Download - TMSPlenary28Aug06-FINAL2
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1 2006 Phelps Dodge Corporation
Sohn International Symposium on Advanced Processing of Metals and Materials:Principles, Technologies and Industrial Practice; August 27-31, 2006 San Diego, CA, USA
Recent Developments in Copper Hydrometallurgy
John O. MarsdenSenior Vice President, Technology & Product Development
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2 2006 Phelps Dodge Corporation
Outline
Safety Historical context Solution extraction and electrowinning Atmospheric leachingySecondary sulfidesyPrimary sulfides
Pressure leaching Other developments affecting copper hydrometallurgy
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3 2006 Phelps Dodge Corporation
Safety
Phelps Dodge philosophy Zero & Beyond
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4 2006 Phelps Dodge Corporation
Hydrometallurgy in Copper Extraction
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5 2006 Phelps Dodge Corporation
Phelps Dodge Long Track Record of Technology Deployment
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Large scale SX/EW Computerized haul truck dispatch GPS ore control Leach recovery optimization Concentrate grade enhancement
TyroneSX/EW
MorenciSX/EW
ChinoSX/EW Morenci
NorthwestExtension
Candelaria 1
MorenciSouthside
Candelaria 2
Expert control systems Concentrator adaptive control Mine for leach Haul truck tire technology Concentrate leach (2003)
Morenci MFL,El Abra ROM
CyprusAcquisition
CurtailmentCommenced
Chino 1/3 Acquisition
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6 2006 Phelps Dodge Corporation
Solution Extraction and Electrowinning
MineHeap
Leaching(Oxide)
(Chalcocite)
SolutionExtraction
Milling(Chalcocite)
(Chalcopyrite)Smelting Electro-Refining
Electro-Winning
Acid
Flotation
PrimaryCrushing
StockpileLeaching
(Oxide)(Chalcocite)
Sec/TertCrushing
Customers
Technology development efforts under way to reduce energy consumption
in electrowinning by 15-35%
Technology not yet proven, but showing promise
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7 2006 Phelps Dodge Corporation
Solution Extraction and Electrowinning at Bagdad, Arizona
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8 2006 Phelps Dodge Corporation
Solution Extraction & Electrowinning
1968 Ranchers Bluebird mine, Arizona1971 Bagdad, Arizona1974 ZCCM, Zambia1976 Miami, Arizona1979 Inspiration, Arizona1980 Cananea, Mexico1981 Pinto Valley, Arizona1984 Tyrone, New Mexico1985 Ray, Arizona1987 Morenci, Arizona1987 Sierrita, Arizona1987 Chuquicamata, Chile1988 Chino, New Mexico
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Example of Technology Transforming Copper Production
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85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03 04
Conventional SX/EW
(PDC share; millions of pounds)
1983 100% conventional2004 66% SX/EW
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10 2006 Phelps Dodge Corporation
Morenci Modoc SX Plant
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11 2006 Phelps Dodge Corporation
Koch Solution Extraction In-Pipe Reactor
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12 2006 Phelps Dodge Corporation
Enhanced Sulfide Heap and Stockpile Leaching
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13 2006 Phelps Dodge Corporation
Biologically Enhanced Leaching
air air
leach solution
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14 2006 Phelps Dodge Corporation
Cerro Verde Leach Pad 4 - Grasshopper Stacker
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15 2006 Phelps Dodge Corporation
Morenci Mine-for-Leach Agglomeration Drums
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16 2006 Phelps Dodge Corporation
Morenci Mine-for-Leach North Stacker
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17 2006 Phelps Dodge Corporation
Leaching Developments Bacterial Augmentation
Stream contains 3x108 cells/ml genetically selected bacteria Delivers two separate bacterial strains simultaneously Skid mounted Design based on Bagdad plant shown below
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18 2006 Phelps Dodge Corporation
Advanced Modeling to Improve Heap Performance
Air and solution modeling in heap
Temperature profile in heap
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19 2006 Phelps Dodge Corporation
Enhanced Chalcopyrite Leaching Bagdad Crystal Mountain
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20 2006 Phelps Dodge Corporation
Morenci Enhanced Stockpile Leaching
Low-grade ore from Western Copper deposityBelow mill cut off grade materialyMixed sulfide minerals chalcopyrite, chalcocitey188 million ton stockpile to be constructedyAir injectionyBacteria augmentationyControlled solution application
Largest engineered chalcopyrite stockpile leach in the world
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21 2006 Phelps Dodge Corporation
Concentrate Leaching Alternative to Smelting & Refining
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22 2006 Phelps Dodge Corporation
Copper Extraction in 1980s and 1990s
Secondary sulfide and oxide ores
Primary sulfide ores Mine
LeachingFlotation
Refining
Smelting
Rod Mill or Customer
SX
EW
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23 2006 Phelps Dodge Corporation
Concentrate Leach Technology Replaces Smelting/Refining
Secondary sulfide and oxide ores
Primary sulfide ores Mine
LeachingFlotation
Refining
Smelting
Rod Mill or Customer
SX
EW
ConcentrateLeaching
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24 2006 Phelps Dodge Corporation
Copper Concentrate Leaching History
Process developments - 1970s and 80syAmmonia - ArbiteryChloride - CLEAR, SOX, CuprexySulfate - Roast/Leach/Electrowin (Lakeshore)yMany others
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25 2006 Phelps Dodge Corporation
Copper Concentrate Leaching History
Process developments - 1970s and 80syAmmonia - ArbiteryChloride - CLEAR, SOXySulfate - Roast/Leach/Electrowin (Lakeshore)yMany others
Reasons for lack of commercial successyHigh cost (capital & operating)yProblems with materials of constructionyProblems with operability/maintainabilityyProcess complexityyPrecious metals recovery problemsyProblems with copper cathode quality yPrimitive, early stage SX/EW technologyyNot integrated with leaching operationsySignificant advances in smelting technology
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26 2006 Phelps Dodge Corporation
Copper Concentrate Leaching More Recent Developments
Ammonia - Escondida Sulfate yPhelps DodgeyPlacer DomeyCESL/Teck Cominco (chloride-assisted)yUBC/Anglo AmericanyActivoxyDynatec
BiologicalyBHP-Billiton BioCopyBactech-MintekyOthers
Chloride/Bromide Process Intec Chloride Outokumpu HydroCopper Nitrate Other
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27 2006 Phelps Dodge Corporation
Phelps Dodge Concentrate Leaching Milestones
2Q 1998 Sulfate-based concentrate leaching development started
1999-2000 Batch testwork at Hazen Research, Dawson and Phelps Dodge Process Technology Center
2000-2001 Continuous Pilot Plant Testing 3Q 2001 Technology Development Agreement
executed with Placer Dome Nov 2001 Bagdad HT Project approved Mar 2003 Start-up: First concentrate feed July 2003 All design parameters met, steady state operation
Four years from first testing to commercial demonstration
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28 2006 Phelps Dodge Corporation
Bagdad Concentrate Leach Plant Schematic
PLS Pond andSX/EW
SlurryStorage
Tank
ConcentrateSlurry PLV
FeedTank
PLVPLV
CCD #1
FlashVesselFlash
Vessel
StrongPLSTank
Neut#1
Neut#2
Neut#3
Neut#4
Tails
CCD #2CCD #3CCD #4
#1
SCRUBBER
#2
SCRUBBER
PLS to SX/EW and Cathode Production
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29 2006 Phelps Dodge Corporation
Bagdad Concentrate Leach Plant
August, 2003
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30 2006 Phelps Dodge Corporation
Pressure Leaching Vessel at Bagdad
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Solid-liquid Separation at Bagdad
August, 2003
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Bagdad Concentrate Leach Plant Copper Production
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Mar-0
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3Au
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Production (lbs) Design Basis Production
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Phelps Dodge Concentrate Leaching Milestones (continued)
May 2004 Conversion of Bagdad demonstration plant to medium temperature process started
May 2005 Start-up: medium temperature and direct electrowinning (MT-DEW) process
Dec 2005 Completion of MT-DEW process demonstration 2Q 2007 Scheduled completion of Morenci facility
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34 2006 Phelps Dodge Corporation
Bagdad MT-DEW Process Conversion Super-fine Grinding
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Direct Copper Electrowinning at Bagdad, AZ
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Morenci Concentrate Leaching Application
Provides economically viable alternative to smelting and refiningyGenerates by-product acid for leachingyEliminates freight cost for concentrate shipments and acid
deliveriesyDecouples Morenci from smelter balance dependency yReduces Morencis mill conversion costs
Morenci Western Copper concentrate mineralogy yMixed chalcopyrite, covellite, chalcocite, pyrite
Medium temperature and direct electrowinning (MT-DEW) process selectedyBest fit with Morenci concentrate production and acid balanceyUtilize existing EW and SX capacity at Morenci
Copper production capacity = 75,000 tons per year Copper recovery slightly higher than smelting and refining
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37 2006 Phelps Dodge Corporation
Production Decisions Impacted by Concentrate/Acid Balance
Chino Smelter650,000 tpy capacity
(off line)
North American Concentrate Bagdad Sierrita Chino (partial capacity) Cobre Morenci (off line)
North American Leach Morenci Bagdad Sierrita Chino Tyrone (partial capacity) Miami (partial capacity)
External acid
source
Candelariaconcentrate
External acid
consumer
Miami Smelter750,000 tpy capacity
(operating)
External concentrate
source
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Morenci Concentrate Leaching Facility 3D Model View
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Other Developments Affecting Copper Hydrometallurgy
Material Characterization Comminution Alternative Products
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40 2006 Phelps Dodge Corporation
High-Pressure Grinding Rolls
Cerro Verde milling circuit to include high pressure grinding rolls (HPGR) instead of SAG mills
Prosy Higher throughputy Greater energy efficiencyy Greater flexibilityy Lower unit cost
Consy Additional capital cost
Financial Impacty Significantly reduces power
consumption and unit production costs
Note - Use yellow to highlight font colors
(but never titles)
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41 2006 Phelps Dodge Corporation
Material Characterization QemSCAN Technology
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42 2006 Phelps Dodge Corporation
New Copper Products
Copper powder technologyy Potential replacement for cathode
to rody Specialty copper powders
Copper powder process reduces or eliminates the following: yManual harvesting of cathodesyCell cleaningy Stainless blank repairs and
replacementy Stripping machinesy Slippery or brittle cathodes
Focused on reducing costs and improving process safety and efficiency
PDC proprietary technology Demonstration plant in operation at
Morenci, AZ
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43 2006 Phelps Dodge Corporation
Sohn International Symposium on Advanced Processing of Metals and Materials:Principles, Technologies and Industrial Practice; August 27-31, 2006 San Diego, CA, USA
Thank You
Recent Developments in Copper HydrometallurgyJohn O. MarsdenSenior Vice President, Technology & Product DevelopmentOutlineSafetyPhelps Dodge Long Track Record of Technology DeploymentSolution Extraction and ElectrowinningSolution Extraction and Electrowinning at Bagdad, ArizonaSolution Extraction & ElectrowinningExample of Technology Transforming Copper ProductionMorenci Modoc SX PlantKoch Solution Extraction In-Pipe ReactorBiologically Enhanced LeachingCerro Verde Leach Pad 4 - Grasshopper StackerMorenci Mine-for-Leach Agglomeration DrumsMorenci Mine-for-Leach North StackerLeaching Developments Bacterial AugmentationAdvanced Modeling to Improve Heap PerformanceEnhanced Chalcopyrite Leaching Bagdad Crystal MountainMorenci Enhanced Stockpile LeachingConcentrate Leaching Alternative to Smelting & RefiningCopper Extraction in 1980s and 1990sConcentrate Leach Technology Replaces Smelting/RefiningCopper Concentrate Leaching HistoryCopper Concentrate Leaching HistoryCopper Concentrate Leaching More Recent DevelopmentsPhelps Dodge Concentrate Leaching MilestonesBagdad Concentrate Leach Plant SchematicBagdad Concentrate Leach PlantPressure Leaching Vessel at BagdadSolid-liquid Separation at BagdadBagdad Concentrate Leach Plant Copper ProductionPhelps Dodge Concentrate Leaching Milestones (continued)Bagdad MT-DEW Process Conversion Super-fine GrindingDirect Copper Electrowinning at Bagdad, AZMorenci Concentrate Leaching ApplicationProduction Decisions Impacted by Concentrate/Acid BalanceOther Developments Affecting Copper HydrometallurgyHigh-Pressure Grinding RollsMaterial Characterization QemSCAN TechnologyNew Copper ProductsThank You