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Design of wash stage in copper solvent extraction

Technical Report · April 2020

DOI: 10.13140/RG.2.2.16517.50407

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 INDEPENDENT METALLURGIST

Design of wash stage

in copper solvent
extraction
KAFUMBILA KASONTA JOSEPH

2020

Page 0
Design of wash stage in copper solvent extraction
© Joseph Kafumbila
jokafumbila@hotmail.com

Joseph Kafumbila Page 1

1. Introduction
Many copper SX-EW circuits experience high entrainment of aqueous in organic
phase. Aqueous entrainment in organic phase results in the carry-over of unwanted ions
into the electrowinning circuit. The elements like iron, chloride and manganese are
controlling the electrolyte bleed in copper EW circuit. Ideally total iron is kept below 2
g/L, chloride below 35 ppm and manganese below 100 ppm (Hans Hein, 2005). In the
case of iron, ferric reacts chemically with the organic phase. Ferrous and ferric are
transferred into electrolyte by physical entrainment and in addition ferric is transferred
from leach solution into electrolyte being chemically loaded in extraction stage and
completely stripped in stripping stage.

Aqueous entrainment in organic phase depends on the reagent type, the reagent
concentration, the temperature, the viscosity, the phase continuity and mixer settler
design (Hans Hein, 2005 and P. Cole et al, 2016). Ferric extraction on the organic phase
depends on the pLS pH and the saturation of organic phase with copper (Hans Hein,
2005 and O. Tinkler et al, 2009).

The originality of this paper is to simulate a block flow diagram of copper SX-
EW having a conventional configuration 2Ex2S by using Data from existing copper
solvent extraction plants to visualize aqueous entrainment problem on SX-EW design.
The simulation take account only the aqueous entrainment in organic phase. The
simulation is done on the extreme cases: saturated organic phase with copper and the
highest copper solvent extraction efficiency.

2. Wash stage configuration

There are three configurations of wash stage in copper solvent extraction. In all
configuration there is an aqueous coalescing tank separated to a surge loaded organic
tank. In the first configuration that is usually used the wash stage comes after the surge
organic tank (Figure 1). In this configuration the aqueous coalescing tank removes a big
portion of aqueous entrainment before the wash stage. In the second configuration the
wash stage comes after the first stage of extraction step (Figure 2). In the third
configuration the wash stage is removed from the copper solvent extraction
configuration and water is sprayed on the loaded organic in E1 organic weir (Figure 3).
The third configuration is used when the chemical transfer of iron is negligible.

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 Figure 1: Wash stage comes after surge organic tank

Figure 2: Wash stage comes after extraction step

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 Figure 3: E1 configuration with wash stage in the organic weir

3. Wash stage design criteria

In the first and second configurations wash stage needs addition mixer – settler
having the same size than extraction and stripping mixers – settlers. The external O/A
ratio varies from 40/1 to 80/1 in industrial practice. In practice the external O/A is
around 50/1. The internal O/A ratio is 1.25 to avoid the formation of crud. The wash
solution must have a pH less than 2 to avoid iron precipitation that can increase the
formation of crud (Liu Jian she et al, 2002). In the conditions where the wash solution is
acidified water; the increase of acid concentration in the wash solution is to strip iron in
the loaded organic. In the same time copper is stripped from loaded organic also. In the
conditions where the wash solution is a mixture of spent electrolyte and water; the
decrease of ratio volume of water on volume of spent electrolyte increases the free acid
in the wash solution for iron stripping. At certain level of copper in the wash solution
copper can be extracted from the wash solution to the loaded organic. (Hans Hein,
2005).

4. Wash stage equilibrium line

4.1. Wash stage equilibrium correlation

The equilibrium correlation between copper concentration in organic phase,

copper concentration in aqueous phase and acid concentration in aqueous phase of
wash stage is the equilibrium correlation of extraction step. In the case where the
extractant is Lix984N, Equation (1) gives the correlation between copper concentration

Joseph Kafumbila Page 4

in organic phase, copper concentration in aqueous phase and acid concentration in
aqueous phase of wash stage (J. Kafumbila, 2017).

Cueorg aq [Ace ]2
*[3.303∗V%−3.0842∗Cu =(-25.698*V%(−1.704) )*Cueorg +10.663*V%(−0.608) (1)
Cueaq e
org ]
2

Cueorg : The concentration of copper in organic phase at equilibrium (g/L).

Cueaq : The concentration of copper in aqueous phase at equilibrium (g/L).
e
Acaq : The concentration of acid in aqueous phase at equilibrium (g/L).
V%: The concentration of Lix984N in organic phase (%).

4.2. Resolution of equation

The semi-empirical model of extraction step using Lix984N as extractant is

given by the equation (1). Equation (2) gives the concentration of free acid at
equilibrium.

e i
Acaq = Acaq + (Cuiaq - Cueaq ) * 1,54 (2)
Cuiaq : The concentration of copper in the wash solution (g/L).
i
“Acaq : The concentration of free acid in the wash solution (g/L).

e
The value of “Acaq ” in equation (1) is replaced by the equation (2), it appears
equation (3).

Cueorg (Aciaq +(Cuiaq −Cue )∗1.54) 2

aq
*(3.3030∗ V%−3.0842∗ =(-25.698*v%(−1.704) ) ∗ Cueor + 10.663* v%(−0.608) (3)
Cueaq Cue org )2

After arrangement equation (3) becomes equation (4).

Cueorg ((Aciaq +1.54∗Cuiaq )−1.54∗Cueaq )) 2

Cueaq
* (3.3030∗ V%−3.0842∗ Cueorg )2
=(-25.698 * v%(−1.704) ) ∗ Cueor+ 10.663 * v%(−0.608) (4)

The new designations are introduced and equation (4) becomes equation (5).

 Y = Cueor
 X = Cueaq

Y (a+b∗X)2
* = e*Y +f (5)
X (c+d∗Y)2

Equations (6), (7), (8), (9), (10) and (11) give the values of a, b, c, d, e, and f.

Joseph Kafumbila Page 5

 i
a=Acaq + 1.54 * Cuiaq (6)

b= −1.54 (7)

c= 3.303*V% (8)

d= −3.0842 (9)

e= −25.698 * V%(−1.704) (10)

f= 10.663 * V%(−0.608) (11)

Equation (5) becomes equation (12) after placing “Y” on one side and “X” on
other side.

(a+b∗X)2 (e∗Y+f)∗(c+d∗Y)2
= (12)
X Y

The value of concentration of copper in the aqueous phase at equilibrium is

known value. The unknown value is the concentration of copper in the organic phase at
equilibrium.

Equation (13) gives the value of constant “g”.

(a+b∗X)2
g= (13)
X

Equation (12) becomes equation (14) after introducing equation (13) where
values of constants α, λ and ε are given by equations (15), (16) and (17) respectively.

Y 3 + α*Y 2 +λ*Y +ε =0 (14)

2∗c∗d∗e+(d)2 ∗f
α= (15)
(d)2 ∗e

2∗c∗d∗f + (c)2 ∗e − g
λ= (16)
(d)2 ∗e

f∗(c)2
ε= (d)2 ∗e (17)

Equation (18) gives the value of variable “Y” as a function of variable “T”.

α
Y=T-3 (18)

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 Equation (14) becomes equation (19) after replacing the variable “Y” by
equation (18). Equations (20) and (21) give the values of constants p and q.

T 3 +p*T +q =0 (19)

(α)2
p= λ - (20)
3

α∗λ 2
q= ε - + 27* (α)3 (21)
3

Equation (19) has a form of Cardan formula (three degree equation). The value
of T is given by the equation (22).

1 1 1 1
q 1 4 q 1 4
T= [− 2 − 2 ∗ ((q)2 + 27 ∗ (p)3 )(2) ](3) + [− 2 + ∗ ((q)2 + 27 ∗ (p)3 )(2) ](3) (22)
2

4.3. Wash stage equilibrium lines

4.3.1. Equilibrium lines with wash solution containing only acid

Figure (4) gives equilibrium lines of wash solutions containing 2, 10 and 20g/L
of free acid respectively and the organic phase contains 20% of Lix984N.

Figure 4: Equilibrium lines of wash solution containing 2, 10 and 20 g/L of acid and 20%
of Lix984N in organic phase

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4.3.2. Equilibrium lines with mixture spent electrolyte and water

The organic phase contains 20% of Lix984N. The spent electrolyte contains 35
g/L of copper and 180 g/L of sulfuric acid.

 Case 1 – wash solution is a mixture of 19 volume of water and one volume spent
electrolyte. The wash solution contains 1.75 g/L of copper and 9 g/L of acid.
 Case 2 – wash solution is a mixture of 11 volume of water and one volume spent
electrolyte. The wash solution contains 2.92 g/L of copper and 15 g/L of acid.
 Case 3 – wash solution is a mixture of 8 volume of water and one volume spent
electrolyte. The wash solution contains 3.89 g/L of copper and 20 g/L of acid.

Figure (5) gives equilibrium lines of mixtures having ratio of water volume on
spent electrolyte volume about 19/1, 11/1 and 8/1 respectively and the organic phase
contains 20% of Lix984N.

Figure 5: Mixtures having ratio of volume water on volume spent electrolyte about 19/1,
11/1 and 8/1 respectively and the organic phase contains 20% of Lix984N.

4.3.3. Observations

Wash stage equilibrium lines developed using this model are similar to those
developed by Hans Hein (Hans Hein, 2005). Applying Data from Figure (3) in Hans Hein

Joseph Kafumbila Page 8

paper (Hans Hein, 2005) Figure (6) gives results. These results are close to Hans Hein
simulation.

7,40
DATA
Reagent: 20% Lix984N
7,38 Spent Electr. (g/l Cu) : 36.00
(g/l H2SO4) : 180.00
7,36 Wash stage Organic flow (m3/h) : 1000
Isotherm Wash solution flow (m3/h):20
Spent electrolyte (m3/h) : 1
7,34
water (m3/h) : 19
Washed O/A Ratio in W1 : 50/1
7,32 Loaded Loaded Organic (g/l Cu) : 7.28
organic
O rganic phase: Cu (g/L)

Initial wash solution (g/l Cu): 1.8

7,30 (g/l H2SO4): 9.00
Mixing Efficiency in W1 : 95%
Temperature : 25°C
7,28
Loaded RESULTS
organic Profile
7,26 Or Aq
Solution
Solution Init. Conc. 7.2800 1.8000
wash
7,24 wash Final Conc. 7.3001 0.7945
in
out
Acid in W1 (g/l H2SO4): 10.5484
7,22

7,20
0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5 4,0

Aqueous phase: Cu g/L

Figure 6: Simulation of wash stage with Data from Hans Hein paper Figure 3

5. Simulation copper solvent extraction circuit

5.1. Equilibrium correlations

The equilibrium correlation between copper concentration in organic phase,

copper concentration in aqueous phase and acid concentration in aqueous phase of
extraction step is given by Equation (1). The equilibrium correlation between copper
concentration in organic phase, copper concentration in aqueous phase and acid
concentration in aqueous phase of stripping step is given by Equation (23) (J. Kafumbila,
2017).

Cueorg [Aceaq ]2
* =(5.11*10(−3) *V% - 0.194)∗ Cueor + 12.81 * v%(−0.901) (23)
Cueaq [3.3030∗ V%−3.0842∗ Cueorg ]2

The resolution of Equation (23) follows the same model explained in chapter
(4.2).

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5.2. Copper solvent extraction without wash stage

5.2.1. Data

Figure (7) gives the block diagram of copper SX-EW circuit without wash stage.
This flow diagram shows only the aqueous entrainment in organic phase. The
description of flows is the following:

Figure 7: Block diagram of copper solvent extraction circuit without wash stage

 PLS: Pregnant leach solution

 E1: Stage 1 of extraction step
 E2: Stage 2 of extraction step
 Raf E1: Raffinate from E1
 Raf E2: Raffinate from E1
 LO E1: Loaded organic from E1
 ELO E1: Entrainment aqueous in LO E1
 LO E2: Loaded organic from E2
 ELO E2: Entrainment aqueous in LO E1
 CO: Aqueous coalescing tank
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  LO CO: Loaded organic from CO
 ELO CO: Entrainment aqueous in LO CO
 DS CO: Discharged solution from CO
 S1: Stage 1 of stripping step
 S2: Stage 2 of stripping step
 SO S1: Stripped organic from S1
 ESO S1: Entrainment aqueous in SO S1
 SO: Stripped organic from S2
 ESO: Entrainment aqueous in SO
 SP: Spent electrolyte
 AD S2: Advance electrolyte from S2
 AD S1: Advance electrolyte from S1
 CuEW: Copper electrowinning circuit
 CuEWB: Copper electrowinning circuit bleed

The design criteria are the following:

- Extraction step
o Number of stages: 2
o Phase continuity: Organic continuous
o PLS flow rate: 1000 m3/h
o PLS - Copper: 8.04 g/L
o PLS - acid: 2 g/L
o PLS - iron: 0.8 g/L
o PLS - manganese: 2.75 g/L
o O/A internal: 1.25
o O/A external: 1.25
o Mixing efficiency E1: 95%
o Mixing efficiency E2: 97%
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
- Stripping step
o Number of stages: 2
o Phase continuity: Organic continuous
o Spent electrolyte - Copper: 35 g/L
o Spent electrolyte - acid: 180 g/L
o Spent electrolyte - iron: 2g/L
o Stripped organic from S1 - Iron: 1ppm
o Advance electrolyte copper: 50 g/L
o Mixing efficiency S1: 98%
o Mixing efficiency S2: 95%

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 o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
- Aqueous coalescing tank
o Aqueous entrainment recovery: 65% (P. Cole et al, 2016)
- Copper tank house
o Spent electrolyte – Iron: 2g/L

There are two cases:

 The first case – the organic phase is saturated with copper – the ratio of
loaded organic on maximum load organic (LO/ML) is equal to 80%. In
this condition the ratio of Cu on ferric (Cu/Fe) in LO E1 is around 1000
(O. Tinkler et al, 2009).
 The second case – the organic phase is unsaturated with copper – the
highest value of extraction efficiency. For this configuration (2Ex2S) the
stripping efficiency must be equal to 60% (J. Kafumbila, 2017). In this
condition the ratio of Cu on ferric (Cu/Fe) in LO E1 is around 500
(assumed).

It has been observed that Ferric concentration in the loaded organic increases
with decreasing PLS pH (Hans Hein, 2005) and increases with decreasing LO/ML (O.
Tinkler et al, 2009). Ferric concentration in loaded organic is around 10 ppm with
concentration of Lix984N in organic phase about 20% and iron concentration in PLS
about 1.16 g/L at pH range of 1.5 – 1.8.

Copper loading has priority over ferric loading. Almost in all SX plants it is
observed, that iron loaded in organic phase exceeds iron loaded in E1 organic phase.
Ferric concentration in the organic phase depends on the concentration of ferric in
solution, saturation of organic phase by copper and the acid concentration in solution. In
this simulation it assumes that ferric is loaded in organic in E1 and is stripped in S1
because the equilibrium correlations of ferric is not yet established. Ferric concentration
in the stripped organic is 1ppm (Hans Hein, 2005).

5.2.2. Simulation results

The procedure of simulation of copper solvent extraction configurations using

the equilibrium correlations is explained in paper (J. Kafumbila, 2017).

5.2.2.1. Saturated organic phase

Tables 1A, 1B, 1C, 1D and 2 give the mass balance of copper solvent extraction
circuit working with saturated organic phase.

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 Table 1A: Mass balance of Cu-SX circuit – Saturated organic phase

Description PLS Raf E1 Raf E2 LO E1 ELO E1

Volume m3/h 1000 1002.63 1001.63 1250.00 2.5
Cu g/L 8.04 2.588 0.403 8.772 2.588
Fe g/L 0.80 0.790 0.793 0.009 0.790
Mn g/L 2.75 2.750 2.744 2.750
Acid g/L 2.0 10.424 14.335 10.424
Cu Kg/h 8040.0 2591.8 403.2 10965.2 6.47
Fe Kg/h 800.0 791.6 794.6 10.97 1.98
Mn Kg/h 2750.0 27454.5 2748.8 6.87
Acid Kg/h 2000.0 10440.7 14358.4 10.42

Table 1B: Mass balance of Cu-SX circuit – Saturated organic phase

Description LO E2 ELO E2 SO ESO SP

Volume m3/h 1250.0 2.5 1250.0 2.5 514.54
Cu g/L 4.414 0.403 2.590 37.328 35.000
Fe g/L 0.001 0.793 0.001 2.000 2.000
Mn g/L 2.744 0.462 0.462
Acid g/L 14.335 176.41 180.00
Cu Kg/h 5518.2 1.01 3237.3 93.32 18008.8
Fe Kg/h 1.25 1.98 1.25 5.00 1029.1
Mn Kg/h 6.86 1.16 237.9
Acid Kg/h 35.84 441.03 92616.5

Table 1C: Mass balance of Cu-SX circuit – Saturated organic phase

Description AD S2 AD S1 SO S1 ESO S1 LO CO
Volume m3/h 514.54 512.91 1250.0 2.5 1250.0
Cu g/L 37.328 50.00 3.523 50.000 8.77
Fe g/L 2.000 2.017 0.001 2.017 0.009
Mn g/L 0.462 0.466 0.466
Acid g/L 176.41 156.58 156.58
Cu Kg/h 19206.6 25645.6 4403.5 125.0 10965.2
Fe Kg/h 1029.1 1034.5 1.25 5.04 10.97
Mn Kg/h 238.0 239.2 1.17
Acid Kg/h 90771.1 80309.3 391.44

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 Table 1D: Mass balance of Cu-SX circuit – Saturated organic phase

Description ELO DS CO CuEWB

CO
Volume m3/h 0.88 1.63 2.70
Cu g/L 2.588 2.588 35.000
Fe 0.790 0.790 2.000
Mn 2.750 2.750 0.462
Acid g/L 10.424 10.424 180.00
Cu Kg/h 2.26 4.20 94.61
Fe 0.69 1.28 5.41
Mn 2.41 4.47 1.25
Acid Kg/h 9.12 16.94 486.58

Table 2: Additional results of mass balance of cu-SX circuit – saturated organic phase

Description
Extractant percentage in organic phase 19.89 %
Extraction efficiency 94.98 %
Net transfer 0.311 g/l/V%
Stripping O/A 2.43
Stripping efficiency 70.48 %
Spent electrolyte Fe/Mn 4.32
Copper production 7.54 t/h
Copper recycle from CuEWB/Copper production 1.25 %

Figures (8), (9) and (10) gives mass flow percentage of copper, iron and
manganese by taking the mass flow of elements in the PLS as 100%. The designation of
flows is on Figure (7).

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Figure 8: Copper mass flow percentage – copper mass flow in PLS 100%

Figure 9: Iron mass flow percentage – iron mass flow in PLS 100%

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 Figure 10: Manganese mass flow percentage – Manganese mass flow in PLS 100%

5.2.2.2. Unsaturated organic phase

Tables 3A, 3B, 3C, 3D and 4 give the mass balance of copper solvent extraction
circuit working with saturated organic phase.

Table 3A: Mass balance of Cu-SX circuit – unsaturated organic phase

Description PLS Raf E1 Raf E2 LO E1 ELO E1

Volume m3/h 1000 1001.63 1001.63 1250.00 2.5
Cu g/L 8.04 1.171 0.193 10.588 1.171
Fe g/L 0.80 0.775 0.778 0.021 0.775
Mn g/L 2.75 2.75 2.744 2.75
Acid g/L 2.0 12.646 14.698 12.646
Cu Kg/h 8040.0 1172.9 193.4 13235.2 2.93
Fe Kg/h 800.0 776.1 779.1 26.47 1.94
Mn Kg/h 2750.0 2745.5 2748.1 6.87
Acid Kg/h 2000.0 12666.6 14722.3 12.65

Joseph Kafumbila Page 16

 Table 3B: Mass balance of Cu-SX circuit – unsaturated organic phase

Description LO E2 ELO E2 SO ESO SP

Volume m3/h 1250.00 2.5 1250.00 2.5 528.52
Cu g/L 5.095 0.193 4.235 38.225 35.000
Fe g/L 0.001 0.778 0.001 2.000 2.000
Mn g/L 2.744 0.186 0.186
Acid g/L 14.698 175.032 180.00
Cu Kg/h 6368.7 0.48 5294.1 95.56 18498.3
Fe Kg/h 1.25 1.94 1.25 5.00 1057.1
Mn Kg/h 6.86 0.46 98.21
Acid Kg/h 36.75 437.58 95134.2

Table 3C: Mass balance of Cu-SX circuit – unsaturated organic phase

Description AD S2 AD S1 SO S1 ESO S1 LO CO
Volume m3/h 528.52 526.90 1250.00 2.5 1250.00
Cu g/L 38.225 50.000 5.575 50.000 10.590
Fe g/L 2.000 2.046 0.001 2.046 0.021
Mn g/L 0.186 0.190 0.190
Acid g/L 175.03 156.66 156.66
Cu Kg/h 20203.0 26344.9 6969.3 125.0 13235.2
Fe Kg/h 1057.2 1077.9 1.25 5.11 26.47
Mn Kg/h 98.2 100.2 0.48
Acid Kg/h 92508.4 82544.7 391.65

Table 3D: Mass balance of Cu-SX circuit – unsaturated organic phase

Description ELO CO DS CO CuEWB

Volume m3/h 0.88 1.63 10.45
Cu g/L 1.171 1.171 35.000
Fe g/L 0.775 0.775 2.000
Mn g/L 2.75 2.75 0.186
Acid g/L 12.646 12.646 180.00
Cu Kg/h 1.02 1.90 365.71
Fe Kg/h 0.68 1.26 20.90
Mn Kg/h 2.41 4.47 1.94
Acid Kg/h 11.07 20.55 1880.81

Joseph Kafumbila Page 17

Table 4: Additional results of mass balance of cu-SX circuit – unsaturated organic phase

Description
Extractant percentage in organic phase 30.50 %
Extraction efficiency 97.59 %
LO/ML 60.45 %
Net transfer 0.208 g/l/V%
Stripping O/A 2.37
Spent electrolyte Fe/Mn 10.76
Copper production 7.48 t/h
Copper recycle from CuEWB/Copper production 4.89 %

Figures (11), (12) and (13) gives mass flow percentage of copper, iron and
manganese by taking the mass flow of elements in the PLS as 100%. The designation of
flows is on Figure (7).

Figure 11: Copper mass flow percentage – copper mass flow in PLS 100%

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 Figure 12: Iron mass flow percentage – iron mass flow in PLS 100%

Figure 13: Manganese mass flow percentage – Manganese mass flow in PLS 100%

Joseph Kafumbila Page 19

5.2.2.3. Observations

 The concentration of Lix984N is 19.39% for saturated organic phase

with copper and 30.50% for unsaturated organic phase with copper.
 LO/ML is 80% for saturated organic phase with copper and 60.45% for
unsaturated organic phase with copper.
 93.8% of copper from PLS are platted as cathode for saturated organic
phase with copper and 93.05% are platted as cathode for unsaturated
organic phase with copper.
 5.02% are exited from the SX-EW circuit in the raffinate for saturated
organic phase with copper and 2.41% are exited from the SX-EW circuit
in the raffinate for unsaturated organic phase with copper.
 1.18% is exited from the SX-EW circuit in the EW bleed for saturated
organic phase with copper and 4.55% are exited from the SX-EW circuit
in the EW bleed for unsaturated organic phase with copper.
 Stripping efficiency is 70.4% for saturated organic phase with copper
and is 60% for unsaturated organic phase with copper.
 Cu/Fe ratio transferred in EW is 1412.53 for saturated organic phase
with copper and is 375.47 for unsaturated organic phase with copper.
 Fe/Mn ratio transferred in EW is 4.32 for saturated organic phase with
copper and is 10.76 for unsaturated organic phase with copper.

The configuration with saturated organic phase need wash stage to wash
manganese only. The wash stage is placed after Aqueous coalescing tank and wash
solution is acidified water. Wash stage works as a dilution process and the dilution
process works well when the ratio Water/solution is high. Copper electrowinning bleed
can be recycled directly to copper extraction step to recover the copper.

The configuration with unsaturated organic phase need wash stage to partial
stripped ferric on the loaded organic. The preferential place of wash stage is before
aqueous coalescing tank and the wash solution is a mixture of water and all copper
electrowinning bleed. The aqueous coalescing tank works as an aqueous cleaner.

Joseph Kafumbila Page 20

5.3. Copper solvent extraction with wash stage

5.3.1. Saturated organic phase

5.3.1.1. Data

Figure (14) gives the block diagram of copper SX-EW circuit with wash stage
and saturated organic phase with copper. This flow diagram shows only the aqueous
entrainment in organic phase. The description of flows is the following:

Figure 14: Block diagram of copper SX-EW circuit with wash stage and saturated organic
with copper

 PLS: Pregnant leach solution

 F E1: Feed solution to E1
 E1: Stage 1 of extraction step
 E2: Stage 2 of extraction step
 Raf E1: Raffinate from E1
 Raf E2: Raffinate from E1
 LO E1: Loaded organic from E1

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  ELO E1: Entrainment aqueous in LO E1
 LO E2: Loaded organic from E2
 ELO E2: Entrainment aqueous in LO E1
 CO: Aqueous coalescing tank
 LO CO: Loaded organic from CO
 ELO CO: Entrainment aqueous in LO CO
 DS CO: Discharged solution from CO
 WS: wash solution
 SAW: solution after wash
 WLO: washed loaded organic
 EWLO: Entrainment aqueous in washed loaded organic
 S1: Stage 1 of stripping step
 S2: Stage 2 of stripping step
 SO S1: Stripped organic from S1
 ESO S1: Entrainment aqueous in SO S1
 SO: Stripped organic from S2
 ESO: Entrainment aqueous in SO
 SP: Spent electrolyte
 AD S2: Advance electrolyte from S2
 AD S1: Advance electrolyte from S1
 CuEW: Copper electrowinning circuit
 CuEWB: Copper electrowinning circuit bleed

The design criteria are the following:

- Extraction step
o Number of stages: 2
o Phase continuity: Organic continuous
o PLS flow rate: 1000 m3/h
o PLS - Copper: 8.04 g/L
o PLS - acid: 2 g/L
o PLS - iron: 0.8 g/L
o PLS - manganese: 2.75 g/L
o O/A internal: 1.25
o O/A external: 1.25
o Mixing efficiency E1: 95%
o Mixing efficiency E2: 97%
o Cu/Fe in loaded organic E1: 1000
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
o LO/ML: 80%
- Stripping step

Joseph Kafumbila Page 22

 o Number of stages: 2
o Phase continuity: Organic continuous
o Spent electrolyte - Copper: 35 g/L
o Spent electrolyte - acid: 180 g/L
o Spent electrolyte - iron: 2g/L
o Stripped organic from S1 - Iron: 1ppm
o Advance electrolyte copper: 50 g/L
o Mixing efficiency S1: 98%
o Mixing efficiency S2: 95%
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
- Aqueous coalescing tank
o Aqueous entrainment recovery: 65% (P. Cole et al, 2016)
- Wash stage
o Number of stages: one
o O/A: 40
o Phase continuity: Organic continuous
o Wash solution - acid: 2 g/L
o Iron stripping efficiency: 0% (assumed)
o Mixing efficiency W: 95%
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
- Copper tank house
o Spent electrolyte – Iron: 2g/L

5.3.1.2. Simulation results

Tables 5A, 5B, 5C, 5D, 5E and 6 give the mass balance of copper SX-EW circuit
working with saturated organic phase and wash stage.

Table 5A: Mass balance of Cu-SX circuit – Saturated organic phase and wash stage

Description PLS FE1 Raf E1 Raf E2 LO E1

Volume m3/h 1000 1032.94 1034.62 1034.62 1291.17
Cu g/L 8.04 7.865 2.610 0.420 8.576
Fe g/L 0.80 0.780 0.770 0.773 0.009
Mn g/L 2.75 2.665 2.665 2.658
Acid g/L 2.0 2.409 10.528 14.447
Cu Kg/h 8040.0 8124.3 2700.3 434.6 11073.3
Fe Kg/h 800.0 805.3 796.8 800.00 11.07
Mn Kg/h 2750.0 2752.3 2756.8 2750.00
Acid Kg/h 2000.0 2488.3 10892.7 14946.87

Joseph Kafumbila Page 23

Table 5B: Mass balance of Cu-SX circuit – Saturated organic phase and wash stage

Description ELO E1 LO E2 ELO E2 SO ESO

Volume m3/h 2.58 1291.17 2.58 1291.17 2.58
Cu g/L 2.610 4.376 0.420 2.548 37.375
Fe g/L 0.770 0.001 0.773 0.001 2.000
Mn g/L 2.665 2.658 0.038
Acid g/L 10.528 14.447 176.34
Cu Kg/h 6.74 5650.69 1.08 3289.6 96.51
Fe Kg/h 1.99 1.29 2.00 1.29 5.16
Mn Kg/h 6.88 6.86 0.10
Acid Kg/h 10.53 37.31 455.4

Table 5C: Mass balance of Cu-SX circuit – Saturated organic phase with wash stage

Description SP AD S2 AD S1 SO S1 ESO S1
Volume m3/h 512.47 512.47 512.47 1291.17 2.58
Cu g/L 35.000 37.375 50.000 3.465 50.000
Fe g/L 2.000 2.000 2.009 0.001 2.009
Mn g/L 0.038 0.038 0.038 0.038
Acid g/L 180.00 176.34 155.78 155.78
Cu Kg/h 17936.6 19153.5 25623.8 4473.9 129.12
Fe Kg/h 1025.0 1025.0 1029.6 1.29 5.19
Mn Kg/h 19.53 19.53 19.62 0.10
Acid Kg/h 92245.5 90368.6 79835.1 402.3

Table 5D: Mass balance of Cu-SX circuit – Saturated organic phase with wash stage

Description LO CO ELO CO DS CO WS SAW

Volume m3/h 1291.17 0.90 1.68 32.28 30.60
Cu g/L 8.580 2.610 2.610 0.082
Fe g/L 0.009 0.770 0.770 0.021
Mn g/L 2.665 2.665 0.073
Acid g/L 10.528 10.528 2.000 2.216
Cu Kg/h 11073.3 2.36 4.38 2.5
Fe Kg/h 11.07 0.70 1.29 0.64
Mn Kg/h 2.41 4.47 2.22
Acid Kg/h 9.52 17.67 64.56 67.81

Joseph Kafumbila Page 24

 Table 5E: Mass balance of Cu-SX circuit – Saturated organic phase with wash stage

Description WLO EWLO CuEWB

Volume m3/h 1291.17 2.58 2.34
Cu g/L 8.576 0.082 35.000
Fe g/L 0.009 0.021 2.000
Mn g/L 0.073 0.038
Acid g/L 2.216 180.00
Cu Kg/h 11073.0 0.21 81.75
Fe Kg/h 11.07 0.05 4.67
Mn Kg/h 0.19 0.09
Acid Kg/h 5.72 420.44

Table 6: Additional results of mass balance of cu-SX circuit – saturated organic phase

Description
Extractant percentage in organic phase 19.50 %
Extraction efficiency 94.59 %
Net transfer 0.309 g/l/V%
Stripping O/A 2.52
Stripping efficiency 70.29 %
Spent electrolyte Fe/Mn 52.48
Copper production 7.61 t/h
Copper recycle from CuEWB/Copper production 1.07 %
Wash stage - Organic stripping efficiency 0.003 %

Figures (15), (16) and (17) gives mass flow percentage of copper, iron and
manganese by taking the mass flow of elements in the PLS as 100%. The designation of
flows is on Figure (14).

Joseph Kafumbila Page 25

Figure 15: Copper mass flow percentage – Copper mass flow in PLS 100%

Figure 16: Iron mass flow percentage – Iron mass flow in PLS 100%

Joseph Kafumbila Page 26

 Figure 17: Manganese mass flow percentage – Manganese mass flow in PLS 100%

5.3.2. Unsaturated organic phase

5.3.2.1. Data

Figure (18) gives the block diagram of copper SX-EW circuit with wash stage
and saturated organic phase with copper. This flow diagram shows only the aqueous
entrainment in organic phase. The description of flows is the following:

 PLS: Pregnant leach solution

 F E1: Feed solution to E1
 E1: Stage 1 of extraction step
 E2: Stage 2 of extraction step
 Raf E1: Raffinate from E1
 Raf E2: Raffinate from E1
 LO E1: Loaded organic from E1
 ELO E1: Entrainment aqueous in LO E1
 LO E2: Loaded organic from E2
 ELO E2: Entrainment aqueous in LO E1
 CO: Aqueous coalescing tank

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Figure 18: Block diagram of copper SX-EW circuit with wash stage and unsaturated
organic with copper

 LO CO: Loaded organic from CO

 ELO CO: Entrainment aqueous in LO CO
 DS CO: Discharged solution from CO
 WS: wash solution
 SAW: solution after wash
 WLO: washed loaded organic
 EWLO: Entrainment aqueous in washed loaded organic
 S1: Stage 1 of stripping step
 S2: Stage 2 of stripping step
 SO S1: Stripped organic from S1
 ESO S1: Entrainment aqueous in SO S1
 SO: Stripped organic from S2
 ESO: Entrainment aqueous in SO
 SP: Spent electrolyte
 AD S2: Advance electrolyte from S2
 AD S1: Advance electrolyte from S1
 CuEW: Copper electrowinning circuit

Joseph Kafumbila Page 28

  CuEWB: Copper electrowinning circuit bleed

The design criteria are the following:

- Extraction step
o Number of stages: 2
o Phase continuity: Organic continuous
o PLS flow rate: 1000 m3/h
o PLS - Copper: 8.04 g/L
o PLS - acid: 2 g/L
o PLS - iron: 0.8 g/L
o PLS - manganese: 2.75 g/L
o O/A internal: 1.25
o O/A external: 1.25
o Mixing efficiency E1: 95%
o Mixing efficiency E2: 97%
o Cu/Fe in loaded organic E1: 500
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
- Stripping step
o Number of stages: 2
o Phase continuity: Organic continuous
o Spent electrolyte - Copper: 35 g/L
o Spent electrolyte - acid: 180 g/L
o Spent electrolyte - iron: 2g/L
o Stripped organic from S1 - Iron: 1ppm
o Advance electrolyte copper: 50 g/L
o Mixing efficiency S1: 98%
o Mixing efficiency S2: 95%
o Stripping efficiency: 60%
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)
- Aqueous coalescing tank
o Aqueous entrainment recovery: 65% (P. Cole et al, 2016)
- Wash stage
o Number of stages: one
o O/A: 40
o Phase continuity: Organic continuous
o Wash solution: mixture of water and spent electrolyte
o Iron stripping efficiency: 50% (Hans Hein, 2005)
o Mixing efficiency W: 95%
o Aqueous entrainment in organic: 2000 ppm (250-2500 ppm
industry)

Joseph Kafumbila Page 29

 - Copper tank house
o Spent electrolyte – Iron: 2g/L

5.3.2.2. Simulation results

Tables 7A, 7B, 7C, 7D, 5E and 8 give the mass balance of copper SX-EW circuit
working with unsaturated organic phase and wash stage.

Table 7A: Mass balance of Cu-SX circuit – unsaturated organic phase and wash stage

Description PLS FE1 Raf E1 Raf E2 LO E1

Volume m3/h 1000 1032.26 1033.94 1033.94 1290.32
Cu g/L 8.04 7.858 1.188 0.202 10.336
Fe g/L 0.80 0.795 0.771 0.774 0.021
Mn g/L 2.75 2.670 2.666 2.660
Acid g/L 2.0 2.662 13.020 15.083
Cu Kg/h 8040.0 8111.6 1228.1 209.2 13336.1
Fe Kg/h 800.0 821.1 796.8 800.0 26.67
Mn Kg/h 2750.0 2756.5 2756.8 2750.0
Acid Kg/h 2000.0 2748.2 13561.6 15594.7

Table 7B: Mass balance of Cu-SX circuit – unsaturated organic phase and wash stage

Description ELO E1 LO E2 ELO E2 SO ESO

Volume m3/h 2.58 1290.32 2.58 1290.32 2.58
Cu g/L 1.188 5.000 0.202 4.134 38.204
Fe g/L 0.771 0.001 0.774 0.001 2.000
Mn g/L 2.666 2.660 0.029
Acid g/L 13.020 15.083 175.06
Cu Kg/h 3.07 6451.5 0.52 5334.5 98.59
Fe Kg/h 1.99 1.29 2.00 1.29 5.16
Mn Kg/h 6.88 6.86 0.07
Acid Kg/h 13.02 38.92 451.78

Joseph Kafumbila Page 30

Table 7C: Mass balance of Cu-SX circuit – unsaturated organic phase with wash stage

Description SP AD S2 AD S1 SO S1 ESO S1
Volume m3/h 536.37 536.37 534.69 1290.32 2.58
Cu g/L 35.000 38.204 50.000 5.443 50.000
Fe g/L 2.000 2.000 2.020 0.001 2.020
Mn g/L 0.029 0.029 0.029 0.029
Acid g/L 180.00 175.06 156.61 156.61
Cu Kg/h 18772.9 20491.5 26734.6 7022.6 129.03
Fe Kg/h 1072.7 1072.8 1080.2 1.29 5.21
Mn Kg/h 15.38 15.38 15.49 0.07
Acid Kg/h 96546.5 93899.2 83737.7 404.15

Table 7D: Mass balance of Cu-SX circuit – unsaturated organic phase with wash stage

Description Water WS SAW WLO EWLO

Volume m3/h 28.52 32.26 32.26 1290.32 2.58
Cu g/L 4.055 2.219 10.379 2.219
Fe g/L 0.232 0.654 0.001 0.654
Mn g/L 0.003 0.201 0.201
Acid g/L 20.856 23.194 2.194
Cu Kg/h 130.82 71.58 13392.7 5.73
Fe Kg/h 7.48 21.11 13.34 1.69
Mn Kg/h 0.11 6.47 0.52
Acid Kg/h 672.79 748.18 59.85

Table 7E: Mass balance of Cu-SX circuit – unsaturated organic phase with wash stage

Description LO CO ELO CO DS CO CuEWB

Volume m3/h 1290.32 0.90 1.68 3.74
Cu g/L 10.38 2.219 2.219 35.000
Fe g/L 0.001 0.654 0.654 2.000
Mn g/L 0.201 0.201 0.029
Acid g/L 23.194 23.194 180.00
Cu Kg/h 13392.7 2.00 3.72 130.82
Fe Kg/h 13.34 0.59 1.10 7.48
Mn Kg/h 0.18 0.34 0.11
Acid Kg/h 20.95 38.91 672.79

Joseph Kafumbila Page 31

Table 8: Additional results of mass balance of cu-SX circuit – unsaturated organic phase

Description
Extractant percentage in organic phase 30.02 %
Extraction efficiency 97.40 %
Net transfer 0.207 g/l/V%
LO/ML 60.13 %
Stripping O/A 2.41
Spent electrolyte Fe/Mn 69.75
Copper production 7.83 t/h
Copper recycle from CuEWB/Copper production 1.67 %
Wash stage – extraction efficiency from solution 45.28 %

Figures (19), (20) and (21) gives mass flow percentage of copper, iron and
manganese by taking the mass flow of elements in the PLS as 100%. The designation of
flows is on Figure (18).

Figure 19: Copper mass flow percentage – Copper mass flow in PLS 100%

Joseph Kafumbila Page 32

 Figure 20: Iron mass flow percentage – Iron mass flow in PLS 100%

Figure 21: Manganese mass flow percentage – Manganese mass flow in PLS 100%

Joseph Kafumbila Page 33

5.3.3. Observations

 The concentration of Lix984N is 19.50% for saturated organic phase

with copper and 30.02% for unsaturated organic phase with copper.
 LO/ML is 80% for saturated organic phase with copper and 60.13% for
unsaturated organic phase with copper.
 94.59% of copper from PLS are platted as cathode for saturated organic
phase with copper and 97.4% are platted as cathode for unsaturated
organic phase with copper.
 5.41% are exited from the SX-EW circuit in the raffinate for saturated
organic phase with copper and 2.60% are exited from the SX-EW circuit
in the raffinate for unsaturated organic phase with copper.
 Stripping efficiency is 70.29% for saturated organic phase with copper
and is 60% for unsaturated organic phase with copper.
 Cu/Fe ratio transferred in EW is 1645.53 for saturated organic phase
with copper and is 1065.05 for unsaturated organic phase with copper.
 Fe/Mn ratio transferred in EW is 52.48 for saturated organic phase with
copper and is 69.75 for unsaturated organic phase with copper.

For this case, chapters (5.3.1.) and (5.3.2.) give the configuration of the extreme
cases. In the case with saturated organic with copper the solvent extraction efficiency is
low. Copper loss in the water balance bleed of the copper circuit is high. In the case with
unsaturated organic with copper the percentage of extractant in the organic phase is
high. The cost of organic loss in organic entrainment in aqueous phase is high.

Most of the time designers take the flow diagram of saturated organic phase
with copper and increase the extractant percentage in the organic phase at 25%. In this
case, copper loss in the water balance bleed and the cost of organic phase entrainment in
aqueous phase decrease. The optimum flow diagram is the flow diagram with saturated
organic phase with copper and the copper in the water balance bleed can be recovered
by addition a third stage of solvent extraction on the water balance bleed (D.R. Shaw et
al, 2004) or by introducing the split circuit (G.M. Miller, 2005). Depending on the level of
manganese in the PLS, wash stage placed after organic surge tank can be removed in the
circuit and loaded organic phase can be sprayed with water in organic weir of E1 stage.

For the low concentration of copper in the PLS, it is important to find the copper
SX configuration that can facilitated to reach the saturation of organic phase with copper
and can give high copper solvent extraction efficiency.

Joseph Kafumbila Page 34

 6. References
Liu Jian she et al, Mechanism of crud formation in copper solvent extraction, J. CENT.
SOUTH UNIV. TECHNOL., Vol. 9, No. 3, 2002.

Hans Hein, Importance of a wash stage in copper solvent extraction, Hydrocopper 2005.

J. Kafumbila, Design and optimization of copper solvent extraction configurations,

Researchgate, 2017.

https://www.researchgate.net/publication/321849653_Design_and_optimization_of_co
pper_solvent_extraction_configurations

P. Cole et al, Understanding aqueous in organic entrainment in copper solvent

extraction, SAIMM, Vol. 116, 2016.

O. Tinkler et al, The Acorga OPT series: Comparative studies against aldoxime: Ketoxime
reagents, SAIMM, 2009.

D.R. Shaw and D.B. Dreisinger, The commercialization of the FENIX iron control system
for purifying copper electrowinning electrolytes, the journal of the minerals, metals and
materials society, July 2004.

G.M. Miller and A. Nisbett, Decreasing operating costs and soluble loss in copper
hydrometallurgy with use of innovative solvent extraction circuits, First extractive
metallurgy operations conference, Brisbane, 2005.

Joseph Kafumbila Page 35

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