THE STUDY ON ENVIRONMENTALLY-FRIENDLY OPERATION OF MINERAL PROCESSING PLANT USING BIOTECHNOLOGY IN THE REPUBLIC OF CHILE

Transcription

1 JAPAN INTERNATIONAL COOPERATION AGENCY (JICA) THE REPUBLIC OF CHILE MINISTERIO DE MINERIA EMPRESA NACIONAL DE MINERIA THE STUDY ON ENVIRONMENTALLY-FRIENDLY OPERATION OF MINERAL PROCESSING PLANT USING BIOTECHNOLOGY IN THE REPUBLIC OF CHILE FINAL REPORT DECEMBER, 2002 DOWA ENGINEERING CO., LTD. MITSUI MINERAL DEVELOPMENT ENGINEERING CO., LTD. MPN JR

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4 Position of Chile and Ovalle Plant La Serena Ovalle plant Santiago

5 Panoramic View at Ovalle Plant

6 Ovalle Plant (Sulphide Ore Process) Crude Ore Floatation Concentrate

7 Ovalle Plant (Oxide Ore Process) Crude Ore Agglomeration Precipitate

8 Pollution Situation around Ovalle Plant Upstream at Ovalle Plant Evaporation Pond and Bank Body Downstream at Ovalle Plant

9 Sample Collection Location of Environmental Examination

10 Basic Laboratory Tests Oxidizing Test Cake of Neutralized Sludge

11 Iron Oxidizing Bacteria Ovalle Strain Andacollo Strain

12 Model Plant Panoramic View

13 Demonstration Test Run Oxidizing Tank Neutralizing Tank Flocculation Tank Filter Press Bacteria Collector Dehydrate Cake

14 Waste Solution of Each Process and Dehydrate Cake Waste Solution, Oxidized Solution A, B, C, Top of Bacteria Collector, Neutralized Solution, Treated Solution Dehydrate Cake

15 Seminar The First Seminar The Second Seminar

16 Contents Purpose and Outline of the Study Mining Situation in Chile Outline of Mining Industry Environmental Related Organization and Regulations in Chile Outline of ENAMI Examination of Ovalle Production Plants Outline of Ovalle Plants Examination of Plant Operation Examination on Environmental Situation Technical Transfer of Iron Oxidizing Bacteria Method Basic Laboratory Tests Installation and Outline of the Model Plant Results of Demonstration Tests Present and Future of the Model Plant Instructing Subjects for Technology Transfer Design of Full Scale Solution Treatment Plant Prerequisites for Design Outline of Full Scale Plant Design Estimate of Installation and Operation Costs Economical and Financial Analysis for Waste Solution Treatment Background and Outline of the Project Procedure for Project Approval Market and Production Process Executing Program Financial Analysis Economic Analysis Economic Effects for the Third Party (Cu Precipitate Producers) Conclusion on Economical and Financial Analysis ANNEX Environmentally Friendly Operation Plan at Ovalle Plant Most Desirable Operation More Practicable Operation

17 7.3 Environmentally- Friendly Operation Program Possible Application of Bio-Technology in Chile (M/P) Outline of Bio-Technology in This Report Prerequisites for Application of Technology Possibility of Application Discussion on Possible Application Sites in Chile Summary of Possible Application of Bio-Technology in Chile Conclusion

18 Final Report Abbreviation collection and glossary Abbreviation and acronym 1. COCHILCO : Comisión Chilena del Cobre 2. CODELCO : Corporación Nacional del Cobre de Chile 3. CONAMA : Comisión Nacional del Medio Ambiente 4. COREMAS : Comisiones Regionales del Medio Ambiente 5. DCF : Discounted Cash Flow 6. ENAMI : Empresa Nacional de Minería 7. IRR : Internal Rate of Return 8. LME : London Metal Exchange Market 9. LME-spot : Spot transaction price in London Metal Exchange 10. MIDEPLAN : Ministerio de Planificación y Cooperación 11. NPV : Net Present Value 12. RCU : Rate of Capacity Utilization 13. SAG : Servicio Agrícola y Ganadero 14. SEIA : Sistema de Evaluación de Impacto Ambiental 15. SERNAGEOMIN : Servicio Nacional de Geología y Minería 16. SX-EW : Solvent Extraction-Electro winning Glossary < Processing technology term > 1. Mineral processing : The one to separate, and to gather only object mineral by using difference of physical characteristic of magnetic, grit between minerals, specific gravity, and interfacial wet abilities (hydrophobic property/hydrophilic), interfacial conductivity etc. There is technologies of the classification, the gravity concentration, the flotation, the magnetic concentration, and the electrostatic separation, etc. 2. Oxide ore : The ore which lies mineral which unites with oxygen is originally said. However, the ore which lies to minerals other than sulfides such as the hydroxide, the anglesite thing, the phosphate mineral, the carbonate, halides, and silicate minerals is said additionally in this report. In the copper minerals, chrysocolla (CuSio 3 nh 2 O) and malachite (CuCO 3 Cu(OH) 2 ), etc. correspond. 3. Sulphide ore : The ore which lies mineral which unites chiefly with sulfur (S) is said. In the copper ore thing, chalcopyrite(cufes 2 ), chalocite(cu 2 S), and covelline(cus), etc. correspond. 4. Precipitation (Cementation) process : It is the one in this report for the oxidation copper ore to produce Copper precipitate by the Crushing Agglomeration Leaching substitution precipitation. It is necessary to do the dry smelting and electrolysis refinements of Copper precipitate to produce electrolytic coppers.

19 5. SX-EW Solvent Extraction Electro Winning process : It is the one in this report for the oxidation copper ore and secondary sulphide copper ore to produce Electrolytic copper by Crushing Agglomeration Leaching solvent extraction electrolytic winning. 6. Unit consumption : Quantity of material per unit volume of concrete, for example, amount of consumption to ore 1ton 7. Primary sulphide copper ore : What generated during an origin rock formation action or mineralization is called a primary mineral. Copper pyrites etc. correspond in the copper minerals. 8. Secondary sulphide copper ore : After generating Primary sulphide copper ore, the secondary mineral generated by the action of the enrichment of Secondary sulphide copper ore etc. is said. Chalcocite and covelline, etc. correspond in the copper ore thing. 9. Flotation process : It is the one in this report for the chalocite ore to produce Copper concentrate by Crushing Grinding flotation. It is necessary to do the dry smelting and electrolysis refinements of Copper precipitate to produce electrolytic coppers. < Economic term > 10. External economy (benefit) : Economically gain for third parties of the project. 11. External diseconomy : Economically loss for third parties of the project. 12. Environmental liability : Accumulation pollution because of past pollution, payable by the causer. 13. Cash Cost : It is a cost balanced depreciation expense from the sales cost. 14. Net Present Value NPV : Future or past effective value adjusted to the present value using discount rate equivalent to capital cost. 15. Internal Rate of Return IRR : Discount rate that arises to cero the net present value of project cash flow. 16. Sunk cost : Cost into which amount of money does not change even if which solution is adopted. 17. Discounted Cash Flow DCF : Effective cash flow adjusted to present value discounting capital cost rate. Units 1. CH$ : Chilean pesos Currency of Chile 2. CH$/Ha : Chilean pesos / Hectare 3. CH$/mt : Chilean pesos / ton 4. CH$/US$ : Chilean pesos/ US$ 5. dmt : dry metric ton 6. dmt/month : dry metric ton / month 7. dmt/year : dry metric ton / year 8. fmt : Content metal ton

20 9. Ha : Hectare 10. mt : metric ton 11. mt/month : metric ton /month 12. mt/year : metric ton /year 13. US$/dmt : US$ / dry metric ton 14. US$/mt : US$ / metric ton

21 Contents of Figures and Tables FIGURES Mining Situation in Chile Figure 2-1 Major Mine Location in Chile 2-1 Figure 2-2 Recent Copper Production 2-2 Figure 2-3 Forms of Cu Products 2-2 Figure 2-4 Destination of Copper Export (2000) 2-3 Figure 2-5 Organization Chart of CONAMA and Related Institutions 2-5 Figure 2-6 Organization Chart of the Ministry of Mines 2-8 Figure 2-7 Organization Chart of ENAMI 2-9 Examination of Ovalle Production Plants Figure 3-1 Location of Facilities of Ovalle Plant 3-6 Figure 3-2 Block Diagram(outline) with Material Balance for Oxide Copper Ore in Ovalle Plant, ENAMI Figure 3-3 Block Diagram for Oxide Copper Ore: Ovalle Plant, ENAMI 3-22 Figure 3-4 Relation between RCU(Rate of Capacity Utilization) for Oxide Copper Ore 3-24 and Cu Metal Price Figure 3-5 Block Diagram(outline) with Material Balance for Sulfide Copper Ore in Ovalle Plant, ENAMI Figure 3-6 Block Diagram for Sulfide Copper Ore: Ovalle Plant, ENAMI 3-48 Figure 3-7 Relation between RCU(Rate of Capacity Utilization) for Sulfide Copper Ore 3-50 and Cu Metal Price Figure 3-8 Optimum Efficiency and Reduction of Cost in Grinding Section 3-51 to Obtain Necessary and Sufficient Liberation Particle Size Figure 3-9 Topographic Map 3-64 Figure3-10 M-1, M-2, M-3 Monitoring Point Analysis ('99 Dec '02 Feb) 3-70 Figure3-11 M-4, M-4A, M-4B Monitoring Point Analysis ('99 Dec '02 Feb) 3-71 Figure 3-12 M-5, M-6, M-7 Monitoring Point Analysis '99 Dec '02Feb 3-73 Figure3-13 M-1 M-5 Flux Volume of T-Fe, Cl, SO 4 ('99 Dec '02 Feb) 3-75 Technical Transfer of Iron Oxidizing Bacteria Method Figure 4-1 Basic Tests (1) - Change in Oxidation Rate of Fe Figure 4-2 Basic Tests (1) - Change in Fe 2 Concentration 4-4 Figure 4-3 Basic Tests (1) - Flow of Neutralization Tests 4-9 Figure 4-4 Change in Oxidation Rate of Fe Figure 4-5 Change in Fe 2+ Concentration 4-15 Figure 4-6 Process Flow of the Model Plant 4-16 Figure 4-7 Layout of Model plant 4-20

22 Figure 4-8 Fe 2+ and T-Fe Concentration of Feed Solution 4-23 Figure 4-9 Fe 2+ Concentration of the Oxidation Circuit 4-24 Figure 4-10 The Oxidation Rate of Fe 2+ in Each Oxidation Tank 4-24 Figure 4-11 Total Sediment Volume (m 3 /day) vs. Feed Solution 4-26 Figure 4-12 Total Sediment Volume (t-dry/day) vs. Feed Solution 4-27 Figure 4-13 Change of Moisture Content in Filtered Cake 4-27 Figure 4-14 Sediment with Calcium Carbonate vs. T-Fe in Oxidized Solution 4-28 Figure 4-15 Test Results with Treated Solution 4-29 Figure 4-16 Test Results with Oxidized Solution 4-30 Figure 4-17 Recent Analytical Data of the Waste Solution 4-33 Design of Full Scale Solution Treatment Plant Figure 5-1 Cu Metal Price vs. Monthly Ore Treatment 5-1 Figure 5-2 Process Flow of Fullscale Plant 5-3 Figure 5-3 Flowsheet of Fullscale Plant (Case1) 5-13 Figure 5-4 Plot Plan of Fullscale Plant (Case1) 5-14 Figure 5-5 Flowsheet of Fullscale Plant (Case2) 5-20 Figure 5-6 Plot Plan of Fullscale Plant (Case2) 5-21 Economical and Financial Analysis for Waste Solution Treatment Figure 6-1 Oxide Copper Ore Treatment Process at Ovalle Plant (Previous) 6-2 Figure 6-2 Oxide Copper Ore Treatment Process at Ovalle Plant (Actual) 6-3 Figure 6-3 ENAMIs Projects Approval Process 6-4 Figure 6-4 Cement Copper Supply versus Copper Price 6-6 Figure 6-5 Cement Copper Supply Share (Year 2000) 6-7 Figure 6-6 Oxide Copper Ore Treatment Process at Ovalle Plant (Future) 6-16 Figure 6-7 El Ingenio River Impacted Area Estimation 6-21 Figure 6-8 Copper Precipitate Value Added per Cu Grade 6-26 Figure 6-9 Proposal-Benefit Interrelation 6-29 Environmentally Friendly Operation Plan at Ovalle Plant Figure 7-1 The Best Operation Flow Thoughtful to Environment for Oxide Copper Ore 7-1 Figure 7-2 Development of Technology to Recover Metals from Mine Drainage: Test Flow 7-8 Figure 7-3 Study on the Operation Conformation Flow with Consideration for Environment 7-9 Possible Application of Bio-Technology in Chile (M/P) Figure 8-1 An Application of Bio-technology to Treatment of Mine Drainage 8-2 Figure 8-2 An Application of Bio-technology to Cu Smelting Operation (Flue dust) 8-3

23 TABLES Mining Situation in Chile Table 2-1 ENAMI s Processing Plants 2-6 Table 2-2 Actual Results of ENAMI Smelting and Refining Operation (2000) 2-7 Examination of Ovalle Production Plants Table 3-1 Production Situation of Ovalle Plant, ENAMI 3-2 Table 3-2 Position of Ovalle Plant in Chilean Cu Production (in 2000) 3-3 Table 3-3 Result of Operation of ENAMI Mineral Processing Plants in Table 3-4 Comparison among Processing Methods for Copper Ores 3-25 Table 3-5 Result of Processing for Oxide Copper Ore in 1994 at Ovalle Plant, ENAMI 3-26 Table 3-6 Result of Processing for Oxide Copper Ore in 1995 at Ovalle Plant, ENAMI 3-27 Table 3-7 Result of Processing for Oxide Copper Ore in 1996 at Ovalle Plant, ENAMI 3-28 Table 3-8 Result of Processing for Oxide Copper Ore in 1997 at Ovalle Plant, ENAMI 3-29 Table 3-9 Result of Processing for Oxide Copper Ore in 1998 at Ovalle Plant, ENAMI 3-30 Table 3-10 Result of Processing for Oxide Copper Ore in 1999 at Ovalle Plant, ENAMI 3-31 Table 3-11 Result of Processing for Oxide Copper Ore in 2000 at Ovalle Plant, ENAMI 3-32 Table 3-12 Unit Consumption of Major Materials (Oxide Cu ores) 3-8 Table 3-13 Result of RCU for processing of Oxide Copper Ore at Ovalle plant, ENAMI 3-33 Table 3-14 Copper Metal Price 3-35 Table 3-15 Summary of Correlation between Capacity Use and Copper Price 3-9 Table 3-16 Target of Processing for Oxide Copper Ore Ovalle Plant, ENAMI 3-36 Table 3-17 Result of Processing for Sulfide Copper Ore in 1994 at Ovalle Plant, ENAMI 3-52 Table 3-18 Result of Processing for Sulfide Copper Ore in 1995 at Ovalle Plant, ENAMI 3-53 Table 3-19 Result of Processing for Sulfide Copper Ore in 1996 at Ovalle Plant, ENAMI 3-54 Table 3-20 Result of Processing for Sulfide Copper Ore in 1997 at Ovalle Plant, ENAMI 3-55 Table 3-21 Result of Processing for Sulfide Copper Ore in 1998 at Ovalle Plant, ENAMI 3-56 Table 3-22 Result of Processing for Sulfide Copper Ore in 1999 at Ovalle Plant, ENAMI 3-57 Table 3-23 Result of Processing for Sulfide Copper Ore in 2000 at Ovalle Plant, ENAMI 3-58 Table 3-24 Result of Processing for Sulfide Copper Ore in 2001 at Ovalle Plant, ENAMI 3-59 Table 3-25 Unit Consumption of Major Materials (in 2000) 3-37 Table 3-26 Result of RCU for Processing of Sulfide Copper Ore at Ovalle Plant, ENAMI 3-60 Table 3-27 The Relation between RCU at Ovalle vs. Cu Price 3-38 Table 3-28 Target of Processing for Sulfide Copper Ore Ovalle Plant, ENAMI 3-62 Table Monitoring Point Analysis (December 99 February 02) 3-76 Table 3-56 Standard for Industrial Waste Water Waste Liquid /Irrigation Water 3-65 (metal mining concerned) Table 3-57 Calculated Flux Volume of Penetrating Drainage (M-4) 3-66 Table 3-58 Maximum Permitted Discharge Volume of Arsenic in Existing Discharge Points 3-69

24 Technical Transfer of Iron Oxidizing Bacteria Method Table 4-1 Composition of 9K Medium 4-2 Table 4-2 Composition of Silica Gel Medium 4-2 Table 4-3 Basic Tests (1) - Feed Solution and Test Period 4-3 Table 4-4 Basic Tests (1) - Test Conditions 4-3 Table 4-5 Basic Tests (1) - Addition of Nutrient 4-5 Table 4-6 Basic Tests (1) - Results of Repeated Cultivation 4-6 Table 4-7 Chemical Composition of the Actual Ovalle Solution (November 5 th, 1999) 4-7 Table 4-8 Chemical Composition of the Actual Ovalle Solution 4-7 (The another Ovalle Ssample taken two months ago and preserved at the laboratory) Table 4-9 Basic Tests (1) Alkali Consumption of Non Oxidized Solution (solution as it is) 4-8 Table 4-10 Basic Tests (1) Alkali Consumption of Oxidized Solution 4-8 Table 4-11 Basic Tests (1) Results of Neutralization Tests with Calcium Carbonate 4-10 Table 4-12 Basic Tests (1)-Solution Quality after (Oxidation Neutralization) with Calcium Carbonate 4-10 Table 4-13 Basic Tests (1) - Alkali Consumption for Neutralization of Solution after Oxidation 4-10 Neutralization with Calcium Carbonate Table 4-14 Basic Tests (1) - Results of Neutralization Tests with Slaked Lime 4-10 Table 4-15 Basic Tests (1) - Direct Neutralization Results of Ovalle Solution with Slaked Lime 4-11 Table 4-16 Basic Tests (1) - Comparison of Required Neutralizer 4-11 Table 4-17 Basic Tests (1) - Results of Comparative Tests 4-12 Table 4-18 Basic Tests (2) - Quality of Feed Solution 4-14 Table 4-19 Basic Tests (2) - Test Conditions 4-14 Table 4-20 Specification of Waste Solution to be Treated 4-17 Table 4-21 Specification of Equipment 4-18 Table 4-22 Viewpoints for Modifying Test Conditions 4-21 Table 4-23 Analytical Results of Feed Solution (periodical) 4-22 Table 4-24 Quality of Waste Solution (daily analyses, Sept. 6, 2001 March 31, 2002) 4-22 Table 4-25 Actual Consumption of Calcium Carbonate on Demonstration Tests 4-25 Table 4-26 Actual Consumption of Slaked Lime on Demonstration Tests 4-25 Table 4-27 Estimated Reagent Cost (Treated Volume 100m 3 /day) 4-25 Table 4-28 Grade of Individual Sediment 4-28 Table 4-29 Leaching Test Conditions with Treated Solution 4-29 Table 4-30 Leaching Test Conditions with Oxidized Solution 4-30 Table 4-31 Operational Conditions at the Model Plant 4-31 Appendix 4-1 Quality of Feed and Oxidized Solution 4-35 Appendix 4-2 Daily Results in Oxidation Circuit 4-43 Appendix 4-3 Daily Results in Neutralization Circuit 4-51 Appendix 4-4 Periodical Analysis 4-59

25 Design of Full Scale Solution Treatment Plant Table 5-1 Volume of Waste Solution to be Treated 5-2 Table 5-2 Specification of Waste Solution 5-2 Table 5-3 Specification of Feed Solution for Model Plant Design 5-3 Table 5-4 Necessary Modification in the Model Plant 5-5 Table 5-5 List of Equipment to be Installed or Modified in Case Table 5-6 Equipment List to be Installed in Case Economical and Financial Analysis for Waste Solution Treatment Table 6-1 Copper Precipitate Supply (unit: dmt) & Copper Price 6-6 Table 6-2 ENAMIs Copper Oxide Ore Processing Plant Operation Results (Year 2000) 6-7 Table 6-3 ENAMI Own Mining Rights Ore Reserves (Oxide Copper Mineral) 6-8 Table 6-4 Complementary Supply Materials: Oxide Copper Ore Processing Plant 6-9 Table 6-5 Complementary Supply Materials: Waste Water Treatment Plant 6-9 Table 6-6 Factory Supplies and Maintenance Costs: Oxide Copper Ore Processing Plant 6-9 Table 6-7 Utilities: Oxide Copper Ore Processing Plant 6-10 Table 6-8 Administration Overhead Costs: Oxide Copper Ore Processing Plant 6-10 Table 6-9 Human Resource Costs: Oxide Copper Ore Processing Plant 6-11 Table 6-10 Waste Water Treatment Plant Performance and Operating Cost 6-11 Table 6-11 Financial Analysis Results 6-17 Table 6-12 Metallic Copper Process Value Added Analysis 6-18 Table 6-13 Environmental Liability Improvement Works Investment 6-19 Table 6-14 Externalities for Surrounding Small and Medium Mines 6-22 Table 6-15 Externalities due to Water Recycling Savings 6-22 Table 6-16 Externalities Resumes 6-23 Table 6-17 Economic Analysis Results 6-23 Table 6-18 Outside Copper Precipitate Producer Value Added Calculation Sheet 6-26 Environmentally Friendly Operation Plan at Ovalle Plant Table 7-1 Table 7-2 List of Treatment Process: Ovalle Plant, ENAMI 7-7 Operation Flow Suitable for Present Conditions 7-6 Possible Application of Bio-Technology in Chile (M/P) Table 8-1 Treatment of Mine Drainage from Operating or Abandoned Mines 8-8 with Bio-technology (Scheme) Table 8-2 Major Copper Mine in Chile 8-9 Chapter 4 Chapter 6 OTHERS Photo 4-61 ANNEX 6-30