Recent Developments in Copper · PDF file1 ©2006 Phelps Dodge Corporation Sohn International Symposium on Advanced Processing of Metals and Materials: Principles, Technologies and

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


Outline

SafetyHistorical contextSolution extraction and electrowinningAtmospheric leaching

Secondary sulfidesPrimary sulfides

Pressure leachingOther developments affecting copper hydrometallurgy


Safety

Phelps Dodge philosophy – “Zero & Beyond”


Hydrometallurgy in Copper Extraction


Phelps Dodge – Long Track Record of Technology Deployment

0

500

1,000

1,500

2,000

2,500

3,000

83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 00 01 02 03Year

Cop

per P

rodu

ced

(mill

ions

of p

ound

s)

• 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


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


Solution Extraction and Electrowinning at Bagdad, Arizona


Solution Extraction & Electrowinning

1968 Rancher’s 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


Example of Technology Transforming Copper Production

0

500

1,000

1,500

2,000

2,500

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


Morenci Modoc SX Plant


Koch Solution Extraction In-Pipe Reactor


Enhanced Sulfide Heap and Stockpile Leaching


Biologically Enhanced Leaching

air air

leach solution


Cerro Verde Leach Pad 4 - Grasshopper Stacker


Morenci Mine-for-Leach Agglomeration Drums


Morenci Mine-for-Leach – North Stacker


Leaching Developments – Bacterial Augmentation

Stream contains 3x108 cells/ml genetically selected bacteriaDelivers two separate bacterial strains simultaneously Skid mountedDesign based on Bagdad plant shown below


Advanced Modeling to Improve Heap Performance

Air and solution modeling in heap

Temperature profile in heap


Enhanced Chalcopyrite Leaching – Bagdad Crystal Mountain


Morenci Enhanced Stockpile Leaching

Low-grade ore from Western Copper depositBelow mill cut off grade materialMixed sulfide minerals – chalcopyrite, chalcocite188 million ton stockpile to be constructedAir injectionBacteria augmentationControlled solution application

Largest engineered chalcopyrite stockpile leach in the world


Concentrate Leaching – Alternative to Smelting & Refining


Copper Extraction in 1980s and 1990s

Secondary sulfide and oxide ores

Primary sulfide ores Mine

LeachingFlotation

Refining

Smelting

Rod Mill or Customer

SX

EW


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


Copper Concentrate Leaching History

Process developments - 1970’s and 80’sAmmonia - ArbiterChloride - CLEAR, SOX, CuprexSulfate - Roast/Leach/Electrowin (Lakeshore)Many others


Copper Concentrate Leaching History

Process developments - 1970’s and 80’sAmmonia - ArbiterChloride - CLEAR, SOXSulfate - Roast/Leach/Electrowin (Lakeshore)Many others

Reasons for lack of commercial successHigh cost (capital & operating)Problems with materials of constructionProblems with operability/maintainabilityProcess complexityPrecious metals recovery problemsProblems with copper cathode quality Primitive, early stage SX/EW technologyNot integrated with leaching operationsSignificant advances in smelting technology


Copper Concentrate Leaching – More Recent Developments

Ammonia - EscondidaSulfate

Phelps DodgePlacer DomeCESL/Teck Cominco (chloride-assisted)UBC/Anglo AmericanActivoxDynatec

BiologicalBHP-Billiton “BioCop”Bactech-MintekOthers

Chloride/Bromide Process – IntecChloride – Outokumpu “HydroCopper”Nitrate Other


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 approvedMar 2003 Start-up: First concentrate feedJuly 2003 All design parameters met, steady state operation

Four years from first testing to commercial demonstration


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


Bagdad Concentrate Leach Plant

August, 2003


Pressure Leaching Vessel at Bagdad


Solid-liquid Separation at Bagdad

August, 2003


Bagdad Concentrate Leach Plant Copper Production

0

500,000

1,000,000

1,500,000

2,000,000

2,500,000

3,000,000

3,500,000

4,000,000

Mar-03

Apr-03

May-03

Jun-03

Jul-0

3Aug-03Sep

-03Oct-

03Nov-0

3Dec

-03Ja

n-04Feb

-04Mar-

04Apr-0

4May

-04Ju

n-04Ju

l-04

Aug-04Sep

-04Oct-

04Nov-0

4Dec

-04

Prod

uctio

n (lb

s)

Production (lbs) Design Basis Production


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 demonstration2Q 2007 Scheduled completion of Morenci facility


Bagdad MT-DEW Process Conversion – Super-fine Grinding


Direct Copper Electrowinning at Bagdad, AZ


Morenci Concentrate Leaching Application

Provides economically viable alternative to smelting and refiningGenerates by-product acid for leachingEliminates freight cost for concentrate shipments and acid deliveriesDecouples Morenci from smelter balance dependency Reduces Morenci’s mill conversion costs

Morenci Western Copper concentrate mineralogy Mixed chalcopyrite, covellite, chalcocite, pyrite

Medium temperature and direct electrowinning (“MT-DEW”) process selected

Best fit with Morenci concentrate production and acid balanceUtilize existing EW and SX capacity at Morenci

Copper production capacity = 75,000 tons per yearCopper recovery slightly higher than smelting and refining


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


Morenci Concentrate Leaching Facility – 3D Model View


Other Developments Affecting Copper Hydrometallurgy

Material CharacterizationComminutionAlternative Products


High-Pressure Grinding Rolls

Cerro Verde milling circuit to include high pressure grinding rolls (HPGR) instead of SAG millsPros

Higher throughputGreater energy efficiencyGreater flexibilityLower unit cost

ConsAdditional capital cost

Financial ImpactSignificantly reduces power consumption and unit production costs

Note - Use yellow to highlight font colors

(but never titles)


Material Characterization – QemSCAN Technology


New Copper Products

Copper powder technologyPotential replacement for cathode to rodSpecialty copper powders

Copper powder process reduces or eliminates the following:

Manual harvesting of cathodesCell cleaningStainless blank repairs and replacementStripping machinesSlippery or brittle cathodes

Focused on reducing costs and improving process safety and efficiencyPDC proprietary technologyDemonstration plant in operation at Morenci, AZ


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

Documents

Recent Developments in Copper · PDF file1 ©2006 Phelps Dodge Corporation Sohn International Symposium on Advanced Processing of Metals and Materials: Principles, Technologies and