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Hydro Metallurgy in Codelco Norte
Hydro Metallurgy in Codelco Norte
ABSTRACT
Codelco Norte is a large mining and metallurgical complex located in the Second Region in Chile.
The operation considers two main lines of mineral processing: the Concentration line and the
Hydrometallurgical line. The annual fine copper productions in 2003 were 478 kt and 429 kt of fine
copper, respectively. Codelco Norte has nowadays the largest hydrometallurgical copper complex
in the world.
This article describes the hydrometallurgical processing plants, the main results of its operations in
2003 and the development projects considered in this process line.
There are two operation to be emphasized in the leaching of sulfide ore resources: the ROM leach
operation denominated SBL Plant, operating since 1994, and the huge secondary sulfide resources
in Radomiro Tomic Mine, still not beneficiated.
1.
CODELCO
Production
kt copper
907
80
236
339
1.536
Net Cost
US$/lb
49,7
82,3
62,8
61,5
65,4
2.
CODELCO NORTE
2.1
Integrated Vision
Codelco Norte was created in 2002 to integrate and rationalize the management of resources and
facilities that Codelco has in II Region, given the huge existing potential value and the large
reserves and mining resources of its property concentrated there. Joining the ex- Divisions
Chuquicamata and Radomiro Tomic (RT) is part of the current business strategy to duplicate the
economic value of the Corporation.
In the above framework an integrated handling of the District was adopted. The best practices of
each ex- Division were chosen, thus generating an integrated geo-mining-metallurgical planning, in
order to guarantee that each ton of mineral entering to the process is maximizing its contribution to
the business. Also a rearragement in the sequence of exploitation of the deposits and the best way
to employ the distrital territory has been identified. Figure 1 illustrates the Codelco Norte district,
which contains about 16.6 billion tons of ore bearing 0.5% of total copper as average grade within
an area of 25x68 km2.
The distrital management includes two areas according to mineral type, oxide or sulfide, which are
distributed as illustrated in Figures 2 and 3.
2.2
3.
Concentration Line, that includes concentration, smelting and refining steps, with an annual
fine copper production in 2003 of 478 kt of copper.
HYDROMETALLURGICAL LINE
The hydrometallurgical line has had an increasing development due to the incorporation of new
leachables resources, being these oxides and leachable sulfides, those that are processed in the
North and South Hydrometallurgy.
It should be emphasized that production cost in the hydrometallurgical line are lower than those in
the concentration line.
3.1
Leachable Resources
The existing leachable resources are summarized in Table 2, some of which are being leached and
considered in the Division production plans, whereas the stock of leachable resources, ripios in
reprocess and secondary sulfides from RT appear like development projects.
Table 2. Existing Leachables Resources in Hydrometallurgical Line of Codelco Norte.
3.2
North Hydro
South Hydro
Source
Chuquicamata Mine
South Mine
North Extension South Mine (ENMS)
Stock of leachable resources
Stock of ripios in reprocess
Type
Oxide
Secondary Sulfide
Low Grade Oxide (OBL)
Low Grade Leached (LBL)
Processing Plants
429 kt of copper per year is the current capacity of the Codelco Norte
hydrometallurgical plants. Three plants are distinguished according to the mineral type
processed and its location in the district:
SOUTH MINE
SMELTING DUSTS
PLANT
H2SO4 H2O
H2SO4
Agglomeration
GREEN HOUSE
WELL
H2O
Raffinate Pond
CHUQUICAMATA
RIPIOS LEACHING
VAT
LEACHING
(Cu 20 g/l, 500 m3/h)
PLS
(Cu 6-8 g/l)
PLS Pond
SOLVENT EXTRACTION
Extraction
ACL
Solutions
Loaded Organic
Loaded Electrolyte
(Cu 52-55 g/l)
ELECTROWINING
Stripping
Unloaded Organic
Spent Electrolyte
(Cu 37-40 g/l)
CopperCathode
99.99%
SHIPPING
PLS
Flowrate : 1500 m3/h
Cu: 2-3 g/l
SBL DUMP
PLS Pond
Raffinate Pond
Recycled Raffinate to Leaching
Recovered Organic
EXTRACTION
2 STAGES
PARALLEL
Unloaded Organic
Crud
Loaded
Organic
Orgnico
Cargado
Coalescer
STRIPPING
1 STAGE
Spent Electrolyte
Flowrate : 155 m3/h
Rich Electrolyte
Sparkler Filter
CELL EO
Total : 94
Copper
Cathode
Cu : 99.99 %
Figure 5.
Rectifier
Copper solutions from all leach steps are processed in a SX-EW plant. Main characteristics are as
follows:
SX-EW Capacity
307 kt Cuf/year
Ore Type
Radomiro Tomic mine oxides
Production year 2003 279,053 t Cuf (primary leaching)
24,585 t Cuf (secondary leaching)
3,000 t Cuf (ROM leaching).
Botadero de
Dump
InertesInert
TKOrganico
Loaded
TK
Organic
Cargado
Coalescers
Mine
Mina
Extraccin
Extraction
Reextraccin
Stripping
Lavado
Washing
Chancado
Primary
Crushing
Primario
Flotationde
Columnas
Column
Flotacin
Stock Pile
Stock
CoarsePile
Gruesos
Stock Pile
Stock Pile
Medium Size
Intermedios
SET 6
SET 4
SET 5
SET 3
SET 2
Filters
Filtros
Chancado
Secondary
Secundario
Crushing
SET 1
Chancado
Tertiary
Terciario
Crushing
TK de electrolito
TK Filtrate
Filtrado
Electrolyte
Cure on Belt
Heat
Intercambiadores
Exchange
de Calor
Heapde
Pilas
Leaching
Lixiviacin
TK Loaded
TK de electrolito
yte
Electrol
Rico
OfF RaffinatePond
Dump Waste
Raffinate
Pond
Lagunas de Refino
Desanding
Ponds
Lagunas
de PLS
PLS Pond
Botadero de Ripios
OBLLixiviacin
Leaching
Medium
Sln
Intermedia
Solution
OBL
ILS
Sln Intermedia
4.
DEVELOPMENT PROJECTS
4.1
Oxide Ores
Grades
Recovery
Recovered Cuf
Total
Year
ktf
ktf/a
Resource
Moisture
Resource
M (th)
M (ts)
CuT
%
CuS
%
158,4
0,22
0,16
55,4
193
28
53,4
218
20
11
88
11
171,3
7,5
167,8
10
151
0,27
0,16
61,4
59,6
0,33
0,29
45,0
Years
N
Grades
Resource
Moisture
Resource
M (th)
M (ts)
CuT
%
CuS
%
Recovery
%
Recovered Cuf
Total
Year
ktf
ktf/a
20
18
1,26
0,87
65,0
40,0
151
34
LBL from RT
Economically processable resource
170
167
0,19
0,14
40,0
123
Years
N
9
15
4.2
According to the integrated management of the resources, the secondary sulfide existing at
Radomiro Tomic should involve the study of hydrometallurgical and concentration routes prior to
decide the best business option for the Corporation.
Each alternative process was subjected to a preliminary study, based on cost variables, anticipated
cash flows and plant capacities, all inserted within the Business and Development Plan 2004.
At profile level it was evaluated feasibility to process this ore in the Chuquicamata concentrator or
leaching them in RT. In the following diagram each alternative is described (Figure 7), For the
concentrator alternative, the ore should be transported 14 km from the RT mine to the
Chuquicamata plant.
PIT
EXTRACTION
MINERAL
CRUSHING
LX SX -EW
PIT
EXTRACTION
TRANSPORT
CONCENTRATOR
SMELTING
REFINERY
Project
Processing of RT Secondary Sulfide
Primary - Secondary Leaching
SSF
SSD
Primary - Secondary Leaching Optimized
Grades
CuS
CuT
%
%
Rec
%
Cuf Recovered
Total
Year
ktf
ktf/a
Years
M (th)
M (ts)
253
246
0,67
0,07
47,5
798
100
102
151
3
3
99
147
0,84
0,55
0,1
0,05
54,3
42,9
452
347
56
43
246
0,67
0,07
1033
235
129
63,0
Concentrator
< 1 hour
86
63
2006
Hydrometallurgy
300 400 days
48 63
45 39
2012
Differential NPV associated to each process alternative with a discount rate of 8.5% and a copper
price of 85 USS/lb are shown in Table 6. The reference used is the hydrometallurgical processing
beginning at 2012, with 47.5% as total copper recovery.
Table 6. Differential NPV Associated to Each Process Alternative.
Line Process
Hydrometallurgy year 2012 (R = 48%)
Hydrometallurgy year 2012 (R = 63%)
Concentration year 2006 (R = 86%)
NPV MUS$
0
+94
+42
Both alternatives present advantages and disadvantages and together with the economic feasibility
study would allow to determine the best process alternative. The choice also would depends on
policies and commitments adopted by the administration. Variables such as plant availability, start
up opportunity, recoveries, ore resource availability, ore supplying alternative, environmental
variables and process time, among others.
The study of processing alternatives for the RT secondary sulfide ores goes on, with the target of
improving information to generate a better geo-mining-metallurgical planning that allows to establish
the best options and process opportunities and business.
5.
CONCLUSIONS
The production of 429 kt Cuf during the year 2003 in the Hydrometallurgical line in Codelco Norte, is
an important contribution to the Codelco Norte production, particularly considering the low
production cost, it stands out the relevance of the development projects mentioned before, because
its application would significantly impact the future operational result of the whole Division.
Interesting additional leachable resources appear to be worked out, to establish their stage and
process alternative, according to the integrated management plan. Reprocessing of existing ripios
and the ROM leaching operations are the most attractive alternatives to beneficiate these
resources.
The challenge to detect the marginal capacities of the existing plants, will allow to adapt the plants
to higher demands with low investments and reduced times, thus increasing profit of the business.
It should be noted that considering a low copper recovery (48%), the concentrator option is more
attractive than the hydrometallurgical route, besides in the first one an important benefit occurs by
advancing the start up in the year 2006 compared to 2012 in the hydrometallurgical route.
Still within a conservative frame, the increase of leaching copper recovery from 48 to 63% would
report important economic profit increasing the differential NPV to 94 MUS$, exceeding to the
concentration route in 52 MUS$. Therefore, although the processing of these ores is planned for the
2012, the pertinent studies to define processing conditions, required investments, better knowledge
of the resource (mineralogy, grades) and more precise metallurgical response (copper recovery,
acid consumption), must begin as soon as possible due to the high potential business.
6.
REFERENCES
1.
J. Camus, F. Azcar. Integrated Planning in the Mining Business, Copper 2003 - Copper 2003 Volume I Plenary Lectures, Economics and Applications of Copper, Santiago, Chile, 2003, 279-291.
2.
3.
4.