WO2004067449A1

WO2004067449A1 - Modular device and methods for copper exploitation from waste, flotation waste, mine waters and waste waters

Info

Publication number: WO2004067449A1
Application number: PCT/YU2003/000002
Authority: WO
Inventors: Milos Karovic
Original assignee: Milos Karovic
Priority date: 2003-01-29
Filing date: 2003-01-31
Publication date: 2004-08-12
Also published as: YU5803A; AU2003215032A1

Abstract

The RTB BOR-Majdanpek mine has been exploited for more than one hundred years so today we have a mine with extremely low concentration of copper (below 0,6 % per tonne). What we also have is 1500 km2 of degraded area. Our wish is to find a satisfactory way of dealing with this problem in order to prolong the 'life' of the mine for the period of the next 10-20 years and to carry out a refurbishment of the degraded area. Having this in mind, we have developed methods and equipment which are based on the technologies that have already been tested in this area, and specifically on selective ion exchange of copper ions. Our methods and equipment are able to satisfy both ecological and economical criteria. Application of ion exchange resins and modular construction technologies will significantly cut down the expenses of installation, service and exploitation. Even though the starting point was non-profit making copper concentration below 0.03 %, we have managed to develop methods and equipment that are economically speaking and technically speaking applicable.

Description

MODULAR DEVICE AND METHODS FOR COPPER

EXPLOITATION FROM WASTE, FLOTATION WASTE, MINE

WATERS AND WASTE WATERS

THE AREA OF TECHNOLOGY THE INVENTION ORIGINATES FROM Having in mind that the invention is from the area of the technology consisting of several technological entireties and machines, I shall therefore try to define them as follows: o percolated, agitated and on line separation o separation o quick laminated sedimentation tank o selectiv e extraction of copper ions

• reverse osmosis o electrolysis of mixture and getting cathode copper

The invention can be classified among the technologies of separation, filtration, ultrafiltration, metallurgical means of getting copper and electrolysis.

THE TECHNICAL PROBLEM

After the ecological disaster that took place in 1995 as a consequence of breakthrough of the floating waste "Valja fundata" RTB Majdanpek, which is a part of RTB BOR GROUP, "Aeroakva In .enjering" from Belgrade was hired b> The Government of Republic of Serbia and its Ministry of Protection of Environment to do "an expert research about environmental conditions and consequences on the area of the copper mine "Majdanpek". "Aeroakva Inzenjering" has continued developing technology that w ill be able to refurbish the degraded area of 1500 km^" surrounding RTB BOR-MAJDANPEK in Republic of Serbia.

Our work was based on:

1) the expert research about environmental conditions and consequences on the area of the copper mine "Majdanpek", specifically: • the geolocigal foundation of the entire area • soil mechanics

• definition of diffusion of ecological disaster

• physical and chemical analysis of the soil, water and air

• microbiological analysis of water

• construction of genetic card of flora and fauna

• conclusions that the area has been seriously degraded

1) production of integral program of refurbishment and revitalization of the degraded area of the copper mine RTB BOR - MAJDANPEK. The program consists of an immediate program of refurbishment and a long-term program of refurbishment of degraded area. We use the word "integral" because both RTB BOR and the local community have to take part in this program.

Having established the starting points for defining the technology, we could easily continue developing our technology.

Consequently we came to the following conclusions: ι

1) Exploitation of the mine started a hundred years ago and at that time the concentration of copper was 5% per one tonne of ore. Today, the concentration is 0,4% per one tonne of ore.

2) The total amount of cathode copper produced is about 4,000,000 tonnes,

3) With technology of mining and flotation that is being used today we don't get even 50% of copper from the copper ore. The reason is very simple. After analizing the waste, we came to the conclusion that oxidized copper didn't extrac and neither did the admixtures (10%- 20% of other copper compounds).

By conducting chemical analysis of mine w aters, flotation waste and waste, we came to the conclusion that the concentrations of copper were over 0,4 g/1 in liquid mixture, and in the waste there was more than 0,6% of oxidized copper. 5) Reserves of minerals in the waste - liquid or solid w aste are more than

3,000,00ϋt. Tecnical problem is :

1 ) To design a modular device which will be able to produce 1200-1500 tonnes of copper per year by extracting copper ions from the liquid mixture. Furthermore, since the devices are modular, they can easily be multiplied depending on the desired quantity of production of the cathode copper (Cu).

2) The prices of exploitation are ment to be lower than 10003 per one tonne υi^' copper.

3) To refurbish the degraded area by first removing heavy metals from the waste and then by putting the waste back to the mine shaft. Water from the flotation, the mine and the existing technology is to be as clean as the First Class Water.

THE CONDITION OF THE TECHNOLOGY

The existing methods that we are familiar with are mostly based on the technology that has alredy been applied in refurbishment of degraded areas: percolated, agitated and on line separation, various methods of extraction as well as some methods of exchange of copper and steel ions. Still, we have not been able to find a profitable plant which is selectively extracting copper ions with concentration of 0.3-0.6 g/1

ABOUT THE INVENTION

The essence of this invention is that it applies new methods and equipment but also satisfies both ecological and economical criteria when it comes to refurbishment of highly degreded area, such as copper mines and other precious metals mines. Classical technologies such as flotation and mining do not satisfy these criteria. The main goal of this invention is to obey the rules of nature and the rules of physics w hich sa> that all cycles are circled, and therefore restoration is possible. If we apply these methods and equipment we will make it possible for mine to continue with its work. At the same time the refurbishment of the entire degraded area w ill be achieved. DETAILED DESCRIPTION OF THE TECHNICAL SOLUTION The whole device consists of only two plants, at scheme marked as I and II (Fig. 1)

• The plant number one (Fig. 1- 1) works together with the plant number two (Fig. 1- II) and they are used for tretment of solid waste. The plant number one turns solid waste into the liquid waste

• The plant number two works independently and it is used for treatment of flotation (liquid) waste, mine waters and waste waters.

I) The plant number one (Fig. 1)- technical description

Solid waste is transported by belt transporters to low-speed rotary cylinders (1 ). Low-speed rotary cylinders posses helical parts whose function is to slowly mix waste and sulphuric acid solution. At this stage cupric oxide compounds with SO and produces copper sulphate solution (CuSO ). Cylinder's other half is perforated in order to be able to separate solid parts from the liquid ones. The solid parts are then returned to the mine holes. The treatment of the liquid waste continues.

Liquid waste is transported to classical tanks (3) where the remaining solid waste is exposed to natural sedimentation. Muddy water pumps (2) and filtering-presses are used to return this remaining solid waste back to the mine holes. The pump (4) continues to transport the liquid waste to the quick laminated sedimentation tank. Mixing machine (5), dosing device (6), filtering-press (8) and the pump for the continuing transport arc all parts of the quick laminated sedimentation tank. At this stage the solid substance is still being separated from the liquid one. Another filtering-press is used for the treatment of the solid substance, which is at the end also returned to the mine holes.

Fine mechanical filtration is a final stage of separating the solid substance from the liquid one. By doing this we have completely replaced the treatment of solid waste with the treatment of liquid waste.

II) The plant number two (Fig. 1) - technical description

The plant number tw o is designed to be able to receive w ater from the plants, from the flotation waste, from the mine waters and mine drain aters.

The plant number two is entirely automatic. Parameters which guide the process are fluid Ph value, concentration of copper ions, fluid flow rate and fluid pressure. Firstly , we have to reach an optimal Ph value of the fluid. Then we use force pump (9) to transport the fluid through the fine mechanical filter (2) and into the selective ion exchangers (3). The selective ion exchangers are used to extract copper ions from the fluid. After the ion exchange, there are two possible directions of fluid flow. In the first case both plants are working together and the fluid is returning to the plant number one, since the fluid is a solution of the sulphuric acid (H₂SO₄). Tf only a plant number two is in function, fluid first has to be neutralized. (6) Then the fluid enters into the reverse osmosis device (8). The product of the reverse osmosis process is an ultra clean water (the First Class Water).

Device (4) and the pump (10) are used for regeneration of selective ion exchangers (3). After the regeneration has been completed, eluate is transported to electrolysis (7). The copper concentration in eulate is 40-50 g/1. The electrolysis anode is made of platina-titan, and the cathode is made of copper. The cathode copper is extracting at the cathode. After the electrolysis has been completed, eulate is being sent to the tank (1).

Since the regeneration process is completed, the whole system is rinsed (5) with the water from the reverse osmosis device (8) and with the help of the pump (11).

Conclusion:

Having done this, we have concluded the process and reached following outputs:

1) Cathode copper

2) Clean water

Claims

PATENT APPLICATION

1

Process: Extarction of copper sulphate (CuSO₄) from mine waters, flotation waste, waste waters and waste, after that they had been exposed to the treatment in the plant number one (I)

Method: The liquid solution, which contains copper (Cu) ions, is passed through ion selective resin, where the process of selective exgange of copper and hydrogen ions is performed. Afterwards we expose the ion selective resin to the regenerative process and get eulate with high concentration of copper ions.

2

Process: Extraction of copper brines from the waste.

Method: Grained and granulated waste is transported to low-speed rotary cylinders which mix waste and sulphuric acid (H₂SO₄) and provide arifieal separation. Cylinder s other half is perforated and it is used for separation of solid parts from the liquid parts.

Subsequently through several series of fine mechanical filtration ( natural sedimentation, quick laminated sedimentation and quick mechanical filters ) the solid substance is separated from the waste.

3

Process: Extraction of cathode copper from eulate after ion filters regeneration is completd.

Method: After the ion filters regeneration is completed, elecrolyte is transported into eulate. Electrolyis process is being performed; the anode (platina-titan) is special!) made for this process and the cathode is made of copper, and as output we get 99,9% clean cathode copper.

4

Process: Extraction of cathode copper from mine waters, flotation waste, waste waters and waste

Method: The entire process is to be economically profitable; more exactly - the price of one tonne of copper is to be less than 10003. In order to be able to achieve this, the concentration of copper ion in the input fluid ( the plant number two) has to reach at least 300 mg/1, so that when the electrolysis process begins, the eulate can have concentration of 40-50 g/1. The electrolysis process is performed until the concentration of copper ion reaches 10 g/1.

5

The plant number two (I): serves for extraction of copper eulate from drain waters, flotation waste, mine waters and brines from the waste.

Method: The plant is designed to satisfy all the prescribed criteria for modular devices that can be transported in containers. To achieve this, a module has been designed, with the capacity of 1200-1500 tonnes of copper produced; the input capacity of solution is

200 m³/h.

6

The plant number two (II): serves for extraction of copper brines from mine waste. Method: All the entireties ( low-speed rotary cylinders, quick laminated sedimentation tank and mechanical filter ) are modular and they have capacity to produce 200 m³/h of brines. The overall dimensions and weight are suitable for transport in containers (lorry, train, ship).

7

The plant number two (II): serves for production of ultra clean water (The First Class

Water)

Method: The plant is designed to be a modular device. The overall dimensions and weight are suitable for transport in containers. After the solution passes through ion selective filters, which have processing capacity of 200 m /h, the plant number two carries out ultra flitration of w ater. The water can no be returned back to the technological cycles and used to wash out all mechanical filters or to wash out ion filters, or it can be released back to the recipient.

8

The device that automatically guides the entire process described in the patent application 4 Method: The entire process in the plant number two (II) is automatic and guided by PLC controller with the help of measuring devices. We have measuring devices which instantly measure fluid flow rate, measuring devices which instanly measure temperature and measuring devices which instantly measure pressure in the solution. At this way we've made sure that the plant number one (I) always works within the assigned limits and we've entirely ruled out the human factor.