Mintek 75. Using Computing Power in Process Development. Mike Dry
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1 Mintek 75 Using Computing Power in Process Development Mike Dry
2 Laterite Uranium Excel AspenPlus
3 Nickel
4 Ni grade, mass % 1.1 Co grade, mass % Cu grade, mass % Fe grade, mass % 8.5 Mg grade, mass % 3.5 Extraction, % 92 H 2 SO 4 demand, kg/t 210 Total ore reserve, Mt 31 Ni production, tpa Calculated life of mine, years 21
5 H 2 SO 4 Water Laterite Heap Leach Spent heaps PLS CaCO 3 Fe Precipitation FeOOH/CaSO 4 (Ni,Co,Cu)SO 4 Base Metal MgO (Ni,Co,Cu)(OH) Precipitation 2 MgSO 4 Mg CaO Mg(OH) 2 /CaSO Precipitation 4 Process water
6 NiO + H 2 SO 4 CoO + H 2 SO 4 CuO + H 2 SO 4 MgO + H 2 SO 4 NiSO 4 + H 2 O CoSO 4 + H 2 O CuSO 4 + H 2 O MgSO 4 + H 2 O 2FeOOH + 3H 2 SO 4 Fe 2 (SO 4 ) 3 + 4H 2 O
7 Per 1000 kg ore: kmol of NiO kmol of CoO kmol of CuO kmol of MgO kmol of Fe, as FeOOH and Fe 2 O 3
8 2.141 kmol H 2 SO 4 is consumed in total kmol consumed by Ni, Co, Co and Mg kmol of Fe is consumed kmol FeOOH in the ore kmol total Fe in ore kmol Fe 2 O 3 in the ore
9 NiO 1.40% CoO 0.04% CuO 0.01% MgO 5.80% FeOOH 4.10% Fe 2 O % SiO %
10 H 2 SO 4 Water Laterite Heap Leach Spent heaps PLS CaCO 3 Fe Precipitation FeOOH/CaSO 4 (Ni,Co,Cu)SO 4 Base Metal MgO (Ni,Co,Cu)(OH) Precipitation 2 MgSO 4 Mg CaO Mg(OH) 2 /CaSO Precipitation 4 Process water
11 H 2 SO 4 + CaCO 3 CaSO 4 + H 2 O + CO 2 Fe 2 (SO 4 ) 3 + 3CaCO 3 + H 2 O 3CaSO 4 + 2FeOOH + 3CO 2
12 H 2 SO 4 Water Laterite Heap Leach Spent heaps PLS CaCO 3 Fe Precipitation FeOOH/CaSO 4 (Ni,Co,Cu)SO 4 Base Metal MgO (Ni,Co,Cu)(OH) Precipitation 2 MgSO 4 Mg CaO Mg(OH) 2 /CaSO Precipitation 4 Process water
13 NiSO 4 + MgO + H 2 O Ni(OH) 2 + MgSO 4 CoSO 4 + MgO + H 2 O Co(OH) 2 + MgSO 4 CuSO 4 + MgO + H 2 O Cu(OH) 2 + MgSO 4
14 Assumed Ni in MHP: 50 mass % Ni(OH) 2 in MHP: MHP produced: Co(OH) 2 in MHP: Cu(OH) 2 in MHP: Therefore, MgO in MHP: kg/ton ore kg/ton ore kg/ton ore kg/ton ore kg/ton ore
15 H 2 SO 4 Water Laterite Heap Leach Spent heaps PLS CaCO 3 Fe Precipitation FeOOH/CaSO 4 (Ni,Co,Cu)SO 4 Base Metal MgO (Ni,Co,Cu)(OH) Precipitation 2 MgSO 4 Mg CaO Mg(OH) 2 /CaSO Precipitation 4 Process water
16 MgSO4 + CaO + H2O Mg(OH)2 + CaSO4
17 H 2 SO 4 Water Laterite Heap Leach Spent heaps PLS CaCO 3 Fe Precipitation FeOOH/CaSO 4 (Ni,Co,Cu)SO 4 Base Metal MgO (Ni,Co,Cu)(OH) Precipitation 2 MgSO 4 Mg CaO Mg(OH) 2 /CaSO Precipitation 4 Process water
18 ROM ore Dilute acid Acid Water NEW HEAPS OLD HEAPS SPENT HEAPS Vent BASE METAL PRECIPITATION Magnesia Steam Vent Limestone Steam FERRIC IRON PRECIPITATION Water MAGNESIUM PRECIPITATION Vent Lime Steam MHP CCD TRAIN Mg residue Water Iron residue
19 Reagent Calculation Model Limestone, as 100% CaCO 3 Magnesia, as 100% MgO Lime, as 100% CaO
20 Reagent $/t H 2 SO CaCO 3 50 NaOH 1000 MgO 300 CaO 200 Metal $/lb Ni 5.00 Co Cu 1.50
21 Company Type kt/y Capex Skye (2005) Scoping Ambatovy Pre-feas Goro Bankable Ravensthorpe Bankable
22 10000 Capital cost, $ million Nickel production, kt/y
23 Spreadsheet AspenPlus IRR
24 Uranium
25 Na 2 CO 3 Ore NaOH H 2 SO 4 Leach SDU ppt'n Dissolution Eluate CCD IX UO 4 ppt'n Water Eluant Na 2 SO 4 Residue Na 2 CO 3 H 2 O 2 U Product
26 U 3 O 8 grade, mass % 0.06 Total ore reserve, Mt 51 Assumed leach extraction, % 99 Assumed life of mine, years 20 Calculated U 3 O 8 dissolution, tpa 1515
27 K 2 (UO 2 ) 2 (VO 4 ) 2 3H 2 O 0.10 NaCa 2 Mg 4 Al 3 Si 6 O 22 (OH) 2 2 KAl 3 Si 3 O 10 Cl 2 3 CaSO CaCO 3 10 SiO
28 K 2 (UO 2 ) 2 (VO 4 ) 2 3H 2 O + 6CO 3 2-2K + + 2UO 2 (CO 3 ) VO OH - + H 2 O NaCa 2 Mg 4 Al 3 Si 6 O 22 (OH) 2 + 8CO H 2 O Na + + 2CaCO 3 + 4MgCO 3 + 3Al(OH) 3 +6H 2 SiO HCO 3 - KAl 3 Si 3 O 10 Cl 2 + 7CO H 2 O K + + 3Al(OH) 3 + 3H 2 SiO Cl - + 7HCO 3 - CaSO 4 + CO 3 2- CaCO 3 + SO 4 2- HCO OH - CO H 2 O
29 2(R 4 N) 2 CO 3 + UO 2 (CO 3 ) 3 4- (R 4 N) 4 UO 2 (CO 3 ) 3 + 2CO 3 2- (R 4 N) 4 UO 2 (CO 3 ) 3 + 2CO 3 2-2(R 4 N) 2 CO 3 + UO 2 (CO 3 ) 3 4-
30 2UO 2 (CO 3 ) OH - + 2Na + Na 2 U 2 O 7 + 6CO H 2 O Na 2 U 2 O 7 + 3H 2 SO 4 2Na + + 2UO SO H 2 O xh 2 O + UO H 2 O 2 UO 4 xh 2 O + 2H +
31 Incoming ore Sodium hydroxide/ carbonate Eluant Floc Sodium hydroxide Water LEACH IX SDU PRECIPITATION Floc Water Water Floc Floc Floc Floc Water Water Water Acid SDU DISSOLUTION Water FILTER Product Sodium hydroxide Hydrogen peroxide Vent U PEROXIDE PRECIPITATION Effluent Water Water Evaporation Water TAILINGS DAM Excess IX barrens
32 Operating days per year Moisture in incoming ore, mass % Na 2 CO 3 consumption in leach, kg/t S/L ratio to leach, kg/m 3 Residual Na 2 CO 3 ex leach, g/l IX barrens wash ratio to CCD 4 S/L ratio ex CCD, kg/m 3 S/L ratio of final tailings, kg/m 3 Evaporation on tailings dam, % Uranium recovery in IX, etc., % Na 2 CO 3 in IX eluant, M U 3 O 8 in IX eluate, g/l NaOH ex SDU precipitation, g/l Times stoichiometric H 2 SO 4 to SDU Times stoichiometric H 2 O 2 to UO
33 Item Calculation Model Solids to leach, t/h Water in incoming ore, m 3 /h Total solution to leach, m 3 /h Gangue dissolution in leach, % Solids ex leach, t/h Solution ex leach, m 3 /h U 3 O 8 in solution ex leach, g/l V in solution ex leach, g/l SO 2-4 in solution ex leach, g/l Cl - in solution ex leach, g/l Na 2 CO 3 in solution ex leach, g/l NaHCO 3 in solution ex leach, g/l 3 3
34 Carbonate Losses: Leach gangue reactions Ca/Mg carbonate Bicarbonate CCD underflow tailings
35 Leached slurry PLS to IX Wash liquor Residue
36 Leached slurry PLS to IX IX barrens Water TAILINGS DAM Evaporation Return dam water
37 F, x W, y O, z O = F + W U U, z z = xf + yw O + U
38 U 3 O 8 in overflow, g/l Wash ratio = 0.5 Wash ratio = 1.0 Wash ratio = CCD stage
39 Incoming ore Solids: 304 t/h Water: 16 m³/h NaOH: 0.3 t/h 18 m³/h Make-up Na₂CO₃: 4 t/h NaOH: 1.1 t/h Leach SDU ppt'n Eluate: 18 m³/h CCD Water: 215 m³/h 1227 m³/h 367 m³/h Residue: 299 t/h Solution: 367 m³/h 860 m³/h IX Eluant: 18 m³/h Na₂CO₃: 1.9 t/h Excess IX barrens: 0 m³/h Return dam water: 119 m³/h
40 Incoming ore Solids: 304 t/h Water: 16 m³/h NaOH: 0.3 t/h 18 m³/h Make-up Na₂CO₃: 4 t/h NaOH: 1.1 t/h Leach SDU ppt'n Eluate: 18 m³/h CCD Water: 215 m³/h 1227 m³/h 367 m³/h Residue: 299 t/h Solution: 367 m³/h 860 m³/h IX Eluant: 18 m³/h Na₂CO₃: 1.9 t/h Excess IX barrens: 0 m³/h Return dam water: 119 m³/h
41 Loss to final underflow 20% 15% 10% 5% 100% water 50% water 0% Wash ratio
42 Item Calculation Model U 3 O 8 recovery over CCD, % U3O8 lost to residue, % Carbonate recovery over CCD, % Carbonate lost to residue, %
43 Selectivity = [U] R /[U] S [X] R /[X] S Selectivity = (U flow) R /(U flow) S (X flow) R /(X flow) S (X flow) R (U flow) R /(U flow) S = (X flow) S Selectivity Extraction of X = Extraction of U Selectivity
44 Item Calculation Model Pregnant liquor to IX, m 3 /h U 3 O 8 in PLS to IX, g/l V in PLS to IX, g/l SO 2-4 in PLS to IX, g/l Cl - in PLS to IX, g/l Na 2 CO 3 in PLS to IX, g/l NaHCO 3 in PLS to IX, g/l IX eluant/eluate, m 3 /h U 3 O 8 in IX eluate, g/l V in IX eluate, g/l SO 2-4 in IX eluate, g/l Cl - in IX eluate, g/l CO 2-3 in IX eluate, g/l 52 52
45 Item Calculation Model NaOH to SDU precipitation, t/h Na 2 U 2 O 7 ex SDU precipitation, t/h H 2 SO 4 to SDU re-dissolution, t/h H 2 O 2 to UO 4 precipitation, t/h NaOH to UO 4 precipitation, t/h Na 2 SO 4 ex UO 4 precipitation, t/h
46 Reagent $/t kg per kg U 3 O 8 Cost distribution Na 2 CO % NaOH % H 2 SO % H 2 O % Reagent $/t kg per kg U 3 O 8 Cost distribution Na 2 CO % NaOH % H 2 SO % H 2 O %
47 Labour costs, $ million/y Maintenance, $million/y 10 2 Capital cost, $ million Assumed tax rate, %
48 Internal rate of return : 37% NPV at 10% discount rate : $315 million Internal rate of return : 39% NPV at 10% discount rate : $344 million
49 Message Evaluation enhances process development Do need leach tests early on S/L separation also needs testing early Spreadsheet calculations are useful Use the potential economics as an input to rational decision making.
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