Process Design for Mineral Sem inar – Process Design for Mineral Operations Operations Luis A. Cisternas Director – CICITEM Research Center for Mining and Department of Chemical Engineering Universidad de Antofagasta Antofagasta - Chile PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Outline Sem inar – Process Design for Mineral Operations Motivation General Strategy Crystallization Design Problem Flotation Circuit Design Problem Final Remark PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Price of copper Motivation Sem inar – Process Design for Mineral Operations • High price cycle unprecedented • Lowering the cost of production • Achieving the balance of acceptable economic, environmental and social effects. Figure From: http://www.lanacion.cl/prontus_ • Improve energy efficiency noticias/site/artic/20070802/pags /20070802215453.html Copper Technology Roadmap Review 2006, AMIRA PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Sem inar – Process Design for Mineral Operations The engineer`s lover Carlo Carrá Italian 1881-1966 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Problems: Process design has multiple dimensions Sem inar – Process Design for Mineral Operations Roberto Matta Chilean 1911-2002 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Solution: Sem inar – Process Design for Mineral Operations Look as Picasso Pablo Picasso Spanish 1881-1973 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
The Onion Model Sem inar – Process Design for Mineral Operations PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Crystallization Design Sem inar – Process Design for Mineral Operations Problem Crystallization design problem overview Fractional Crystallization Fractional Crystallization with Heat Integration & Cake Washing PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Crystallization design problem overview Sem inar – Process Design for Mineral Operations Crystallization is extensively used in different industrial applications, including the production of a wide range of materials such as fertilizers, detergents, foods, and pharmaceutical products, as well as in the treatment of waste effluents PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Problems Sem inar – Process Design for Mineral Operations The crystallization stages are usually accompanied by other separation techniques. Leaching. Various types of crystallization exist: cooling, evaporation, reactions, and drowning-out The characteristics of the product affects a series of other associated operations. filtration & washing. The separation is limited by multiple saturation points. Temperature changes & external chemical agents. Kinetic factors and metastability may affect the design. PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Phase Diagram Sem inar – Process Design for Mineral Operations The greatest advantages obtained in the use of the phase diagram are the possibilities for the visualization of the behavior of phase equilibria, describing the processes, and obtaining mass balances with the help of the lever arms rule. The phase diagrams, however, also have a series of limitations as a design tool PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Phase Diagram Sem inar – Process Design for Mineral Operations PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Goals Sem inar – Process Design for Mineral Operations Determine optimal stream configuration. Determine operational conditions & flowrates. Selection of equipment type. Determine solid-liquid separation. Washing & Filtration. Determine heat integration. PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Fractional Crystallization Sem inar – Process Design for Mineral Operations Basic Crystallization Separation Relative Composition Diagram Feasible Pathway Diagram State Superstructure Connectivity Matrix Mathematical model Examples PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Basic Crystallization Separation Sem inar – Process Design for Mineral Operations Isothermal Cut KCl+NaCl+H2O KNO3+NaNO3+H2O L serine acid + L aspartic acid + water PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Basic Crystallization Separation Sem inar – Process Design for Mineral Operations p2 p1 Isothermal Cut KCl+NaCl+H2O KNO3+NaNO3+H2O L serine acid + L aspartic acid + water PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Basic Crystallization Separation Sem inar – Process Design for Mineral Operations B Heat and Evaporate b H Cool and Dilute h C c a S A (a) Basic Cycle PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Relative Composition Diagram Sem inar – Process Design for Mineral Operations Weight Compositio n of B = RB 8 R Weight Compositio n of A RC a R B > R C > R H > R A RH H C F RA= 0 S (a) PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Feasible Pathway Diagram Sem inar – Process Design for Mineral Operations RB 8 R B > R C > R H > R A RC a RH R B > R C > R H > R A H C F RA= 0 S (a) PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
State Superstructure Sem inar – Process Design for Mineral Operations C A F R B > R C > R H > R A S S B H PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Connectivity Matrix Sem inar – Process Design for Mineral Operations R B > R C > R H > R A C H S 2 A B 1 2 F 7 C A 1 3 4 S 1 8 F 2 5 6 5 8 7 C 3 S 9 S 4 6 9 10 H B H 10 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Mathematical model Sem inar – Process Design for Mineral Operations 7 C A 1 General model 8 F Cisternas, L.A. (1999), Optimal design of 2 crystallization-based separation schemes, 5 6 3 S AIChE J. , 45, 1477-1487. 9 S 4 B H 10 ∑ Min w l w l + + = + + w x w x w x w x w x w x 1 1 , i 3 3 , i 6 6 , i 5 5 , i 7 7 , i 8 8 , i + + = + + w x w x w x w x w x w x 2 2 , i 4 4 , i 5 5 , i 6 6 , i 9 9 , i 10 10 , i + = F w x w x C 1 1 , i 2 2 , i 1 , i ≥ = w 0 ; i A , B , S l PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Examples-Sylvinite Sem inar – Process Design for Mineral Operations Equilibrium Data Weight Temperatur Composition key e Solid Phase [° C ] KCl NaCl C1 30 11.7 20.25 KCl+NaCl H1 100 22.2 15.9 KCl+NaCl R KCl R H1 R C1 R NaCl ∞ 1.40 0.58 0.0 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Examples-Sylvinite Sem inar – Process Design for Mineral Operations Relative Composition Diagram Feasible Pathway Diagram R KCl > R H1 > R C1 > R NaCl R KCl > R H1 > R C1 > R NaCl 7 H1 NaCl 1 8 Sylvinite 2 State Diagram 5 6 3 H2O 10 H2O 4 Kcl C1 8 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Examples-Sylvinite Sem inar – Process Design for Mineral Operations State Diagram Flow Sheet Sylvinite 7 H1 NaCl 1 Sylvinite 2 LEACHING AT 5 6 LEACHING AT 100 ‘C 30 ‘C K Cl C1 8 NaCl KCl PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
Examples-Astrakanite Equilibrium data for MgSO 4 +Na 2 SO 4 +H 2 O system. Sem inar – Process Design for Mineral Operations Saturated solution, % w keys Solid phase R T ºC MgSO 4 Na 2 SO 4 18.7 C 20.57 11.8 Mg 7 + Na 10 1.7 25 D1 21.15 13 Mg 7 + SD1 1.6 25 D2 16.6 17.8 SD1 + Na 10 0.9 50 E1 31.32 4.74 Mg 6 + SD1 6.6 50 E2 11.98 23.25 SD1 + Na 0.5 97 F1 32.2 5.55 Mg 1 + SD2 5.8 97 F2 14.4 19.15 SD2 + SD3 0.8 97 F3 5.88 26.9 SD3 + Na 0.2 SD1 35.99 42.48 0.8 SD2 45.86 54.14 0.8 SD3 22.02 77.98 0.3 Mg7=MgSO4.7H2O; Mg1=MgSO4.1H2O; Mg6=MgSO4.6H2O; Na10=Na2SO4.10H2O; Na=Na2SO4; SD1= Na2SO4.MgSO4.4H2O; SD2= Na2SO4.MgSO4; SD3= MgSO4.3Na2SO4 PASI 2 0 0 8 PASI 2 0 0 8 Pan Am erican Advanced Studies I nstitute Program on Em erging Trends in PSE
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