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Clean mining and clean energy:what technology makes it possible?

Doris Hiam-Galvez, Director, HATCH PERU

September 2011

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Membrane treatment process for Water Reuse

Background

Straits Resources Limited operates an Antimonymetal, Gold bullion and Tungsten facility atHillgrove Mine in Australia.

A build up of inorganic impurities in the TailingsStorage Facility (TSF) led to poor metal recoveries

Operations were suspended while seeking for aviable solution for treating TSF water

Reverse Osmosis (RO) treatment wasunsuccessfuly tested by a third party due tomembrane fouling issues.

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Flow through a spiral wound membrane

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Membrane classification & types

MF0.2 to 0.4

Particulates

DetergentsProtein

In H2O

UF1

StarchGelatin

AcidsNaNO3Cl-

UF20.003 to 0.0030 to 50

NF5 to 10

RO1 to 5

Metal ions

DyesSO42+

Ca2+

. o .

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Process Block Diagram

Pretreatment Membrane Tech.

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Benefits

Nano filtration membrane technology (NF)allowed lowered operating pressures, henceenergy savings and reduced operating costs incomparison to Reverse Osmosis RO.

to achieve very good metallurgical recoveries inthe flotation circuit.

Good pre treatment guarantees continuousoperation with minimum membrane cleaning and

replacement

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Results

Recovery data from flotation tests

Test Sb recovery(%)

Au recovery(%)

Potable Water 99 94

TSF Water 7.5 15

NF permeate 97 95

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Clean Water

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Slag heat recovery

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Overview of Ferronickel Flowsheet

l l

Coal (50-70 kg/ tonne DO)

Rotary Dryer

"Dried" Ore

Blend Pile

Wet Ore (20% Lim/ 80% Sap)

Run ofMine Ore

Fuel (Coal/NG/HSFO)

AirHot G as Generator

Blend Pile

Rotary Drier

Run ofMine Ore

290 wt/h Ore,25% Moisture

230 wt/h Ore,15% Moisture

Water (~75 p si)

GranulatedSlag to

Dewatering and

Dump

Ferronickel

Electric Furnace

Slag

Infiltration Air

Ladle Refining(de-S and P)

Shotting

Shotted FeNi toMarket

ESP Off Gas

> 10% CO

Off Gas< 1.0% CO

W.C. Comb.Chamber

Air

l l

Air

ESP

Rotary KilnPre-reduced Calcine

Water

Rotary Kiln

Electric Furnace

80

MW

160 t/h Calcine, 750 deg C

144 t/h Slag1600 deg C

10 t/h Metal1450 deg C

110

MW

Power Plant

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Conceptual

Level

Test/Pilot Full-scale

Granulation

SlagEnergy

Recovery

@ Full -Scale

ContinuousCasting

Evaluation of SHR Technologies

DoubleRotatingDrum

MechanicalGranulator

(40 t/hr)

RotatingCup/Disc

(150 t/hr) *

Air Blast (120 t/hr) ~ 80%

* Trials ongoing

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AIR BLAST (Full scale implementation NKK 1983)

Granule formation (80 t/hr BOF slag),

Heat Recovery to Steam (40%) and Air (40%)

Granulation and Heat Recovery Operated for ~10 years (80 t/h)

Evaluation of SHR Technologies

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Energy Integration OpportunitiesSlag Heat Recovery Energy Balance

USERS

Ore drying

Kiln secondary air

Boiler secondary air

INPUTS OUTPUTS

110,500 Nm3/h (600oC)

125,000 Nm3/h 550oC

Ambient Air110,500 Nm3/h

0 MW

24MW

Hot Air

Power generation(integration into captive

power plant or dedicatedslag heat recovery powerplant).

Heating(boiler feed-

water, utili ties)

TOTAL ENERGY 106MW 106MW

Overall efficiency of slag energy recovery ~ 82%

173,500 Nm3/h (400oC)

Slag

144 t/h1600oC

98 MW 63 MW

Oxidation of FeO19 MW Losses

Steam/preheatedwater

8 MW

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Hot air applications

Desalination, Preheating the sea water

Dryer wit hot air

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Pressure Hydrometallurgy

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Autoclave Process

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Autoclave Vessel

3450 kPa(g), 230oC operating conditions

100 mm thick SA-516 Gr.70N, 5.6 m ID, 34.8 m T/T,

718 tonnes ASME Section VIII, Div. 1 & 2

Compress Codeware

WRC 107

Zicks Analysis

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Zero fugitive emissions Inertization and stabilization of

Arsenic.

Benefits

residues.

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Mixing Efficiency and Gas dispersion

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Autoclave technology

Pueblo Viejo Autoclaves:

780 t each (largest in the world by weight)

Brick lined

Designed by Hatch with quality assuranceduring fabrication

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Rio Tinto, QIT-Fer etTitane, UGS ALPReactor Relinin


Project, Sorel, Quebec.The new reactormembranes andrefractory linings haveperformed

exceptionallywell, with no failuresafter 6 10 years ofservice.

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BHP Billiton, RavensthorpeNickel Operations, Pressure


Letdown Modifications.

These improvementsenabled RNO to become thefirst high pressure acidleach plant in the world toachieve design throughput

within a 12 month ramp-upperiod.

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Companhia Vale Rio Dolce,Usina HidrometallurgicalCarajas, Brazil.


opens the door for theapplication of the CESLprocess to a variety of orebodies in South America.

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Lihir Management Pty.Ltd., Lihir Heat RecoveryProject, Papua NewGuinea.


The heat recovery project

successfully returned Lihirto profitability within 30days of start-up.

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Clean Energy

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GHG Emissions

800

1000

1200

2/kWh

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Source:

Weisser, D. A guide to life-cycle greenhouse gas (GHG) emissions from electric supplytechnologies. IAEA

0

200

400

600

Coal Oil Gas Nuclear Hydro Wind Solar

Lifecycle

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Costs

160

180

200

$580/MWh

0

20

40

60

80

100

120

140

Nuclear Coal Hydro ROR

Hydro

Wind Solar

CapitalCost[$/MWh]

O&M

Investment

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Cost reduction of energy

25

)

30

and bigger turbines ( MW) & efficient

1 American Wind Energy Association

0

5

10

15

20

1980 1985 1990 1995 2000 2005 2010

Cost/KWh(centsU


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Growth of Solar Power

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Balancing Supply and Demand

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Power Storage

]CAES

PumpedStorage

Hydro

Power[M

Wh kWh MWh GWh and higher

CapacitoresBateras

Flywheeling

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Hydropower plants in construction in the world

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Plants >2,000MW to be completed between 2010 2022

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Source: 3Tier

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Hydro with storage + solar

The Andean region of the world has the

topography for the solar generation ofelectricity and the storage of that electricityusing pumped energy storage. Theavailability of hydroelectricity in the regionis well-established. However, the potential

for solar energy generation is as great, ifnot greater.

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Typical Pumped Storage Plant

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Demand

Day 150 MW Night 120 MW

Capacity

Hydroelectric/Solar Energy Storage

Day Hydro 100 MW Solar 70 MW

Night Hydro 100 MW Solar 0 MW

Capacity Imbalance

Day + 20 MW

Night - 20 MW

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Solar Thermal Energy Storage with Molten Salts

Molten salt thermal energy storage has

been suggested for two mainapp ications: t erma concentrate

solar power plants and conventionalthermal power plants that cannot easilyturn down their power output.

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Power Tower

Hot Salt

Cold Salt

Receiver

Parabolic Trough

Concentrated Solar Power with Thermal EnergyStorage

Solar Field(Flat Mirrors)

SteamGeneration

Solar Field(Parabolic Mirrors)

Cold Salt

Hot Salt

Oil Circuit

SteamGeneration

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Conclusions

Membrane technology is effective for recovery of

valuable products and contaminants

Membranes produce prime potable standardwater

o energy n s ags s recovera e

Recovered slag energy can be recycled throughthe process to reduce costs and for electricitygeneration

Autoclaves are very effective for complex ores,

contaminants such as arsenic, high altitude, noemissions

Solar energy can be combined with hydroelectricenergy to balance supply and demand fluctuation

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Questions or comments.

THE ART OF INNOVATION

Av. Conquistadores 626 ,San Isidro, - Lima, Per

Tel: (51-1) 714 4000

[email protected]

www.hatch.ca

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