2nd International Workshop on Metals Recovery from Mining Wastes - M2R

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1 This presentation has been prepared for 2nd International Workshop on Metals Recovery from Mining Wastes - M2R It contains intellectual property belonging to Xstrata Technology The information contained herein should not be copied, reproduced, loaned, exhibited or otherwise distributed in whole or in part without written approval of Xstrata Technology Pty Limited isasmelt@xstratatech.com

2 Modern, Flexible and Clean Technologies for Recovery and Recycling of Valuable Materials

3 Presentation Contents 1. Introduction to Xstrata Technology s core technologies 2. Brief Explanation of the ISASMELT /ISACONVERT TSL Principle 3. Process Flowsheets for Recovery and Processing of Valuable Metals 4. Other Demonstrated Uses of ISASMELT for Recycling 5. New Opportunities 6. Conclusions

Technologies in all areas of processing IsaMill step change in grinding technology. Much higher energy efficiency. Metallurgy improvements from inert grinding media.

$To treat low grade or refractory copper streams. Fixes arsenic. ISASMELT high intensity smelting process with low capital cost, energy efficient, flexible scale.$

4 Technologies in all areas of processing IsaMill step change in grinding technology. Much higher energy efficiency. Metallurgy improvements from inert grinding media. JAMESON CELL - high intensity flotation. High throughput small footprint, flexible design. Ability to achieve final grade concentrate in a single cell. ALBION PROCESS simple atmospheric leaching. To treat low grade or refractory copper streams. Fixes arsenic. ISASMELT high intensity smelting process with low capital cost, energy efficient, flexible scale. ISACONVERT high intensity converting process with low capital cost, high SO 2 gas strength, energy efficient, flexible scale. Tankhouse Technology producing most of the world s refined and EW copper. Experts in tankhouse design. Bottom Blowing Oxygen Cupel: The benefits of process intensification applied to precious metal refining

5 What is ISASMELT? - Simply Smarter Smelting -

$ISASMELT Oxygen enriched air (21 to 90% O 2 ) and fuel injected through the lance Refractory lined steel shell Slag splash coats the lance$

6 Lance The offgas is extracted, cooled-either with a spray cooler or waste heat boiler, then cleaned either with a baghouse or electrostatic precipitator 1-2 % carryover Feed mix 8-10% H 2 O is continuously dropped through a port in the roof and falls into the molten bath ISASMELT Oxygen enriched air (21 to 90% O 2 ) and fuel injected through the lance Refractory lined steel shell Slag splash coats the lance and protects it The molten products are either periodically or continuously tapped at the bottom of the furnace Bath turbulence ensures fast reaction

7 Presentation Contents 1. Introduction to Xstrata Technology s core technologies 2. Brief Explanation of the ISASMELT /ISACONVERT TSL Principle 3. Process Flowsheets for Recovery and Processing of Valuable Metals 4. Other Demonstrated Uses of ISASMELT for Recycling 5. New Opportunities 6. Conclusions

8 Process Flowsheets for Recovery and Processing of Valuable Metals Large scale ISASMELT plants Complex Feeds Secondary Copper Cu/Pb/PGM Materials Secondary Lead Silver Refining Technology Images Sourced from metalprices.com/artwork

9 Cu ISASMELT TSL Air Oxygen Concentrate Stockpile Flux WHB Offgas ESP Offgas Acid Plant Stack Flotation Fuel Dust Recycle Offgas + Dust Dust to Recycle Air Flux Grinding Slag + Matte Peirce Smith Converter(s) Slag to ISASMELT / Crushing Slag Cleaning/ Settling Furnace Liquid Matte Blister Copper To Pyro and Electro Refining Granulation ISACONVERT Flowsheet Slag to ISASMELT Mining Clean Slag Discard/ Flotation Plant

500,000 tpa Copper ISASMELT Feed Composition Cu 28.0 19.3 tph Converter Slag Element Fe 29.0 % Cu S 28.0 31.0 S i O 2 6.5 30.6 Nm3/s 13.9 Nm3/s Fe 29.0 To Acid CaO 0.3 35.3 % SO 2 Plant 31.

4 tph 0.2 tph 250 tph 0.7 tph 44 tph 105 tph Matte Smelting Conditions Concentrate, tph 250.0 Smelt Conditions Oxygen, Concs. %O Tph 2 25031.0 % O2 80 Matte, %Cu 70.0 Matte % Cu 70 SiO2/Fe 2 0.8 0.

10 500,000 tpa Copper ISASMELT Feed Composition Cu tph Converter Slag Element Fe 29.0 % Cu S S i O Nm3/s 13.9 Nm3/s Fe 29.0 To Acid CaO % SO 2 Plant 31.8 % SO 2 S SiO 2 Al2O MgO Nm3/s 6.3 Nm3/s 6.5 Air Air CaO Blended 0.3 Concentrates Al 14.8 Nm3/s Matte 2 O Nm3/s Oxygen Stockpile Lime Coal Oxygen Concs. Coal Silica 7.4 tph 0.2 tph 250 tph 0.7 tph 44 tph 105 tph Matte Smelting Conditions Concentrate, tph Smelt Conditions Oxygen, Concs. %O Tph % O2 80 Matte, %Cu 70.0 Matte % Cu 70 SiO2/Fe tph Slag SiO2/ SiO CaO 2.4 Slag Granulation 2 /CaO tph tph 73.8 tph Converting Conditions Discard Slag Settling Furnace Matte Matte Blister % O2 50 Granulation 0.3 % S Oxygen, %O Matte % H2O 3 Moisture Slag Fe/CaO in Matte Anode Slag Fe/SiO2 Fe/CaO Furnaces Slag % Cu 18 Recycle Fe/SiO 2? Cu in Slag, % 18.0 Casting Wheel

11 Process Flowsheets for Recovery and Processing of Valuable Metals Large scale ISASMELT plants Complex Feeds Secondary Copper Cu/Pb/PGM Materials Secondary Lead Silver Refining Technology Images Sourced from metalprices.com/artwork

12 Complex Copper with ISASMELT TSL Air Oxygen Concentrate Stockpile Flux WHB Offgas ESP Offgas Acid Plant Stack Fuel Offgas + Dust Dust Valuable Metal Stream Flotation dust leach Impurity Stream Air Flux Grinding Slag + Matte Peirce Smith Converter(s) Slag to Slag Cleaning/ Flotation Plant Crushing Slag Cleaning/ Settling Furnace Liquid Matte Blister Copper To Refinery Granulation ISACONVERT Flowsheet Slag to ISASMELT / Slag Cleaning/ Flotation Plant Mining Clean Slag Discard/ Flotation Plant

13 Typical Aspects of Complex Concentrates Smelting Operation Minor elements: Not minor any more! Minor elements content can reach 10% of the feed material feed composition Minor elements composition in matte can reach values over 10% Recycling of converting slag to slag cleaning furnace could impact on matte quality Depending on nature of converting process converting slag could be processed via flotation, recycling to electric furnace or smelting unit Over blowing of blister required to slag the lead Anode refining requires minor element removal stage Refinery needs to be designed to new standards Separate dust treatment required for bleeding minor elements

Oxygen Underflow CYCLONE Overflow NEUTRALIZATION Lime Slurry S/L

14 Dust Leach Flowsheet Smelter Dust Weak acid RESLURRY Refinery Bleeds Concentrated Acid ACID LEACH Oxygen Precious Metals to the Smelter Air Oxygen Underflow CYCLONE Overflow NEUTRALIZATION Lime Slurry S/L SEPARATION Waste Repulp to Tails (eg As) Copper Return to Smelter CEMENTATION

15 Process Flowsheets for Recovery and Processing of Valuable Metals Large scale ISASMELT plants Complex Feeds Secondary Copper Cu/Pb/PGM Materials Secondary Lead Silver Refining Technology Images Sourced from metalprices.com/artwork

16 Aurubis- Lünen Plant Flowsheet Source: www. Aurubis.com

17 Aurubis ISASMELT Plant Typical Raw Materials Cu Scrap Cu Residue s & Slags Secondary Materials Stockpile WHB Offgas Offgas + Dust Bag House Dust Offgas Lime Scrubber Stack Slimes Industrial Residues Air Oxygen Fuel Schredde r materials Slag + Entrained Cu Black Copper to TRBC Printed Circuit Boards Slag Cleaning/ Settling Furnace Slag Black Copper To TRBC To Market 0 80% Cu Bearing Materials

18 % of Desgin Capacity Aurubis ISASMELT Plant 180,0 160,0 140,0 120,0 100,0 80,0 >160% of Design Capacity 60,0 40,0 20,0 0,0 FY 01/02 FY 02/03 FY 03/04 FY 04/05 FY 05/06 FY 06/07 FY 07/08 FY 08/09 FY 09/10 FY 10/11 Only 4 Months of Operation for Fiscal Year 01/02 Fiscal Year

19 PROVEN ENVIRONMENTAL PERFORMANCE

20 Process Flowsheets for Recovery and Processing of Valuable Metals Large scale ISASMELT plants Complex Feeds Secondary Copper Cu/Pb/PGM Materials Secondary Lead Silver Refining Technology Images Sourced from metalprices.com/artwork

materials, input 1000 t/day + 17 metals recovered, value 3 billion USD (2007) (Au, Ag, Pt, Pd,

21 The Umicore Flowsheet ISASMELT A two - stage batch smelting and converting process Refinery Cu leaching and electrowinning Precious Metals Refinery Recovery of valuable elements Recycled materials, input 1000 t/day + 17 metals recovered, value 3 billion USD (2007) (Au, Ag, Pt, Pd, Rh, Ru, Ir, Cu, Pb, Ni, Sn, Bi, Se, Te, Sb, As, In) Source: Dr. C. Hagelüken, R 09, Davos,

Casting/ Cooling and Crushing To Pb Blast Furnace Copper Matte: Remains in the Furnace for

22 Smelting Stage Air Dust Recycle Pb/Cu/PGM Materials Stockpile Flux Fuel Oxygen WHB Offgas + Dust ESP Offgas Acid Plant Stack Dust Recycle Smelting Stage Main Products: Smelting Stage Slag Slag Casting/ Cooling and Crushing To Pb Blast Furnace Copper Matte: Remains in the Furnace for Converting Stage High lead slag: Sub product for the Base Metals Operation Plant Off gas: To Acid Plant

23 Converting Stage Air Dust Cu Materials Stockpile Flux Fuel Dust Recycle Blister Copper Oxygen WHB Offgas + Dust ESP Offgas Acid Plant Stack Converting Stage Main Products: Converting slag: Remains in the ISASMELT for next cycle Off gas: To Acid Plant Blister copper: To Refining Stage Cu Refining To Leaching and Electrowinning Precious Metals Refining

24 PROVEN ENVIRONMENTAL PERFORMANCE

25 Process Flowsheets for Recovery and Processing of Valuable Metals Large scale ISASMELT plants Complex Feeds Secondary Copper Cu/Pb/PGM Materials Secondary Lead Silver Refining Technology Images Sourced from metalprices.com/artwork

26 Secondary Lead with ISASMELT TSL Images sourced from: Errington Hawkins & Lim, PbZn 2010, TMS

27 300,000 tpa Secondary Pb ISASMELT

28 Process Flowsheets for Recovery and Processing of Valuable Metals Large scale ISASMELT plants Complex Feeds Secondary Copper Cu/Pb/PGM Materials Secondary Lead Silver Refining Technology Images Sourced from metalprices.com/artwork

Offgas Applications Retorted Parkes Crust (Ag, Pb, Zn, Cu) Slag Pb and Cu Slimes

29 Refining Silver and Precious Metals Ag/Zn Skim Liquation Vacuum Retort High Silver Feed Low Grade Dust Recycle Air Oxygen Fuel Dust Recycle Offgas + Dust Bag Filter Offgas Applications Retorted Parkes Crust (Ag, Pb, Zn, Cu) Slag Pb and Cu Slimes bullion PGM Bearing Feeds High Purity Ag Refining Casting and Stacking Bi Crust Enrichment Silver Doré

30 Presentation Contents 1. Introduction to Xstrata Technology s core technologies 2. Brief Explanation of the ISASMELT /ISACONVERT TSL Principle 3. Process Flowsheets for Recovery and Processing of Valuable Metals 4. Other Demonstrated Uses of ISASMELT for Recycling 5. New Opportunities 6. Conclusions

31 DEMONSTRATED USES OF ISASMELT FOR RECYCLING Treatment of Roast Leach EW Zinc Plant Residues Pb, Zn, Ag, Ge, In Recovery Production of disposable slag Fuming of Lead BF Slag Zn, Pb Recovery Production of disposable slag Treatment of Lead Smelter Dross Cu-Pb Separation & Recovery Fume Pb and produce Cu matte Cu-As Residue Treatment Recovery of Cu as matte

32 DEMONSTRATED USES OF ISASMELT FOR RECYCLING Pyrolysis of CCA-treated Wood Energy Recovery Production of disposable slag Economic disposal of As Fuming of Steel EAF Dust Zn, Pb Recovery (Unavoidable halide recovery) Production of disposable slag

33 Presentation Contents 1. Introduction to Xstrata Technology s core technologies 2. Brief Explanation of the ISASMELT /ISACONVERT TSL Principle 3. Process Flowsheets for Recovery and Processing of Valuable Metals 4. Other Demonstrated Uses of ISASMELT for Recycling 5. New Opportunities 6. Conclusions

New Opportunities Collaboration with Xstrata Zinc Zinc processing capability of Asturiana de Zinc Tecnologia (AdZT) AdZT know-how on zinc leaching, purification, tank house design and casting

34 New Opportunities Collaboration with Xstrata Zinc Zinc processing capability of Asturiana de Zinc Tecnologia (AdZT) AdZT know-how on zinc leaching, purification, tank house design and casting Collaboration with Xmetech, (Korea Zinc Group Company) on lead and precious metals refining Electrorefining of lead Precious metals refining With these partners XT can provide a comprehensive scope for the execution on smelting and refining projects in copper, lead, zinc and precious metals

35 New Opportunities Pb processing Pyrorefining of lead bullion Electrorefining of lead bullion Precious metals refining Conventional pyro-refining of Ag-Zn Combination of pyro-refining of Au-Ag slimes from the Pb electrorefining and electorefining of silver and gold. Production of enriched Bi alloys via Production of high purity Bi as sub product of Au-Ag slimes processing using Slag processing Use of slag atomization with heat recovery Zn processing Albion process for zinc concentrates (direct leaching) Processing of zinc residues

36 Conclusions Xstrata has developed a number of technologies at its operations that lead to more efficient production of base metals and precious metals These technologies have been successfully applied to the recovery of valuable metals from secondary materials through recycling Xstrata Technology with its technology partners can open the door to new opportunities by delivering complimentary process solutions for the recycling of base and precious metals.

37 Questions? Modern, Flexible and Clean Technologies for Recovery and Recycling of Valuable Materials Gerardo R.F. Alvear F., A. S. Burrows and S. Nikolic 2nd International Workshop on Recovery of Metals from Mining Waste, M2R2, Santiago, Chile, 12th-13th April

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