Mario Sanchez_Universidad de Concepcion

8/3/2019 Mario Sanchez_Universidad de Concepcion

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Opciones para el manejo ycomercializacin de escorias de cobre

Pedro Reyes, Gerente General Divisin Chagres, Angloamerican Chile

Armando Valenzuela, Director AL Prospecta Consultores, Chile

Mario Snchez, Prof. Depto. Ingeniera Metalrgica, Universidad de Concepcin, Chile


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AGENDA

1.- Introduccin 2.- Origen y caracterizacin de las

escorias 3.- Generacion de escorias, tratamiento

y valorizacin

4.- Estudio de casos internacionales:Canad, India, Japn, Alemania, otros 5.- Comentarios finales


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PARADIGMA = los Residuos Mineros son Desechos.

y si consideramos estos desechos como RECURSOS?

Estos NUEVOS RECURSOS tienen varias ventajas:Se encuentran en SUPERFICIE (bajos costos mineros).Los VOLUMENES DISPUESTOS SON CONOCIDOS y por lo

general caracterizados (bajos costos geolgicos).La RECUPERACION, RECICLAJE Y REUTILIZACIN de sus

componentes tiene un EFECTO POSITIVO (transporte,disposicin, impacto ambiental).

PrincipiosIntroduccin


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La minera del cobre es la actividad ms importante en Chile.Aporta un porcentaje considerable del producto interno bruto. Sinembargo el impacto ambiental que ha producido ha sido una

preocupacin permanente del Estado y de las Empresas.Del total de mineral extrado en una mina, slo el ~1% correspondeal metal, el resto es descartado como desechos:

Residuos Slidos Tasa de generacin (ton/ton Cu)

Escoria de fundicin ~ 2

Relave de flotacin ~ 100

Ripios de lixiviacin ~ 200

Estril de mina ~ 400

Introduccin


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Efluentes en Procesos Mineros-Metalrgicos

Circuito de la Cuna a la Tumba para Metales y Residuos Generados en el proceso

MINERA SUBTERRNEAMINERA RAJO ABIERTO

REDUCCIN DE TAMAOTRITURACIN

MOLIENDA

PROCESOS DE CONCENTRACINSEPARACIN GRAVITACIONAL

SEPARACIN MAGNTICAFLOTACIN

ESPESAMIENTOFILTRADO

SECADO

PROCESOS PIRO, HIDRO,ELECTROMETALRGICOS

METAL

MINERAL

MINERAL LIBERADO

CONCENTRADO HMEDO

CONCENTRADO SECO

FAENAS MINERAS

PROCESAMIENTODE

MINERALES

EXTRACCINDE METAL

ESTERILESLASTRE

MINERAL DE BAJA LEYAGUA DE MINAS

TRANQUES DE RELAVESLODOSREACTIVOSAGUAS DE DESECHOS

GASES DE FUNDICINPOLVOSRESIDUOS DE LIXIVIACINAGUAS DE DESECHOSEFLUENTES

Introduccin


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Situacin histrica => acumulacin de EscoriasIntroduccin


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CHUQUICAMATA (CODELCO)

POTRERILLOS (CODELCO)

ALTONORTE(XSTRATA)

CHAGRES (ANGLOAMERICAN)

VENTANAS(CODELCO)

CALETONES (CODELCO)

PAIPOTE(ENAMI)

Fundiciones de Concentrados enChile

7 Fundiciones: 4 deCODELCO, 1 de ENAMI, 2Privadas

Produccin anual: 1.8 millones

ton cobre blister + aprox 4millones ton de escorias

Acumulado: Cerca de 40millones de toneladas deescorias

POR QULASESCORIAS?

Origen y caracterizacin de las escorias


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Composicin media de una escoria de descarte en Chile:

30-40 % hierro,35-40% silice,~ 10 % alumina oxido de calcio~ 1 % cobre~ 0.3 % molibdenoCantidades importantes de zinc y metales preciosos (Au, Ag)

los metales (materiales) que otorgan mayor valor a la escoria, en orden

descendente, son el Molibdeno, el Cobre, el Hierro, la Slice

Origen y caracterizacin de las escorias


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Fuentes de generacin de escorias:

1. Etapa de Fusin 2% - 10% Cu

2. Etapa de conversin

- Soplado de Fe 5% - 15% Cu

- Soplado de Cu 25% - 55% Cu

3. Etapa de refino > 50% Cu

Alternativas de Procesamiento:

1. Tratamiento Pirometalrgico

2. Flotacin de Escorias

Generacion de escorias, tratamiento y valorizacin

Fundamentalmenterecuperar cobre

NO SE PONE ATENCION A OTROS COMPONENTES !!!


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FUSION CONVERSION

CONCENTRADO COBRE BLISTER

Q(+) Q(-)Necesidad de Calor Generacin de Calor

Horno de Reverbero Convertidor Peirce Smith

FeS+3/2O2=FeO+SO2+Q Cu2S+O2=2Cu+SO2+QConcentrado+Fundentes+Q=Mata+Escoria+Gas

~25% Cu 80 % Cu >95 % CuFeS + Cu2S

MataCu2S

Metal Blanco

Flash Outokumpu Convertidor Peirce Smith

Bath El Teniente Convertidor Peirce Smith

Q(-)

Q(+)

Horno Electrico Convertidor Peirce Smith

TB Isasmelt Convertidor Peirce Smith



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Generaciondeescoriasypropuestasdetra

tamiento


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Estudio de casos internacionales


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Typically it is composed of Ferro silicate material and metal oxides, formed whenthe molten slag is quenched in cold water. This cooling process fractures theslag into coarse, angular particles making it an ideal choice in many abrasiveapplications.

Copper slag is a fast cutting, high quality, yet economical choice for shipyards andcontractors. More than 20 years of history stand behind this type of abrasivegrain. This copper slag was shown to be the best abrasive not only in cuttingspeed, but also in cost per sq. ft.It is also environmentally friendly, approved to be recycled into the manufacture ofPortland cement.



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Typical Chemical Analysis (%):Iron Oxide Fe203 - 57.0Silicon Dioxide (total) SiO2 - 29.5Aluminum Oxide AL203 - 5.0Zinc - 3.5

Calcium Oxide CaO - 2.5Magnesium Oxide MgO - 1.0Copper Cu - 1.0


Typical Physical Properties:Grain Shape AngularBulk Density (loose) 117 lbs./ft.3

Moh Hardness -7Specific Gravity -3.8

Typical Gradation:COARSE: marine growth, cement buildup, heavy corrosion and concreteexposed aggregate blastingFINE: Selective coating removal, steelwork, tanks, pipes, brickwork andconcreteEXTRA FINE: Wet blasting, motor bodywork, selective coating removal, timbercleaning


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Production of Slag in Japan

0

5000

10000

15000

20000

25000

30000

35000

40000

45000

1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007

EF-production

LD-production

BF-production

1000t



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Slag Utilization

Uses of BF Slag in Japan (2007)

Road

Soil improbement

Civil works

Cement

Concrete

Aggregate

Uses of Slag in Japan(2007)

Road

Soil improvement

Civil works

Cement

Fertilizer

OthersLand fill

Total production 40939000 tTotal Uses 41868000 t



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Iron silicate stone AURUBIS

>During the melting of copper concentrates an iron silicate melt is achieved by theaddition of sand and is made into two basic products: iron silicate stone and granules.

>These products are processed and sold by the subsidiary PEUTE BAUSTOFF GMBH.>In a crushing and screening plant the iron silicate stone is processed to constructionmaterials, primarily for hydraulic construction purposes.>Hydraulic construction stone made of iron silicate stone is used for securing riverembankments and for levees in ports, rivers and as coastal protection.>Due to its high weight compared with other stone it offers considerable advantages.


E di d i i l


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Iron-silicate stone> When cooled down slowly in large cast iron pots, a high-grade crystallinestone is produced with edge lengths of up to 1,000 mm.> About 95 % of this consists of the mineral olivine and is comparable withmagmatic rock, such as basalt.

> Iron-silicate stone is a high-grade, extremely dense and hard mineralconstruction material with special technological properties such as: High apparentdensity, High strength, Optimal surface roughness, Full volumestability, Very low water absorption, Very good frost resistance, Highresistance to weather

Iron-silicate granulateAn amorphous granulate is produced after suddencooling in a water jet, comparable with washed sand0-4 mm.


E di d i i l


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Where are iron-silicate products used?

These products play an important role in modern hydraulic construction work.> They secure embankments and the beds of rivers, canals and harbour basinsagainst current and wave impact.They protect harbour moles and break the waves rushing to the coast.> Iron-silicate products are also used in track construction, horticulture andlandscaping as well as in urban development and as a cement additive.

Advantages of iron-silicate stone are:Consistent qualityAvailability throughout the yearHigh weathering and long-term resistanceFulfils all requirements of application regulations

Conservation of natural resources


E t di d i t i l


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Clear advantages result in slope construction> Smaller layers are possible which also result inconsiderable savings in soil excavation work.

> The use of smaller stones has significantadvantages as regards interlocking, stability andadaptation to the existing bank protection.

> Basically, when using iron-silicate stone, the design engineer can arrange

the structure with smaller types of stone and lower structure thickness.


Iron-silicate products in embankmentconstruction

E t di d i t i l


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Iron-silicate stone as an extra load and as harbour

bottom protection

> Increasingly larger vessels and current actionrepeatedly cause erosion on the bottoms of

harbours, canals, sluice areas and rivers that canbe remedied or even avoided by the use of iron-silicate stone.> A hydraulic construction stone mixture for theseapplications is produced by optimal mixing ofindividual fractions of iron-silicate stone.


E t di d i t i l


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Iron-silicate stone in road construction

> Stone particles made of iron-silicate can

be used as an anti-freeze layer and ballastas well as pavement beds in roadconstruction.

Special advantages:Very good load-carrying capacity

Very good resistance to frostGood water permeability




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Further areas of application for iron-silicate products

Urban development> Iron-silicate stone offers interesting design possibilities for urban constructionobjects as well as in horticulture and landscaping..

> Iron-silicate granulate is ideally suitable for drainages and in landfill

construction due to its material-specific properties.




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Iron-silicate stone was used in the Mhlenberger Loch in

Hamburg-Finkenwerder for bank protection, slopes andsecuring the harbour bottom along the new about 7 km longflood control system.

Iron-silicate hydraulic construction stone has beensuccessfully used in the Kiel Canal for the canal extension. Thebank protection has to withstand very high stress on account ofthe shipping traffic.

EXAMPLES OF UTILIZATION


The deeper waterways in Hamburgs Harbour have made it

necessary to secure the river beds over the Elbe Tunnel.This was performed with iron-silicate stone 80 cm thick layerwith bordering sheet pile walls on both sides of the loweringtunnel.

Comentarios finales


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SlagsDesafios ambientales del futuro

Grandes Montaas de escorias en distintas partes del mundo

Metales y materiales que pueden recuperarse y valorizarse

Es utpico pensar en una prctica Zero Slag ?

Comentarios finales

Cada metro cbico de escoria ferrosilicatada utilizada, significa no

usar aproximadamente 1.4 m3 deroca, lo que resulta en una grancontribucin a no alterar lanaturaleza circundante y por endea hacer ms sustentable nuestrosrecursos naturales.

Comentarios finales


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Quo vadis?

En relacin a los Metales y materiales presentes en las escorias

(Mo, Fe, SiO2, etc.) : Usarlos o no?

~ Estabilizacin o Extraccin

En relacin a las acciones de las Empresas: Fines Econmicos o Ecolgicos?

~ Situacin del Mercado Mundial de los Metales

En relacin a la situacin de cada pas: Posible o imposible el zero waste?

~ Regulaciones y normativas

Comentarios finales

Fin
http://www.mch.cl/noticias/index_neo.php?id=14782


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Fin

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Mario Sanchez_Universidad de Concepcion

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