryViaElectrolysistoYieldaFilterableSludge COGaleandTWeldon 73 Smelting and Converting TheClyde-WorleyParsonsProposalforaFlashFurnaceFeedSystem MEReed,PACockburn, 81 RCWest,CUJones, BSnowdon,PEWalkerand RCSims SamplingandMeasurementsintheReactionShaftatOlympicDam FJorgensen,ACampbell, 87 RTaylorandBWashington ImprovingBlisterTappingatOlympicDam DJenkinsandACampbell 95 TheNewAngloPlatinumConvertingProject PViviersandKHines 101 ModellingofSlagBlowinCopperPeirce-SmithConverters PTanandPVix 109 ThermodynamicsofConvertingHigh-ImpurityCopperMatte MDevia,MCernaand 117 JRapkoch Peirce-SmithConverterMouthRedesignOverview NAyre 123 Process Improvement DesignConsiderationsforSmelterGasHandling PSearle,JRapkochand 131 MDevia ImprovementinAustralianBulkMinerals’IronOrePelletQualityand HPham,MDarby,FLovell 137 ProcessPerformance andBBurdett PreventionofScalingandCorrosionofTitaniumAlloyHeatExchanger RWAllan 143 TubesattheRisdonElectrolyticZincRefinery PipelineDesignCharacteristicsofSomeIndustrialPaste-LikeSlurries GRAddie,MRCarstens, 147 ASellgren,RVisintainerand LWhitlock Plant Support Commissioning—TheInterfaceBetweenConstructionandOperations BBailey 155 AlkaliEmissionReductionandMeasurementatQueenslandAlumina TLeongandTConnor 163 Limited(QAL) ControlSystemImprovementThroughAlarmReduction CWebsterandRWest 171 ProcessInformationManagementSystematMountIsa PMuza 179 Education and Development of Expertise for the Resources Industry 1 C Sartain ABSTRACT The resources industry in Australia is currently facing a skills shortage that has seen vacancies for skilled tradespeople such as electricians (Australian Government, 2004), and for industry-specific professionals such as mining engineers and metallurgists, go unfilled. For example, research suggests that the industry can only source about 70 per cent of new metallurgists needed throughout Australia annually (JEEMI, 2005). Likewise, the national demand for graduates in mining engineering is also outstripping the national supply (JEEMI, 2005). In his address to The AusIMM’s First Extractive Metallurgy Operators’ Conference, Xstrata Copper’s Chief Executive, Charlie Sartain, will discuss solutions to the skills shortage being pursued by the resources industry, government, educational institutions and companies such as the global resources group Xstrata. Charlie will explain why partnerships between industry, government and educational institutions are the key to successfully addressing the skills shortage. Ideally, these partnerships should be pursued on two levels. The first is at a state-wide and national level. The second, is at an inter-personal and site level, whereby resources company employees, teachers, trainers and others work together to establish and promote pathways for young people to enter the industry and encourage an enthusiasm for careers in the resources industry. Some of the skills and training initiatives Charlie will discuss are Xstrata’s school-based workplace training program, the Queensland Minerals and Energy Academy, the Queensland Resources Council’s Different Directions careers initiative, Xstrata’s apprentice training scheme, the Minerals Council of Australia’s Minerals Tertiary Education Council initiatives and Xstrata’s co-funding of the Xstrata Chair of Metallurgical Engineering at the University of Queensland. REFERENCES Australian Government, 2004. National Skills Shortage List 2004 [online]. Available from: <http://www.workplace.gov.au/workplace/Category/Publications/LabourMarketAnalysis/NationalSkillsShortage List2004.htm>. AustralianGovernmentDepartmentofEducationScienceandTraining,ChamberofMineralsandEnergyWestern Australia,MineralsCouncilofAustralia,NationalInstituteofLabourStudiesFlindersUniversity,NCVER,2005. Prospecting for Skills: The Current and Future Skill Needs in the Minerals Sector,NCVER, Adelaide. JEEMI, Joint Industry/University of Queensland Taskforce, 2005. Engineering Education for the Minerals Industry,Brisbane. 1. Chief Executive, Xstrata Copper, Level 9, Riverside Centre, 123 Eagle Street, Brisbane Qld 4001. First Extractive Metallurgy Operators’ Conference Brisbane, QLD, 7 - 8 November 2005 3 Dialogue With the Dark Side — Geologists and Miners Are People Too 1 T J Napier-Munn ABSTRACT We all live in professional silos – comfort zones, where we talk to like-minded people with the same training, experience and view of the world. We note in passing the existence of other disciplines, but they are tolerated rather than embraced. To the geologist, the metallurgist is a mad scientist conjuring gold out of some foul solution about which the less said the better. To the metallurgist, the geologist is a bearded, self-appointed sage who guesses what is under our feet by sniffing the air, and drives a Land Rover badly. As to the view of mining engineers held by both geologists and metallurgists, this is best left to the imagination. And of course we are all confused bytheterm‘metallurgist’.Iamcalledametallurgistthoughmyskillsareinmineralprocessingnot metal processing, but I can’t be called a mineralogist because that definition is already taken. This presentation considers the differentiation of the professions, and why it is a good idea to breakdowntheprofessionalsilos.Itconcentratesontheminesite,buttheprinciplesareapplicable to the whole value chain including smelting and refining. The planning and operation of the modern, complex, capital-intensive mine, refinery or smelter needs the professions to work together to meet the expectations of shareholders and the wider community.Sustainability isthekeytosuccess,andthisneedsasophisticated, integratedapproach to managing the operation on the mine site. However, our universities still train our industry’s professionals in silos, and the graduate’s early career structure generally does little to break down these work barriers or professional prejudices. And the cost to our industry is massive. About 12 yearsago, agroup of ‘metallurgists’atthe Julius Kruttschnitt Mineral ResearchCentre (JKMRC) in Brisbane was discussing the potential for improving the throughput of large autogenous and semi-autogenous (SAG) mills by feeding them with the right size distribution of rocks(itturns out thatsizeiseverything inthisbusiness).Sincetheyweremetallurgists,theirview was that the game is won or lost in the process plant; that’s where the value recovery and product grade are achieved, and where the deficiencies of their geological and mining colleagues are rectified. The solution clearly lay in persuading the mining engineers to create the right ROM size in the first place. This, however, wasconsidered to be impossible because, well, it involved mining engineers doing something smart. And, most telling, ‘miners never talk to mets on these mine sites’. Then someone pointed out that neither did we, at the JK Centre. The JK is an unusual R&D organisation in that it does work on both mining and mineral processing under one roof. Of course we had followed the usual practice and put the miners and processors in different offices. But in principle we could talk to each other. We just didn’t. This was a profound discovery with a profound outcome. Before long we realised that the two disciplines had much to learn from each other. The SAG mill discussion had arisen from a project with an iron ore company to develop a method of predicting the particle size distribution from small-scale winze blasting as an alternative to wide diameter drilling, for mine planning purposes. The ultimate objective was to predict the particle size of the saleable lump and fine products producedbythecrushingandscreeningplantsfromorefromdifferentpartsofthemine.Thiswork led to the establishment of the highly successful AMIRA P483 ‘Mine-to-Mill®’project, which ran for six yearsand in due course won The AusIMM Operating Techniques Award. P483 developed a suite of tools for predicting and controlling fragmentation in blasting to optimise the comminution performance of the processing plant. Other projects with individual mining companies extended the capabilities of the methodology, until after ten years, getting the mine to produce the right 1. FAusIMM, Manager Project Development, Sustainable Minerals Institute, The University of Queensland. Email: [email protected] Previously: Director, Julius Kruttschnitt Mineral Research Centre, University of Queensland. First Extractive Metallurgy Operators’ Conference Brisbane, QLD, 7 - 8 November 2005 5 T J NAPIER-MUNN ROM size was not only possible but being achieved in many operations. The quantified benefits were often huge: 20 per cent increases in plant throughput for minimal, if any, capital expenditure were not unusual. Of course the truth was that some operations had been cleverly and effectively practising Mine-to-Mill® for years. It just wasn’t called that, and, more importantly, until the sustained R&D was done there was no systematic methodology available to capture and implement the basic idea. Like all the best ideas, it was simple. As Figure 1 shows, the key was ore characterisation, modelling, prediction, andimplementation. IMPLEMENT VALIDATE ROCKSAMPLES YES Comminution CHARACTERISE NO DESIRED Blasting RESULT? 100 ROMSize 80 ADJUST 60 SIMULATEPLANT 40 VARIABLES 20 0 1 10 100 1000 Simulate CHARACTERISE ROCKMASS BLASTDESIGN FIG1 - The Mine-to-Mill®methodology. In recent years it has become apparent that this simple idea is capable of extension to attributes other than fragmentation (and indeed grade, the rather limited property commonly used in mine planning). Some mining companies have begun incorporating other attributes into their planning, and some methodologies have been developed by others to assist in this process. Recent feasibility studies undertaken by the JKMRC, with support from the University of Queensland’s Sustainable Minerals Institute, have confirmed that grindability and texture are useful attributes in this regard. Andwhilethiswasgoing on, our colleaguesatCODES(theCentreforOreDepositStudies) atthe University of Tasmania were thinking along similar, though inevitably geological, lines. The result has been a meeting of the minds of extraordinary fecundity and, one has to say, pleasure. And thus has come to pass GEMIII – Geometallurgical Mapping and Mine Modeling, aka AMIRA Project P843 – supported by 12 international mining companies and the ARC. GEMIII is in every sense a natural evolution of Mine-to-Mill®. As did its predecessor, it exploits careful ore characterisation and classification to achieve large process improvements and thus increased profits. However, it is more ambitious and wide-ranging, and its potential impact on the industry will be correspondingly large. Most importantly, it deliberately sets out to bring together the threeminesiteprofessions – geology,mining and metallurgy – in asynergistic partnership that exploits the skills and passions of each for mutual benefit. In particular, it proposes to join the geologist’s skill in classification with the metallurgist’s need to know the characteristics of the plant feedstock. This leads to the radical idea of the mineral ‘factory’in which the emphasis is on achieving consistency and certainty – ‘no surprises’ – which any metallurgist will tell you is the prerequisite for optimal process performance. But it can’t be done without whole-hearted collaboration between geologists, miners and metallurgists, and a shared bag of tools. 6 Brisbane, QLD, 7 - 8 November 2005 First Extractive Metallurgy Operators’ Conference Pilot Studies of the Ravensthorpe Nickel Project’s Pressure Acid Leach Slurry Heater 1 2 D White and M Miller ABSTRACT The processing route consists of mining, beneficiation, pressure acid leaching, atmospheric leaching, neutralisation and Operators of nickel laterite pressure acid leach and gold pressure purification, residue washing and metals precipitation. The oxidation technology frequently employ a series of steam condensing general hydrometallurgical flow sheet is shown in Figure 1. heaters to preheat the leach feed slurry. The heaters are an economic pinchpoint–althoughthethermalperformanceoftheheatersiscritical tooverallprocessviabilityandoperatingcostminimisation,theyarealso a significant capital item and must be sized accordingly. Despite this, LimoniteBeneficiation SaproliteBeneficiation discussions of the factors underlying heater design are conspicuously absent from technical literature, and existing operations feature a conflictingrangeofheatersizes andconfigurations.Thisvarietywould PressureAcidLeach Acid Pre-Leach suggest that at least some of the chosen heater designs are oversized. As partofits detaileddesignstage, the RavensthorpeNickel Project (RNP) constructed and tested a pilot plant heater to develop an AtmosphericLeach understandingoftheheatingprocessandtoensurethattheRNPheaters were appropriately sized. This testwork used RNP slurry at design density and viscosity on a 450 mm diameter, 6500 mm high column. InducedJarosite Precipitation The pilot plant testwork demonstrated the intrinsic efficiency of the direct steam condensation heating process, which was essentially Limestone PrimaryNeutralisation independentofslurrydensityandviscosity.Presenceofnon-condensable gases in the steam phase decreased the heat transferred in certain circumstances, but heater performance remained consistent with CCD's TailingsStorage thermodynamic limitations. Stagewise heat transfer within the column was rapid, and suggested eitheraveryhighslurrysurfaceareaorexcellentheattransferwithinthe Secondary Neutralisation slurryphase.While the testworkdidnotset outto distinguishbetween these effects, physical evidence pointed to droplet formation in the inter-tray shower zone, giving a high heat transfer area. MgO MiPxeredcHipyidtartoioxnide Filtration&Despatch Forscale-uppurposes,thekeyfactswerethattheheattransferratewas notlimitedbyusinghighviscosityslurriesandheaterscouldbedesigned using the principles applied to the smaller of those in existing operations. Lime PSreccaivpeitnagtieorn This paper discusses existing slurry heater designs, the current understandingfromopenliterature,thepilotplanttestwork,resultsand analysis, and scale-up to commercial sized equipment. ManganeseRemoval TailingsStorage INTRODUCTION FIG1 - Simplified RNP flow sheet diagram. Project background Pressure acid leaching Ravensthorpe Nickel Operations Pty Ltd (RNO) is developing the Ravensthorpe Nickel Project in the south coast region of Pressure acid leaching (PAL) is a critical process step of the WesternAustralia,approximately550kmsouth-eastofPerthand RavensthorpeNickelProject.Itisthemajorconsumerofsulfuric 155 km west of Esperance. RNO is 100 per cent owned by acid and high pressure process steam, and operates at the most Queensland Nickel (QNI), a wholly-owned subsidiary of BHP extreme combination of temperature, pressure and corrosive Billiton. conditionsontheproject.Toachievethis,theequipmentutilised At full production, RNP will produce a nominal 50 000 tpa on the two PAL trains at Ravensthorpe is capital intensive, nickel and 1400 tpa cobalt contained in a Mixed Hydroxide consistingofbrick-linedandtitaniumvessels,titaniumpiping,as Precipitate (MHP) intermediate, most of which is to be shipped well as severe service valves and pumps. to QNI’s refinery at Yabulu, near Townsville, Queensland, for Leaching iscarried outat250ºCandanoperating pressureof finalprocessingtorefinedmarketproducts.TheYabulurefinery approximately 4500 kPag, not primarily for extraction of nickel is to be expanded to accommodate the additional nickel inputs, and cobalt, but for impurity rejection. Iron, aluminium and which will take the site nickel production to 76 000 tpa. chromiumleachandlargelyreprecipitate.Atlowertemperatures The Ravensthorpe project orebody primarily consists of three these elements would stay in solution increasing acid separate laterite deposits with measured and indicated resources consumption. Thus, the elegance of the PAL process lies in it of275Mtat0.66percentNiatacut-offgradeof0.30percentNi. combining the three functions of leaching, impurity rejection, and acid recovery in a single process step. 1. MAusIMM,PrincipalProcessEngineer,BHPBilliton,Ravensthorpe Theonlysignificantexothermicreactionsarethoseassociated Nickel Project, PO Box Z5051, Perth WA 6831. with dilution of sulfuric acid in the leach. In order to reach Email: [email protected] target reaction temperature, additional energy in the form of steam, is added to the slurry. At the first PAL operating plant, 2. MAusIMM, Senior Process Engineer, BHP Billiton, Ravensthorpe Nickel Project, PO Box Z5051, Perth WA 6831. at Moa Bay, most steam is added directly to the Autoclave Email: [email protected] (Carlson and Simons, 1961). This is intrinsically energy First Extractive Metallurgy Operators’ Conference Brisbane, QLD, 7 - 8 November 2005 9 D WHITEand M MILLER intensive. An alternative technique, used in some gold pressure slurry feed temperature is less than its design target, the energy autoclaves and in more recent PAL operations, is to capture the shortfallhastobemetbyadditionalhigh-pressuresteam,withan steam released from the slurry letdown stages and contact this obviousimpactontheplantenergybalanceandoperatingcosts. directly with cold incoming slurry ahead of the autoclave. The Failuretooperatetheautoclaveatdesigntemperaturecanaffect vessels where this slurry-steam contact is made are known as the process by increasing the acid consumption, reducing the leach kinetics or leach efficiency, or adversely affecting the heatersorcondensers.AdiagramofatypicalPALtrainisshown settling characteristics of the leach residue. in Figure 2. Historical context ToGas Scrubbing Directcontactcondensershavebeeninusesinceindustrialscale steamengineswereinventednearly300yearsago(BCLM,2005; HP Csele, 2004). These evolved to the high capacity barometric Heater HP condensers in modern industrial use. Interestingly, although a Flash LP Vessel number of design configurations have been utilised, little Heater information exists on heat transfer rates and even standards for barometric condensers (HEI, 1995) have no information on Steam sizing for thermal performance. Acid LPFlash Whereheattransferrateshavebeendetermined(How,1956)it Vessel is by reverse engineering from operating equipment, where nozzle placement and size appear to be the main drivers of equipment size. Slurry Feed Autoclave NeutrTaolisation In the laterite nickel industry, direct contact heaters were installed on the Tailings Stills at Nicaro, Cuba in 1944 (Boldt, HPHeater Autoclave 1967). Beaverlodge Uranium, Canada, which commenced FeedPump FeedPump operations in 1954, included pressure leaching with vacuum FIG2 - Schematic of a typical PAL autoclave train. flashing and direct contact splash heaters (Mancantelli and Woodward, 1955). The first pressure acid leach operation, at Moa Bay, Cuba commissioned in 1959, uses direct contact The role of the heaters heaters with a packing ‘fabricated of expanded metal lath’ to cope with the ‘extremely high effective viscosity’(Carlson and Heatersarecounter-currentflowdevices,inwhichflashsteamis Simons, 1961). injected at the bottom of a column against a falling stream of slurry, which is pumped into the top of the column. Heat and Gold pressure oxidation operations in North America have masstransferoccursimultaneouslyasthesteamiscondensedby made extensive use of ‘splash heaters’utilising flash steam for the cool slurry. preheating incoming slurry. There have been at least 16 leach trains in six operations built since 1985, with each train Heater designs include splash trays or disk and doughnut containing two or three heaters (Mason and Gulyas, 1999). arrangements to redistribute the slurry and improve the heat transfer (Houghland, Lemieux and Schreiner, 1954; Fair, 1993). In the late 1990s, three laterite PAL plants commenced More complex packing or bubble cap contacting methods are operation in Western Australia. These utilised the basic design generally avoided in slurry service because of the risk of principlesdevelopedfortheNorthAmericanPressureOxidation blockage and scaling. plants. Between two and four stages of direct contact heating Pressure from the autoclave discharge slurry is released were installed. The authors are aware that heater sizes varied through ceramic choke valves into a series of brick-lined flash significantlybetweentheseoperations,despitethroughputsbeing vessels.Each flash vessel is usually associated with a particular similar. As an example, heater diameters varied by a factor of heater andthereareusuallytwoormoreheaters inseriesahead two or more. The number of trays also varied, as did tray of the autoclave. The temperature profile along the heater train spacing.Inoneoperationanumberoftraysfelloutwithoutloss results in a corresponding pressure profile, and pumps are of performance. In another they were all removed and located after each heater to direct the slurry to the next heater performanceapparentlyimproved!Furtherinvestigationrevealed stage and finally to the autoclave vessel. thatsimilarsizedisparitiesexistbetweengoldpressureoxidation operations. Centrifugalpumpsareusedtopumpslurryfromoneheaterto the next, whereas the autoclave feed pumps consist of one or During development of the Ravensthorpe Project, it was more positive displacement pumps operating in parallel. The established that equipment size and capital cost, particularly positive displacement pumps are fitted with water-cooled aroundtheautoclaves,couldbeminimisediftheoreslurrysolids ‘drop-legs’toseparatethesensitivepolymerdiaphragmfromthe content was maximised. hot slurry. The drop-legs maintain an oscillating column of There was scepticism about the practicality of this in three cooled slurry, which transmits the pumping impulse to the hot areas: autoclave feed slurry. While the drop-legs protect the pump 1. pumping, diaphragm from heat degradation, the pump check valves are exposed to the full slurry temperature from the final heater. 2. slurry flow within heaters, and Degradation of the check valves places a ceiling on the temperatures the pump can handle, and thus on the final heater 3. heat transfer. discharge temperature. Typically, this is in the range 160ºC to AdvicewasreceivedfromRheologicalConsultingServicesat 200ºC, and represents the autoclave slurry feed temperature. the University of Melbourne that slurries with a yield stress in After dilution of sulfuric acid, the remainder of the heat excessof100Pacouldbepumpedwithconventionalcentrifugal necessary to bring the slurry to 250ºC is provided by high pumps.DiscussionswithWorsleyAlumina personnelconfirmed pressure steam injection. this, and that thickeners, particularly Deep Cone Thickeners, A major issue to consider in the heating process is efficiency couldproducehighrheologyslurries.Therheologicalproperties of heat transfer. If flash steam bypasses the slurry stream, this of the slurry used in the present work have been reported by energyislosttoatmosphere.If,asaconsequence,theautoclave McCrabb, Chin and Miller (2004). 10 Brisbane, QLD, 7 - 8 November 2005 First Extractive Metallurgy Operators’ Conference

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