Multivariable Modelling For The Cathodic Quality

Multivariable Modelling for the Cathodic Quality
Compaa Minera Doa Ins de Collahuasi SCM Gerencia Lixiviacin
G. vila; F. Romero; R. Fester (CMDIC) & L. Yacher (CONTAC Ing. Ltda.)
Collahuasi Location
Chilean Altiplane (First Region). Mean height of operations: 4,400 m.a.s.l. 230 Km SE of Iquique. Patache Port 60 Km S of Iquique.
Oxide Plant Data

Process design for 50,000 [Ton/y] of Cathodes High Grade, leaching Oxides ores. Cathodes production started on July 1998. LME Grade A Certification. Process: Primary Crusher (1) Secondary Crusher (1) & Tertiary Crushers (4) Agglomeration Drums (2) Static Heaps (main pad: 550[m]x1,950[m]) with Coveyor Belts Train and Radial Stacker Two Leaching Cycles (ILS & Raffinate) SX (1 train for 1,000 [m3/h]) : 2E+1W+2S EW : 188 cells (60 SS cathodes+61 Pb anodes per cell), Kidd Process, 36 [KA].
Actual production data (average): Ore to Heaps : 6,500,000 [Ton/year], 18,000 [Ton/d]. Ore : oxide & mixed ores; grade CuT 1.28 [%]. Leaching recovery : 75 [%] PLS : Cu = 8.0 [gpl], Mn = 12.0 [gpl] SX : extraction efficiency 94 [%] EW : current efficiency 95 [%], current density 290 [A/m2] Cathodes production : 62,000 [Ton/y]
Introduction. Historically Collahuasi have had excellent quality records: ~ 96% Grade A LME. Grade A LME : S 15 [ppm] & Pb 5 [ppm]. Since 2004 an increase of Sulphur (S) in cathodes has affected quality. Pb O.K. Production/Quality trade-off since 2004 because high copper price.
Out of Specification (S>15, Pb>5) 0,2% 2,4% 9,0%
Grade A LME
Refinery Rejection
2003 2004 2005
97,5% 94,8% 90,0%
2,3% 2,8% 1,0%
On 2005 it was decided to develop an study using an multivariable analysis approach to give clarity on cathodic quality. The SCAN (Contac Ing. Ltda.) software was used.
Methodology. SCAN software (off-line version) was used with the following methods:
VFA (Variability Factors Analysis) PLS (Partial Least Squares).
Operational data since Jan-2003 to Dec-2005.

Year 2003 was identified as the desired pattern (best quality, production and stability).
VFA analysis defined the pattern model (2003) allowing to compare 2004 and 2005 operation against this model. Variables that most explain the operational drift those years were identified. Sulphuric acid in electrolyte has remain almost constant (~200 [gpl]) during the period, so does not implies the increase of S in cathodes. Using PLS method it was developed a predictive model of Sulphur (S) content in cathodes as function of Cu in outcoming (poor) electrolyte, flow and temperature of incoming electrolyte to cells and current.
VFA analysis.
Process variables (21) for the analysis.
CLAVE Fe+2 EEC (gpl) Mn+2 EEC (ppm) T EEC (C) Q SN (m3/hr) Co ER (ppm) Mg ER (ppm) Al ER (gpl) SiO2 ER (ppm) SL. SUS ER (ppm) Cu EP (gpl) AC EP (gpl) Corriente promedio por celda (A) Adicin de Goma Guar (Kg) Adicin Sulfato de Cobalto (Kg) Adicin Sulf_ Ferroso (Kg) Descarte Electrolito (m3/hr) Peso Promedio Ctodos Da (Kg) Cu en Cmara de Lavado (gpl) Temp. cmara lavado (C) PESO BORRA DIARIO (Kg) Guar (gr/ton) VARIABLE Fe+2 en el electrolito entrante a celda (gpl) Mn+2 electrolito entrante a celda (ppm) Temperatura electrolito entrante a celda (C) Caudal electrolito por sector de nave EW (m3/hr) Co+2 electrolito rico (ppm) Mg+2 electrolito rico (ppm) Al electrolito rico (gpl) SiO2 electrolito rico (ppm) Slidos en suspensin electrolito rico (ppm) Cu+2 electrolito pobre (gpl) cido electrolito pobre (gpl) Corriente promedio por celda (A) Adicin de Goma Guar diaria (Kg) Adicin Sulfato de Cobalto diaria (Kg) Adicin Sulfato Ferroso diario (Kg) Caudal de Descarte electrolito (m3/hr) Peso Promedio Ctodos Da (Kg) Cu en Cmara de Lavado (gpl) Temperatura cmara lavado (C) Peso de borra diario (Kg) Adicin Goma Guar por tonelada diaria de ctodos cosechados (gr/ton)
VFA analysis. Objective: to reduce the number of variables that explain the process, generating a few variability factors (VF) that explain a high percentage (>70%) of whole process variability.
VARIABILIDAD EXPLICADA
80 70 60 50 40 30 20 10 0 1 2 3 4 5 6 7 8 9 10 11
%VARIABILIDAD EXPLICADA
N VF's
The VFA analysis of 21 variables concludes with 11 VF that explain more than 70% of whole process variability of 2003.
VFA analysis. PATTERN MODEL 2003 AND OPERATION MAP 2003
SCORE PLOT 2003
GLOBAL HOTELLING INDEX 2003
Score plots diagrams allow to supervise the 21 process variables jointly. The two first VF (VF1 and VF2) explain 33% of whole process variability.
The Global Hotelling Index measures the degree of belonging for the operational data set to the pattern model defined, establishing a maximum statistical limit 1.
SCORE PLOT 2004 Variable Current in cells Cu+2 poor electrolyte Incoming electrolyte temp. Difference % (*) 328% 275% 227%
GLOBAL HOTELLING INDEX 2003-2004 Effect of decreasing current in cells Effect of gradual increase in electrolyte temperature
(*): (<Hotelling of variable in 2004> - <Hotelling of variable in 2003>)/<Hotelling of variable in 2003>
SCORE PLOT 2005 Variable Incoming electrolyte temp. Current in cells Cu+2 poor electrolyte Difference % (*) 438% 252% 227%
GLOBAL HOTELLING INDEX 2003-2005
Effect of gradual increase in electrolyte temperature
(*): (<Hotelling of variable in 2005> - <Hotelling of variable in 2003>)/<Hotelling of variable in 2003>
VFA analysis.
Effect of gradual increase in incoming electrolyte temperature (TEEC)
PLS analysis. Objective: to generate a predictive model of output variable as a function of many input variables. By definition the model explains a short-term relationship between the variables. To predict the sulphur (S) content in cathodes the following input variables were chosen:
CLAVE T EEC (C) Q EEC (m3/hr) Cu EP (gpl) I (A) VARIABLE Temperatura electrolito entrante a celda (C) Caudal electrolito entrante a celdas por sector de nave EW (m3/hr) Cu+2 electrolito pobre (gpl) Corriente promedio por celda (A)
For comparison purposes two PLS models of S in cathodes were generated: S2003(ppm) = f TEEC, QEEC, Cu+2EP, I , normal operation S2005(ppm) = f TEEC, QEEC, Cu+2EP, I , high sulphur in cathodes operation
PLS analysis. 2003 PLS model for cathodic quality (sulphur content in cathodes):
S ( ppm ) = 0 ,1 T EEC 0 ,2 Q 0 ,2 Cu + 2 + 2 ,7 10 4 I EP EEC + 253
Scaled regression coefficient for each input variable in 2003 PLS model of S
PLS analysis. 2005 PLS model for cathodic quality (sulphur content in cathodes):
S ( ppm ) = T EEC 0 .2 Q EEC 0 ,1 Cu + 2 + 5 . 4 10 4 I EP + 365
More stable operation in January-May period, for modelling purposes.
Scaled regression coefficient for each input variable in 2005 PLS model of S
Conclusions. The VFA pattern model for 2003 operation was a good pattern model to represent a normal operation of EW tankhouse. It can be clearly seen the operational drift of 2004 and 2005 in the score plots compared with the operation in 2003. The evolution of Global Hotelling Index in 2003-2005 period also reflects this behavior. According to VFA analysis the variables that mainly explain the 2004 operational drift were current in cells (I) and Cu+2 poor electrolyte (Cu+2EP) because its high variability. The third variable was the incoming electrolyte temperature (TEEC). The SX-EW process was disturbed because of major changes in Heaps Leaching process. Also with the VFA analysis extended to 2005, the variable that becomes more relevant to explain the 2005 operational drift was the incoming electrolyte temperature (TEEC). This variable increased gradually since 2004.
Conclusions. The PLS analysis for 2005 (January-May) also demonstrates the great influence of TEEC over sulphur content in cathodes. It is known that in the short-term temperature favors the transport phenomena, so it was necessary to study the external agents that difficult them. Considering a long-term analysis, the gradual increase in TEEC also increased the sulphur content in cathodes S (decreasing the quality). This apparent contradiction in the effect of TEEC over S can be solved by the following hypothesis:
The external agent that difficult transport phenomena is the reagent (Guar Gum) that is used to improve the Cu crystal deposit over the cathode, but in presence of higher temperatures than specification for the reagent. Guar Gum in presence of higher temperatures rapidly decreases its mean life, generating degraded by-products in the electrolyte. It is not possible to measure the amount of degraded Guar Gum in the electrolyte. Those degraded by-products generates an irregular Cu deposit over the cathodes body, promoting the occlusion of electrolyte (and hence sulphur) inside cathodes structure. Electrolyte bleeding in tankhouse can be used to decrease the amount of degraded Guar Gum and hence to improve cathodic quality in terms of sulphur.

Multivariable Modelling For The Cathodic Quality

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Multivariable Modelling for the Cathodic Quality

Compaa Minera Doa Ins de Collahuasi SCM Gerencia Lixiviacin