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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. Marsden
Senior Vice President, Technology & Product Development
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2006 Phelps Dodge Corporation
Outline
Safety
Historical context
Solution extraction and electrowinning
Atmospheric leaching
Secondary sulfides
Primary sulfides
Pressure leaching
Other developments affecting copper hydrometallurgy
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2006 Phelps Dodge Corporation
Safety
Phelps Dodge philosophy Zero & Beyond
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2006 Phelps Dodge Corporation
Hydrometallurgy in Copper Extraction
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2006 Phelps Dodge Corporation
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 03
Year
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Large scale SX/EW
Computerized haul truck dispatch
GPS ore control
Leach recovery optimization
Concentrate grade enhancement
Tyrone
SX/EW
Morenci
SX/EW
Chino
SX/EW
Morenci
Northwest
Extension
Candelaria 1
Morenci
Southside
Candelaria 2
Expert control systems
Concentrator adaptive control
Mine for leach
Haul truck tire technology
Concentrate leach (2003)
Morenci MFL,
El Abra ROM
Cyprus
Acquisition
Curtailment
Commenced
Chino 1/3
Acquisition
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2006 Phelps Dodge Corporation
Solution Extraction and Electrowinning
Mine
Heap
Leaching
(Oxide)
(Chalcocite)
Solution
Extraction
Milling
(Chalcocite)
(Chalcopyrite)
Smelting
Electro-
Refining
Electro-
Winning
Acid
Flotation
Primary
Crushing
Stockpile
Leaching
(Oxide)
(Chalcocite)
Sec/Tert
Crushing
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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2006 Phelps Dodge Corporation
Solution Extraction and Electrowinning at Bagdad, Arizona
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2006 Phelps Dodge Corporation
Solution Extraction & Electrowinning
1968 Ranchers Bluebird mine, Arizona
1971 Bagdad, Arizona
1974 ZCCM, Zambia
1976 Miami, Arizona
1979 Inspiration, Arizona
1980 Cananea, Mexico
1981 Pinto Valley, Arizona
1984 Tyrone, New Mexico
1985 Ray, Arizona
1987 Morenci, Arizona
1987 Sierrita, Arizona
1987 Chuquicamata, Chile
1988 Chino, New Mexico
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2006 Phelps Dodge Corporation
Example of Technology Transforming Copper Production
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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
Conventi onal SX/EW
(PDC share; millions of pounds)
1983 100% conventional
2004 66% SX/EW
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Morenci Modoc SX Plant
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2006 Phelps Dodge Corporation
Koch Solution Extraction In-Pipe Reactor
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Enhanced Sulfide Heap and Stockpile Leaching
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2006 Phelps Dodge Corporation
Biologically Enhanced Leaching
air air
leach solution
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Cerro Verde Leach Pad 4 - Grasshopper Stacker
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2006 Phelps Dodge Corporation
Morenci Mine-for-Leach Agglomeration Drums
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2006 Phelps Dodge Corporation
Morenci Mine-for-Leach North Stacker
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2006 Phelps Dodge Corporation
Leaching Developments Bacterial Augmentation
Stream contains 3x10
8
cells/ml genetically selected bacteria
Delivers two separate bacterial strains simultaneously
Skid mounted
Design based on Bagdad plant shown below
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2006 Phelps Dodge Corporation
Advanced Modeling to Improve Heap Performance
Air and solution modeling in heap
Temperature profile in heap
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2006 Phelps Dodge Corporation
Enhanced Chalcopyrite Leaching Bagdad Crystal Mountain
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2006 Phelps Dodge Corporation
Morenci Enhanced Stockpile Leaching
Low-grade ore from Western Copper deposit
Below mill cut off grade material
Mixed sulfide minerals chalcopyrite, chalcocite
188 million ton stockpile to be constructed
Air injection
Bacteria augmentation
Controlled solution application
Largest engineered chalcopyrite stockpile leach in the world
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Concentrate Leaching Alternative to Smelting & Refining
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Copper Extraction in 1980s and 1990s
Secondary sulfide
and oxide ores
Primary sulfide
ores
Mine
Leaching Flotation
Refining
Smelting
Rod Mill or Customer
SX
EW
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2006 Phelps Dodge Corporation
Concentrate Leach Technology Replaces Smelting/Refining
Secondary sulfide
and oxide ores
Primary sulfide
ores
Mine
Leaching Flotation
Refining
Smelting
Rod Mill or Customer
SX
EW
Concentrate
Leaching
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2006 Phelps Dodge Corporation
Copper Concentrate Leaching History
Process developments - 1970s and 80s
Ammonia - Arbiter
Chloride - CLEAR, SOX, Cuprex
Sulfate - Roast/Leach/Electrowin (Lakeshore)
Many others
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2006 Phelps Dodge Corporation
Copper Concentrate Leaching History
Process developments - 1970s and 80s
Ammonia - Arbiter
Chloride - CLEAR, SOX
Sulfate - Roast/Leach/Electrowin (Lakeshore)
Many others
Reasons for lack of commercial success
High cost (capital & operating)
Problems with materials of construction
Problems with operability/maintainability
Process complexity
Precious metals recovery problems
Problems with copper cathode quality
Primitive, early stage SX/EW technology
Not integrated with leaching operations
Significant advances in smelting technology
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2006 Phelps Dodge Corporation
Copper Concentrate Leaching More Recent Developments
Ammonia - Escondida
Sulfate
Phelps Dodge
Placer Dome
CESL/Teck Cominco (chloride-assisted)
UBC/Anglo American
Activox
Dynatec
Biological
BHP-Billiton BioCop
Bactech-Mintek
Others
Chloride/Bromide Process Intec
Chloride Outokumpu HydroCopper
Nitrate
Other
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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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Bagdad Concentrate Leach Plant Schematic
PLS Pond and
SX/EW
Slurry
Storage
Tank
Concentrate
Slurry
PLV
Feed
Tank
PLV PLV
CCD #1
Flash
Vessel
Flash
Vessel
Strong
PLS
Tank
Neut
#1
Neut
#2
Neut
#3
Neut
#4
Tails
CCD #2
CCD #3
CCD #4
#1
S
C
R
U
B
B
E
R
#2
S
C
R
U
B
B
E
R
PLS to SX/EW and Cathode Production
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Bagdad Concentrate Leach Plant
August, 2003
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2006 Phelps Dodge Corporation
Pressure Leaching Vessel at Bagdad
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Solid-liquid Separation at Bagdad
August, 2003
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2006 Phelps Dodge Corporation
Bagdad Concentrate Leach Plant Copper Production
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500,000
1,000,000
1,500,000
2,000,000
2,500,000
3,000,000
3,500,000
4,000,000
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Production (lbs) Design Basis Production
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2006 Phelps Dodge Corporation
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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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 refining
Generates by-product acid for leaching
Eliminates freight cost for concentrate shipments and acid
deliveries
Decouples Morenci from smelter balance dependency
Reduces Morencis 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 balance
Utilize 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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2006 Phelps Dodge Corporation
Production Decisions Impacted by Concentrate/Acid Balance
Chino Smelter
650,000 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
Candelaria
concentrate
External
acid
consumer
Miami Smelter
750,000 tpy capacity
(operating)
External
concentrate
source
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2006 Phelps Dodge Corporation
Morenci Concentrate Leaching Facility 3D Model View
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2006 Phelps Dodge Corporation
Other Developments Affecting Copper Hydrometallurgy
Material Characterization
Comminution
Alternative Products
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2006 Phelps Dodge Corporation
High-Pressure Grinding Rolls
Cerro Verde milling circuit to
include high pressure grinding
rolls (HPGR) instead of SAG mills
Pros
Higher throughput
Greater energy efficiency
Greater flexibility
Lower unit cost
Cons
Additional capital cost
Financial Impact
Significantly reduces power
consumption and unit
production costs
Note - Use yellow to
highlight font colors
(but never titles)
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Material Characterization QemSCAN Technology
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New Copper Products
Copper powder technology
Potential replacement for cathode
to rod
Specialty copper powders
Copper powder process reduces or
eliminates the following:
Manual harvesting of cathodes
Cell cleaning
Stainless blank repairs and
replacement
Stripping machines
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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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