Download - Doris Hiam
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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
Autoclave technology
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
Autoclave technology
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.
Autoclave technology
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.
Autoclave technology
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
CO
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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
www.hatch.ca
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