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Transféré par joseph kafumbila

https://www.researchgate.net/publication/314512939_DESIGN_OF_COUNTER_CURRENT_DECANTATION_IN_COPPER_METALLURGY
The counter current decantation had been used since 90 years ago in the hydrometallurgical plant. It is currently adopted by all new hydrometallurgical plants located in the Katanga Province of the Democratic Republic of Congo (Ruashi Mining, Mumi Mining etc.) since it is applicable to all products; but its malfunction can limit the production of the plant. This publication is an upgrade of the publication called “Initiation à la simulation des flowsheet” and gives the procedure of CCD circuit design in the simplest way.
In the first chapter, the pulp is characterized using three parameters (mass, volume and specific gravity). This publication gives the mathematical expressions that link the three parameters for the two constituents of the pulp (solid and liquid) and for the pulp. Specially, this publication gives the simplest method to determine the specific gravity of solid when the mineralogical composition of solid is available and the specific gravity of liquid when chemical composition liquid is available.
In the second chapter, this publication gives the description of CCD circuit and the mass balance equations of thickener and CCD in the steady state condition. The difference with the first publication “Initiation à la simulation des flowsheet”, the flocculant is considered a solid.
In the third chapter, this publication gives the preliminary data to have before the design of the CCD circuit and the method for obtaining the value of these preliminary data (the mixing efficiency, the flocculant consumption, the wash ratio and the set value of the control parameter of underflows).
In the fourth chapter, this publication gives the procedure of the cylinder free settling test. The purpose of this chapter is to give the simplest method for obtaining the flocculant consumption and sizing the thickener.
In the fifth chapter, this publication gives the old and new methods for obtaining the optimum number of thickeners in the CCD circuit. In the new method, the determination of optimum number of thickener is illustrated through two examples using the conventional thickener and the High Rate Thickener.
The last chapter gives the procedure of simulation of CCD circuit with the new method on an Excel spreadsheet through the example.

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- Material Balance in Froth Flotation using Microsoft Excel Solver
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- Electrowinning course notes hydrometallurgy
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- Developments Hydrometallurgical Treatment of Copper Concentrates
- Mass Balancing McGill
- Copper SX Training, Nov. 2007
- Copper Electrowinning-Theoretical and Practical Design
- Design and Operations of Leach Pads.pdf
- Electrowinning and Electrorefining of Copper (Murdoch University)
- Hydrometallurgy_2009.pdf

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CURRENT DECANTATION IN

COPPER METALLURGY

Joseph Kafumbila

Design of counter current decantation in copper metallurgy

© 2016 Joseph Kafumbila

jokafumbila@hotmail.com

performed in agitated open leach tanks

With the current market value of cobalt, it is time to revisit the technology used for cobalt

III leaching in the new hydrometallurgical plants in the Democratic Republic of Congo. Dispersion

of SO2 in the leach pulp containing 1 g/L of iron gives slow cobalt leaching kinetic in agitated open

leach tanks. The adoption of filblast technology will improve the kinetic of cobalt III leaching,

resulting an improvement of cobalt leaching recovery and decreasing in the capex of the leach

section. Filblast advice will increase the solubility of SO2 in the leach pulp. The increase in SO2

solubility in the leach pulp will give a rapid cobalt III dissolution reaction. The main advantageous of

filblast is that the recycle pump takes big particles of cobalt III minerals residing in the bottom of

the leach tank, which will be processing in the filblast advice. In this condition the increase in the

cobalt dissolution kinetic will be more significant because the kinetic leaching model of cobalt III

dissolution is shrinking core model. The current leaching conditions in the new hydrometallurgical

plants require us to test this technology. This technology does not require a major modification of

the leach section installation.

https://www.researchgate.net/publication/322385532_Necessity_to_use_filblast_technolog

y_for_cobalt_III_leaching_performed_in_agitated_open_leach_tanks

Content

1. GENERAL 5

1.2. CHARACTERIZATION OF PULP 5

1.2.1. SOLID 6

1.2.2. LIQUID 8

1.2.3. PULP 10

2.2. EQUATIONS OF MASS BALANCE IN CCD 12

2.2.1. DESIGNATION OF PULP 12

2.2.2. EQUATIONS OF MASS BALANCE 13

3.1.1. CHARACTERISTICS OF FEED PULP 16

3.1.2. MIXING EFFICIENCY 16

3.1.3. FLOCCULANT CONSUMPTION 17

3.1.4. WASH RATIO 17

3.1.5. SET VALUE OF CONTROL PARAMETER OF UNDERFLOWS 18

3.2. NUMBER OF THICKENER IN THE CCD 21

4. SETTLING TEST 22

4.1.1. RULE THUMB SIZING 22

4.1.2. CYLINDER SETTLING TESTS 22

4.1.3. DYNAMIC THICKENER TEST WORK 22

4.2. CYLINDER SETTLING TESTS 22

4.2.1. EQUIPMENT 22

4.2.2. CHARACTERIZATION OF PULP 23

4.2.3. FLOCCULANT PREPARATION 23

4.2.4. SETTLING TEST 23

4.2.5. SETTLING CURVE 24

4.2.6. SIZE OF THICKENER 25

Joseph Kafumbila Page 2

5.1.1. FIRST METHOD 27

5.1.2. SECOND METHOD 27

5.2. NEW METHOD 28

5.2.1. CONSTRAINTS 28

5.2.2. FIRST EXAMPLE 28

5.2.3. SECOND EXAMPLE 32

5.2.4. OBSERVATIONS 36

6.1. GENERAL 37

6.2. PLANT DESCRIPTION 37

6.3. PRELIMINARY DATA OF CCD CIRCUIT 37

6.4. SIMULATION TABLE 37

6.5. PROCEDURE OF CCD CIRCUIT SIMULATION 39

7. REFERENCE 50

Foreword

The counter current decantation had been used since 90 years ago in the hydrometallurgical plant. It

is currently adopted by all new hydrometallurgical plants located in the Katanga Province of the Democratic

Republic of Congo (Ruashi Mining, Mumi Mining etc.) since it is applicable to all products; but its

malfunction can limit the production of the plant. This publication is an upgrade of the publication called

“Initiation à la simulation des flowsheet” and gives the procedure of CCD circuit design in the simplest way.

In the first chapter, the pulp is characterized using three parameters (mass, volume and specific

gravity). This publication gives the mathematical expressions that link the three parameters for the two

constituents of the pulp (solid and liquid) and for the pulp. Specially, this publication gives the simplest

method to determine the specific gravity of solid when the mineralogical composition of solid is available and

the specific gravity of liquid when chemical composition liquid is available.

In the second chapter, this publication gives the description of CCD circuit and the mass balance

equations of thickener and CCD in the steady state condition. The difference with the first publication

“Initiation à la simulation des flowsheet”, the flocculant is considered a solid.

In the third chapter, this publication gives the preliminary data to have before the design of the

CCD circuit and the method for obtaining the value of these preliminary data (the mixing efficiency, the

flocculant consumption, the wash ratio and the set value of the control parameter of underflows).

In the fourth chapter, this publication gives the procedure of the cylinder free settling test. The

purpose of this chapter is to give the simplest method for obtaining the flocculant consumption and sizing

the thickener.

In the fifth chapter, this publication gives the old and new methods for obtaining the optimum

number of thickeners in the CCD circuit. In the new method, the determination of optimum number of

thickener is illustrated through two examples using the conventional thickener and the High Rate Thickener.

The last chapter gives the procedure of simulation of CCD circuit with the new method on an Excel

spreadsheet through the example.

1. General

Pulp washing in the CCD is part of the pulp wash process. The pulp wash process is a special

operation that performs both the extraction and the solid - liquid separation. Thus the pulp wash process falls

within the category of mass transfer operations for chemical and metallurgical engineering [1].

Wash by dilution: the thickened pulps are, at the entrance of various stages, diluted with corresponding

wash solutions to achieve such a perfect mixture as possible. The subsequent solid - liquid separation is

generally done by decantation. Such washes technique is suitable for the muddy pulp formed of very

fine particles.

Wash by displacement: the impregnation solution of pulp to be washed is generally removed by the

wash solution, which is substituted directly to it more or less complete. This kind of wash technique is

suitable for the permeable grainy pulp. The solid - liquid separation is usually achieved by filtration or

draining.

By dilution or by displacement, the pulp wash technique can be done in two main ways:

Methodical wash or counter current

In what follows, it will be treated the pulp wash in the CCD since it is more effective and widely

used in the metallurgical industry of Copper.

Generally, the suspension of particles in a solution is called pulp. The suspended particles will be

called solid and form the solid phase while the impregnation solution is the liquid phase. Therefore, the pulp

will always consist of two components: solid and liquid.

It will be discussed first the characterization of the two components of pulp before the

characterization of pulp. The characterization means, in this publication, the designation of important

parameters of a phase and the development of equations linking these parameters.

1.2.1. Solid

The solid is characterized by a mass (Ms ) expressed in (kg) and a volume (Vs ) expressed in (m3). The

specific gravity (SGs ) expressed in (kg/m3) is the ratio of the mass onto the volume of solid. Equation (1)

gives the mathematical expression that links the mass, the volume and the specific gravity of solid.

Ms (

SGs = Vs (1)

The solid is considered insoluble in the CCD circuit and the specific gravity of solid is constant.

There are two methods for obtaining the specific gravity of solid: the laboratory method and the

mineralogical composition method.

A. Laboratory method

When it is possible to have physically the solid, the laboratory method for obtaining the specific

gravity of solid consisting of mineral rock finely crushed is as follows:

Weigh the solid (kg) (weight between 0.100 and 0.300 kg),

Put the solid in a test tube of one liter,

Add the water in the test tube up to 500 ml,

Mix the solid and the water until complete homogenization,

Add more water in the test tube to the mark of a liter and,

Weigh the volume of one liter of pulp.

The weight of water is the difference between the weight of pulp and the weight of solid.

The volume of water is the ratio of weight onto the specific gravity of water (1,000 kg/m3).

The volume of solid is the difference between the volume of pulp and the volume of water.

Finally, the specific gravity of solid is the ratio of the weight onto the volume of solid.

Table (1) shows an example for obtaining the specific gravity of solid by the laboratory method.

This method seems simple, but it requires great accuracy during the weighing and the measuring of values.

Weight of solid kg 0.141

Weight of pulp kg 1.089

Volume of pulp l 1.000

Weight of water kg Weight of pulp – Weight of solid 0.948

Volume of water l Weight of water/specific gravity of water 0.948

Volume of solid l Volume of pulp – volume of water 0.052

SG of solid kg/m3 Weight of solid/volume of solid*1000 2,711.54

B. Mineralogical composition method

When the solid is not provided in order to obtain its specific gravity by the laboratory method, the

determination of specific gravity of solid is taken place by using the mineralogical composition method. This

method is based on the principle that rock is a juxtaposition of minerals. Therefore, the mass of rock is the

sum of masses of minerals and the volume of rock is the sum of volumes of minerals. Based on these

assumptions, the method for obtaining the rock specific gravity consists of:

Calculating the weight of minerals in a unit mass of solid.

Knowing the respective specific gravity of minerals.

Calculating the volumes of minerals.

Determining the volume of solid by the addition of volumes of minerals.

Calculating the specific gravity of solid by using the equation (1)

The weakness of this method is that it ignores porosities or structural defects of solid. Table (2)

shows an example for obtaining the specific gravity of solid by using the mineralogical composition method.

The result from Table (2) shows that for a total weight of 1,000 t of solid and a total volume of

359.77 m3 of solid which is the sum of volumes of minerals, the value of specific gravity of solid is 2,779.55

kg/m3.

of mineral mineral of solid

% t t/m3 m3 kg/m3

Cu2(OH)2(CO3) 1.584 15.836 4.00 3.959

Cu3(PO4)2.Cu2(OH)4 0.146 1.456 4.20 0.347

2CuO.2SiO2.3H2O 0.199 1.989 2.20 0.904

CuO 0.503 5.029 6.40 0.786

CuS 0.005 0.055 4.68 0.012

Cu2S 0.005 0.055 5.65 0.010

CuFeS2 0.005 0.055 4.20 0.013

CoOOH 0.507 5.070 4.00 1.268

FeO(OH) 1.954 19.543 3.65 5.354

Ni(OH)2 0.001 0.010 4.10 0.002

CaCO3.MgCO3 0.900 9.000 2.85 3.158

MnO2 0.127 1.266 4.85 0.261

ZnS 0.007 0.067 4.00 0.017

SiO2 77.139 771.393 2.65 291.092

UO3 0.004 0.040 10.97 0.004

Mg2SiO4 5.381 53.805 3.15 17.081

Ca2SiO4 0.011 0.110 2.71 0.041

CaCl2 0.025 0.250 2.15 0.116

Al2SiO5 11.471 114.710 3.25 35.295

Cr2O3 0.026 0.256 5.22 0.049

CdO 0.001 0.006 8.15 0.001

Total 1000 359.77 2,779.55

1.2.2. Liquid

The liquid is characterized by a mass (ML ) expressed in (kg) and a volume (VL ) expressed in (m3).

The specific gravity (SGL ) expressed in (kg/m3) is the ratio of the mass onto the volume of liquid. Equation

(2) gives the mathematical expression that links the mass, the volume and the specific gravity of liquid.

ML (

SGL = VL (2)

There are two methods for obtaining the specific gravity of liquid: the laboratory method and the chemical

composition method.

A. Laboratory method

When it is possible to have physically the liquid, the laboratory method for obtaining the specific

gravity of liquid is as follows:

Put the liquid in a test tube of one liter to the mark of a liter,

Weigh the volume of one liter of liquid (g),

And the ratio of weight onto the one liter volume of liquid gives the specific gravity.

The specific gravity obtained in this condition is the approximated value at ambient temperature.

A liquid is homogeneous mixture of solvent and solutes. In this publication, the solvent is water and

solutes are the elements appearing in the metallurgy of Copper and dissolved in water as sulphate. These

elements appearing in the metallurgy of Copper are listed in the Table (3). The Sodium is on the list since it

may come from sodium metabisulfite used as a reducing agent during leaching of trivalent Cobalt. The

phosphoric acid comes from pseudo malachite.

The index “k” is an identification number of the chemical element in this publication. At this level, it

is defined two other parameters; the mass of element of index “k” (Mk ) expressed in (kg) in the liquid and the

concentration of element of index “k” (Ck ) expressed in (kg/m3) in the liquid. Equation (3) gives the

mathematical expression that links the mass of element of index “k”, the concentration of element of index

“k” and the volume of liquid.

(

Mk = VL x Ck

(3)

It has been observed for a liquid containing copper sulphate and sulphuric acid that [2]:

The specific gravity of copper sulphate or sulphuric acid liquid is approximately a linear function of

concentration expressed in (%).

The specific gravity of liquids of equal concentration expressed in (%) of copper sulphate and of

sulphuric acid is nearly identical.

The specific gravity of liquid containing appreciable amounts of copper sulphate and sulphuric acid is

dependent principally upon the total concentration (%) and is almost independent of their proportion.

These observations have been extended to the elements appearing in the Copper metallurgy and the

simplest method that allows having the approximated value of specific gravity of liquid from the chemical

composition is given. The method consists of finding a total concentration (Cts ) expressed in (kg/m3) of

elements as salt in the liquid. In this case, the salt is in form of sulphate except the phosphoric acid. After, the

total concentration must be applied in the equation (4) which gives the relation between the liquid specific

gravity and the total concentration of elements. The equation (4) comes from data which give the specific

gravity of liquid as a function of concentration of element as salt in binary system [3].

H2SO4 1

Cu 2

Co 3

Fe 4

Zn 5

Ni 6

Mn 7

Mg 8

Al 9

Ca 10

Na 11

Cr 12

Cd 13

H3PO4 14

(

SGL = -6.139 x 10−4 x [Cts ]2 + 0.9742 x Cts + 1000 (kg/m3)

(4)

Therefore, it is defined a constant αk of element of index “k”. The constant αk is the value to

multiply to the concentration of element index “k” to have the concentration as sulfate salt “Cks ”. The values

of constant 𝛼𝑘 are given in Table (4). The value of concentration “Cks ” of element of index “k” is given by

equation (5).

(

Cks = αk x Ck

(5)

H2SO4 1 1.000

Cu 2 2.511

Co 3 2.629

Fe 4 2.719

Zn 5 2.468

Ni 6 2.635

Mn 7 2.747

Mg 8 4.949

Al 9 6.337

Ca 10 3.395

Na 11 3.088

Cr 12 3.769

Cd 13 1.854

H3PO4 14 1.000

Thus, the value of total concentration “Cts ” of elements in the liquid will be calculated according to

equation (6).

(

Cts = ∑k1 Cks = ∑k1 αk x Ck (6)

Table (5) gives an example for obtaining the specific gravity from the chemical composition of given

liquid. The result of Table (5) shows that the value of total concentration “Cts ” of elements in the liquid is

97.251 kg/m3. This value is the sum of concentrations as sulphate salt of elements. By applying the value of

total concentration of elements in the equation (4), the value of specific gravity of liquid “SGL ” is 1088.94

kg/m3. It is important to have ten major elements so that the calculated specific gravity of liquid will be

closed to the true specific gravity.

kg/m3 kg/m3

H2SO4 1 4.956 1.000 4.956

Cu 2 4.670 2.511 11.725

Co 3 11.233 2.629 29.532

Fe 4 2.925 2.719 7.954

Zn 5 0.099 2.468 0.244

Ni 6 0.000 2.635 0.000

Mn 7 2.812 2.747 7.724

Mg 8 4.440 4.949 21.974

Al 9 1.474 6.337 9.341

Ca 10 0.455 3.395 1.543

Na 11 0.000 3.088 0.000

Cr 12 0.108 3.769 0.407

Cd 13 0.001 1.854 0.002

H3PO4 14 1.849 1.000 1.849

Cts 97.251

1.2.3. Pulp

The pulp is a mixture of solid and liquid. The pulp will be characterized by a mass “MP ” expressed

in (kg), a volume “VP ” expressed in (m3) and a specific gravity “SGP ” expressed in (kg/m3). Equation (7) gives

the mathematical expression that links the mass, the volume and the specific gravity of pulp.

MP (

SGP = VP (7)

The mass of pulp is the sum of masses of solid and liquid. The mathematical expression of this

principle is given by equation (8).

(

MP = M S + ML

(8)

The volume of pulp is the sum of volumes of solid and liquid. The mathematical expression of this

principle is given by equation (9).

(

VP = VS + VL

(9)

Joseph Kafumbila Page 10

The mass of solid can also be calculated from the volume of pulp and the specific gravities of pulp,

solid and liquid. Equation (10) gives the mathematical expression.

(SG −SG ) (

Ms = (SGP−SGL) x SGs x Vp

S L (10)

The volume percentage of solid in the pulp expressed in (%) is given by equation (11).

V

Cvs = V s x 100 (%) (

p (11)

The weight percentage of solid in the pulp expressed in (%) is given by equation (12).

s M (

Cw = MS x 100

P (12)

2. Counter current decantation

The wash of pulp in the CCD is done according to two principles. The mixture of pulp is done in a

particular device (tank, agitated tank or mixer-distributor) and the solid - liquid separation is taken place in the

thickener. The scheme of thickener of rank “p” in the CCD containing “n” thickeners is illustrated in Figure

p−1

(1). The thickener of rank “p” (T p ) is received the underflow from the thickener of rank “p-1” (Tu ) and

p+1

the overflow of thickener of rank “p+1” (To ). Sometimes a solution of flocculant is also added to the

p

thickener of rank “p” (Tf ) allowing faster settling of solid by flock formation. The thickener of rank “p” is

p p

produced the underflow (Tu ) and the overflow (To ). The initial pulp (Tu0 ) is fed in the first thickener. The

overflow of the first thickener (To1 ) is the recovered solution (rich solution). The wash solution (Ton+1) is fed

in the last thickener. The underflow of the last thickener (Tun ) is the final pulp (also called washed pulp).

Figure 1: Scheme of thickener of rank “p” in the CCD containing “n” thickeners

The characterization of pulp gives the basic equations of pulp. Now, the basic equations of CCD

will be given. The inlet and outlet flows of thickener of rank “p” are pulps which are characterized by the

parameters defined above. For a proper understanding, the parameters of pulp leaving a thickener of rank

Joseph Kafumbila Page 12

p p

“p” will be preceded by a prefix "Tu " and "To " designating respectively the underflow and overflow of

p

thickener. The flocculant solution entering the thickener of rank “p” will have a prefix "Tf ".

The equations of mass balance of CCD are the mathematical expressions given the principles of

conservation of mass and volume in a thickener of rank “p” and in the CCD.

A. Thickener

When a thickener operates in a steady state, the sum of masses of solid entering a thickener is equal to

the mass of solid exiting through the underflow. This principle is called the conservation of mass of solid

in a thickener. For a thickener of rank “p”, the equation (13) gives the mathematical expression of this

principle.

p−1 p (

Tu Ms + TfP Ms = Tu Ms (13)

When a thickener operates in a steady state, the sum of volumes of solid entering a thickener is equal to

the volume of solid exiting through the underflow. This principle is called the conservation of volume of

solid in a thickener. For a thickener of rank “p”, the equation (14) gives the mathematical expression of

this principle.

p−1 p (

Tu Vs + TfP Vs = Tu Vs (14)

When a thickener operates in a steady state, the sum of masses of liquid entering a thickener is equal to

the sum of masses of liquid exiting through the overflow and the underflow. This principle is called the

conservation of mass of liquid in a thickener. For a thickener of rank “p”, the equation (15) gives the

mathematical expression of this principle.

p+1 p−1 p p p (

To ML + Tu ML + Tf ML = To ML + Tu ML (15)

When a thickener operates in a steady state, the sum of volumes of liquid entering a thickener is equal to

the sum of volumes of liquid exiting through the overflow and the underflow. This principle is called the

conservation of volume of liquid in a thickener. For a thickener of rank “p”, the equation (16) gives the

mathematical expression of this principle.

p+1 p−1 p p p (

To VL + Tu VL + Tf VL = To VL + Tu VL (16)

When a thickener is operated in a steady state, the sum of masses of element entering a thickener is equal

to the sum of masses of element exiting through the overflow and underflow. This principle is called the

principle of conservation of mass of element in a thickener. For a thickener of rank “p” and an element

of index “k”, the equations (17) and (18) give the mathematical expressions of this principle.

To VL x To Ck + Tu VL x Tu Ck = To VL x To Ck + Tu VL xTu Ck (17)

Joseph Kafumbila Page 13

p+1 p−1 p p (

To Mk + Tu Mk = To Mk + Tu Mk (18)

As mentioned above, in each thickener in the CCD circuit, the wash is done in two steps: the

homogenization of feed and the solid-liquid separation in the thickener. The performance of the

homogenization is given by mixing efficiency “ME p ” expressed in “%” of thickener of rank “p”. When

the homogenization of thickener feed is not complete, the concentration of an element in the overflow is

lower than the concentration in the underflow. Equation (19) gives the mathematical expression of

mixing efficiency for the thickener of rank “p” and for the element of index “k”.

p p+1

(To Ck −To Ck ) (

ME p = p p+1 x 100

(Tu Ck −To Ck ) (19)

p

The flocculant consumption Tf Q expressed in (g/t) is the ratio of mass of flocculant fed into a thickener

of rank “p” onto the mass of solid fed in the CCD circuit. Equation (20) gives the mathematical

expression of flocculant consumption for the thickener of rank “p”.

p

p T Ms (

Tf Q = Tf0 M x 106 (20)

u s

Equation (21) gives the volume of flocculant fed into a thickener of rank “p”. Where 2.650 (kg/m3) is

the specific gravity of the flocculant

p

p

T Ms (

Tf Vs = 2.650

f

(21)

B. CCD

When a CCD operates in a steady state, the sum of masses of solid entering a CCD containing “n”

thickeners is equal to the mass of solid exiting through the underflow of thickener of rank “n”. This

principle is called the conservation of mass of solid in a CCD circuit. The equation (22) gives the

mathematical expression of this principle.

(

Tu0 Ms + ∑n1 TfP Ms = Tun Ms (22)

When a CCD operates in a steady state, the sum of volumes of solid entering a CCD circuit is equal to

the volume of solid exiting through the underflow of thickener of rank “n”. This principle is called the

conservation of volume of solid in a CCD circuit. The equation (23) gives the mathematical expression

of this principle.

(

Tu0 Vs + ∑n1 TfP Vs = Tun Vs (23)

When a CCD operates in a steady state, the sum of masses of liquid entering a CCD circuit is equal to

the sum of volumes of liquid exiting through the overflow of thickener of rank “1” and the underflow of

thickener of rank “n”. This principle is called the conservation of mass of liquid in a CCD circuit. The

equation (24) gives the mathematical expression of this principle.

p

Ton+1 ML + Tu0 ML + ∑n1 Tf ML = To1 ML + Tun ML (

(24)

When a CCD operates in a steady state, the sum of volumes of liquid entering a CCD circuit is equal to

the sum of volumes of liquid exiting through the overflow of thickener of rank “n” and the underflow of

thickener of rank “n”. This principle is called the conservation of volume in a CCD circuit. The equation

(25) gives the mathematical expression of this principle.

p (

Ton+1 VL + Tu0 VL + ∑n1 Tf VL = To1 VL + Tun VL

(25)

When a CCD is operated in a steady state, the sum of masses of element entering a CCD circuit is equal

to the sum of masses of element exiting through the overflow of thickener of rank “1” and the

underflow of thickener of rank “n”. This principle is called the principle of conservation of mass of

element in a CCD circuit. For an element of index “k”, the equations (26) and (27) give the mathematical

expressions of this principle.

(

Ton+1 VL x Ton+1 Ck + Tu0 VL x Tu0 Ck = To1 VL x To1 Ck + Tun VL xTun Ck

(26)

(

Ton+1 Mk + Tu0 Mk = To1 Mk + Tun Mk

(27)

The wash ratio “WR” expressed in (m3/t) is the ratio of the volume of wash solution “Ton+1 VL ” onto the

mass of solid to be washed “Tu0 MS ”. Equation (28) gives the mathematical expression of wash ratio for a

CCD.

(Tn+1

o VL ) (

WR= x 1.000

(T0u MS ) (28)

p

Equation (29) gives the mathematical expression of wash efficiency “Tu WEk expressed in “%” after the

thickener of rank “p” and for element of index “k” in the CCD circuit.

p+1

p (T1o VL x(T1o Ck −To Ck )) (

Tu WEk = p+1 x 100

0 0

(Tu VL x(Tu Ck −To Ck )) (29)

Equation (30) gives the mathematical expression of total flocculant consumption expressed in (g/t) in

the CCD circuit containing “n” thickener.

p

∑n

1 Tf Ms (

Qt = x 106 (30)

T0u Ms

3. Design of counter current decantation

The preliminary data is data that you must have before the design of CCD circuit. These data are the

following:

The mixing efficiency

The flocculant consumption in each thickener

The wash ratio

The set value of control parameter of underflows

The essential characteristics of feed pulp to be known before the design of CCD circuit are:

The specific gravity of solid SGS (kg/m3),

The specific gravity of liquid SGL (kg/m3),

The chemical composition of feed liquid (Tu0 Ck ), and

s

The weight percentage of solid in the pulp Cw (%) or the volume percentage of solid in the pulp Cvs (%).

These characteristics come from the characterization of underflow pulp of primary thickener for

existing plant. In the case of a new plant, the settling tests must be done on the pulp from the leach tests. The

procedure of settling tests will be explained in a separated paragraph.

The Mixing efficiency depends on the method used for the homogenization of thickener feeds.

For the agitated tank with a mechanical agitator, the value of mixing efficiency is more than 98%

For the no agitated tank but fed tangentially to the internal walls of tank and in counter current, the

mixing efficiency is between 95 and 98%

For the mixer – distributor advice, the mixing efficiency is between 80 and 95%.

In an existing plant, the mixing efficiency is the average of mixing efficiencies of thickeners in the

CCD circuit.

3.1.3. Flocculant consumption

The flocculant consumption in each thickener comes from the settling tests done on the outlet pulp

of leach circuit. The type of underflow pump (volumetric or centrifugal) must be taken into account for

adding the flocculant in the CCD circuit.

For a plant using volumetric pumps, the flocculant is added only in the primary thickener. A volumetric

pump maintains the stability of flocks.

For a plant using the centrifugal pumps, the flocculant is added at 60% of primary thickener

consumption level in the first thickener of CCD circuit and at 40% of primary thickener consumption

level in the others thickeners of CCD circuit. If “Q” is the flocculant consumption from the settling test

done on the outlet pulp of leach circuit, the mathematical expression (31) gives the flocculant

consumption for the thickener of rank “p”.

p Q (

Tf Q= fp x100

(31)

thickener of rank “p” comparatively to the flocculant consumption of primary thickener.

There are two types of configuration of Copper hydrometallurgy plant – conventional circuit and the split

circuit.

A. Conventional circuit

The flow diagram of the conventional circuit is given by Figure (2). The wash ratio depends on the

loss of sulphuric acid in the bleed solution of Copper circuit. The loss of sulphuric acid in the bleed of

Copper circuit is taken account the free acid and the acid linked to Copper in the solution. In the case of

Copper and Cobalt production plant, the concentration of Cobalt in the bleed solution of Copper circuit is

also the important parameter. It is better to have a higher concentration of Cobalt to 5 g/l in the bleed

solution for reducing the loss of Cobalt in the effluents of Cobalt circuit.

B. Split circuit

The flow diagram of the split circuit is given by the Figure (3). In this case, the free acid and the acid

linked to the Copper which are in the solution of underflow pulp of primary thickener are already lost.

The wash ratio is limited by the flowrate of the first thickener overflow in the CCD circuit.

Generally, the flowrate of overflow of first thickener is limited by the size of secondary Copper solvent

extraction circuit. In the case of Copper and Cobalt production plant, the concentration of Cobalt in the

bleed solution of Copper circuit is also the important parameter. It is better to have a higher concentration of

Cobalt to 5 g/l in the bleed solution for reducing the loss of Cobalt in the effluents of Cobalt circuit.

A. Settling test

In the old configuration of CCD circuit, the control parameter of underflow was the volume

percentage of solid in the pulp. The value of volume percentage of solid in the pulp came from the

characteristics of underflow obtained from the settling test done on the outlet pulp leach circuit. The

characteristics of underflow have been obtained after 24 hours of free settling time. At the beginning, the

volume percentage of solid in the CCD underflows pulp was the same as the volume percentage of solid in

the CCD feed pulp. Later, the values of volume percentage of solid in the CCD underflow pulps were

different from the volume percentage of solid in the CCD feed pulp. The volumetric pump with a constant

speed has been used for the CCD thickener underflows. The operability of these configurations was very bad

because the control of the bed level of solid in the thickeners was difficult.

Since 80 years, for the improving of CCD operability, the control parameter of CCD underflows

became the specific gravity of underflow pulp and the underflow pump became the centrifugal pump with

variable speed. The value of specific gravity of underflow pulp of primary thickener came from the underflow

characteristic obtained from the settling test done on the outlet pulp of leach circuit. The settling time to have

the underflow characteristic remains 24 hours. The value of specific gravity of CCD underflow pulp taken as

the set value of the control parameter of CCD underflows was the value of specific gravity of underflow pulp

of thickener of rank “n” in the CCD circuit having the value of volume percentage of solid of the underflow

pulp of primary thickener. The type of thickener used for the primary and the CCD was the conventional

thickener.

The weight percentage of solid in the underflow pulp increases with the decreasing of weight percentage

of solid in the feed pulp of thickener for the same dosage of flocculant. This correction is obtained from

the settling tests done in the Outokumpu laboratory in Finland Figure (4).

The settling rate increases with the decreasing of weight percentage of solid in the feed pulp of thickener.

Figure (5) shows an example of the variation of the settling rate with the initial concentration of solid in

the pulp [4].

The value of weight percentage of solid in the pulp taken as the set value of the control parameter of the

underflows shows directly the pumping characteristic of underflow pulp than the value of specific gravity

of pulp.

61

59

Underflow (% solids)

57

55

53

15% solids

51 25% solids

42% solids

49

0 5 10 15 20 25

Flocculent dosage (g/t of solids)

Figure 4: Correlation between the solid pulp concentrations of thickener feed and thickener underflow

From these observations, the design of thickener changes from conventional to High Rate

Thickener which is capable to make an auto dilution of feed pulp of thickener with the overflow to reach

10% weight percentage of solid in the thickener feed cylinder. The control parameter of underflow becomes

the weight percentage of solid in the underflow pulp.

The value of weight percentage of solid in the underflow pulp of primary thickener is the value of

weight percentage of solid in the underflow pulp obtained from the settling test done on the outlet pulp of

leach circuit. The settling time to have the underflow characteristic remains 24 hours. The value of weight

percentage of solid in the CCD underflow pulp taken as the control parameter of underflow is the value of

weight percentage of solid in underflow pulp of the primary thickener.

In case of simulation of CCD circuit, the important parameter which characterizes the underflow

pulp of primary thickener is the volume percentage of solid in the underflow pulp for the conventional or the

High Rate Thickener. The volume percentage of solid in the underflow pulp, the specific gravity of liquid and

the specific gravity of solid will provide the value of weight percentage of solid in the underflow pulp.

The underflow pump will be design according to the rheology test done on the underflow of the

primary thickener.

1,40

1,20

Settling rate (m/h)

1,00

0,80

0,60

0,40

0,20

0,00

0 20 40 60 80 100 120 140 160

Solid concentration in thickener feed pulp (kg/m3)

Figure 5: Settling rate versus solid concentration in the thickener feed pulp

B. Rheology test

Actually, the thickener manufactories derive the thickener having the underflow pump with certain

characteristics. Depending on the type of thickener, the High Rate Thickener is designed to consistently

discharge underflow pulp having a yield stress of less than 25 Pa and the High Density Thickener is designed

to consistently discharge underflow pulp having a yield stress of less than 100 Pa.

Therefore, the rheology test will provide the maximum value of volume percentage of solid in the

underflow pulp. The set value of control parameter of underflows in the CCD circuit is fixed by the type of

thickener (High Rate Thickener or High Density Thickener) and the rheology curve. The set value of the

control parameter of the underflows (weight percentage of solid in the pulp) is obtained at 20 Pa of yield

stress for the High rate Thickener and at 60 Pa of yield stress for the High Density Thickener. The settling

time to reach the set value of the control parameter of the underflows must be less than 4 hours for the High

Rate Thickener and less than 6 hours for the High density Thickener in the continuous fill test with rake.

The rheology tests must be carried out on the underflow pulp of primary thickener to determine the

limit of elasticity or "yield stress". The yield stress for the underflow pulp is the pressure required to be

applied to the underflow pulp to flow from a stationery bed. The yield stress is a function of the physical

properties of pulp (the chemical composition of solid, the particle size distribution, and the solid percentage

of pulp), the type of flocculant used, the dosage of flocculant and temperature.

Figure 6 shows the example of yield stress variation according to the solid percentage of underflow

pulp of Ruashi Mining plants. For the High Rate Thickener, the solid percentage of underflow pulp should

not exceed 56.0% and for the High Density Thickener, the solid percentage of underflow pulp should not

exceed 60.4% [5].

200

175

150

125

100

75

50

25

0

54 56 58 60 62 64

Underflow pulp solids percentage (%)

Figure 6: Yield stress values versus the underflow pulp percentage of solid of Ruashi Mining plants

It has been defined above how to fix the set value of the control parameter of underflows, the

mixing efficiency, the flocculant consumption and the wash ratio. It only remains to find the number “n” of

thickener to align in a CCD to reach the set value of the wash efficiency or the concentration of recoverable

element in the underflow of thickener of rank “n”.

It should be noted that the wash efficiency increases with increasing the volume percentage of solid

in the underflow pulp, the wash ratio, the mixing efficiency, and the number of thickener in series. The

determination of the optimum number of thickener in the CCD circuit will be in another paragraph.

The method is to vary the number of thickeners in the CCD circuit until the value of washing

efficiency or the value of the concentration of a valuable component in the underflow liquid of the last

thickener reach the target value.

4. Settling test

There are 3 types of settling test: the rule of thumb sizing, the cylinder settling tests, and the

dynamic thickener test work.

This type of settling test is used when the indicative feed samples are not available. The performance

of the nearly plant with similar feed characteristics can be taken into account.

These settling tests are the traditional method for thickener sizing. This method can be conducted

with a relatively small amount of feed sample.

The dynamic thickener test work method has been developed by the thickener suppliers until the

1990s. This method is the new version to scale the commercial thickeners. This method requires the larger

amount of sample.

4.2.1. Equipment

Settling tests are conducted in one liter graduated cylinder whose dimensions are the following:

A graduated height of 10 ml into 10 ml to a liter: Up to a liter equal to 348 mm,

An internal diameter: 60 mm,

The agitation of the pulp in the test is done manually by upward and downward movements with the aid

of a 500 mm long rod equipped at its end with a perforated 50 mm diameter disc,

The perforated disc have 6 holes of 12 mm in diameter,

The clarity of the solution is estimated using a turbidity meter.

4.2.2. Characterization of pulp

It is necessary to determine the following characteristics of pulp before starting the settling tests:

The pH of pulp,

The specific gravity of solid,

The specific gravity of liquid,

The specific gravity of pulp,

The weight percentage of solid in the pulp.

solid in the pulp comes after the pH adjustment. In the case of High Rate Thickener, the pulp must be

diluted with the leach solution to the desired weight percentage of solid in the pulp (10 % of solid).

The flocculant is prepared into concentrated solution of 5% (stock solution) which is diluted 20

times in use. The flocculant stock solution can be stored for one week. However the retention period of

diluted solution can’t exceed 24 hours. The preparation method of flocculant stock solution is:

Disperse the flocculant slowly (for 30 minutes) in a one liter beaker containing 500 ml of water with

stirring. The mixer will run at a speed sufficient to create a vortex,

Leave stirring for 2 hours,

Transfer to a polyethylene bottle, taking care to close after filling

This stock solution will be diluted 20 times before use. The weight percentage of flocculant in the dilute

solution will be 0.25 %.

The dosage of flocculant in the settling test cylinder is done according to the assay gram of

flocculant per ton of solid.

Fill the settling test cylinder with pulp to a liter,

Stir the pulp using the rod ten times with a frequency of one pulse per second,

Add the calculated volume of diluted flocculant solution,

Continue to stir the pulp approximately 3 times,

Start the timer when the settling front of pulp passes by the 1.000 ml graduation of the cylinder,

Note the height of the settling front of pulp versus time as prescribed on the running sheet (Table 6

shows the running sheet of settling test),

Determine the clarity of solution after settling test.

The Settling tests are repeated several times for different dosages and flocculant types.

Date Temperature Type of flocculant

Type of pulp pH

Temperature Solid %

pH Solid specific gravity

Liquid specific gravity

Times height (mL)

min white Flocculant dosage (g/t)

0.5

1

1.5

2

2.5

3

4

5

6

8

10

12

14

16

20

25

30

35

40

50

60

24h

At the beginning, the large grains are settled quickly and are deposited on the bottom of the cylinder.

The height of this zone is increased quickly and stabilized after the settling of grains greater than 0.1 mm.

Then, it is quickly appeared, and sometimes immediately, an interface between a clear liquid and a sludge

phase.

By plotting the variation of height (h) of interface between the clear liquid and the slurry phase

according to the time (t) since the beginning of settling test, the settling curve is obtained (Figure 6). It

appears on the settling curve the following four areas:

Domain I - it corresponds to the original time of flocculation and is often non-existent if the

flocculation is fast,

Domain II - this is the area where the flocks begin to gather in flakes and settling rate is constant,

Domain III - from this point, the disruptive action occurs between the flakes and particles. This point is

often poorly defined on the curve,

Domain IV - from this point, the isolated solids are in contact and form semi-rigid pseudo-networks.

The liquid is discharged through the mass of sediment following the voids created by the pseudo-

networks and after sliding the mud layers. This domain is called compression zone.

1000

a

900 I

Interface Height (mL)

800

700 II b

600

500 III

IV

400

0 10 20 30 40 50 60

Times (min)

The classic work on the capacity of a continuously operating thickener was provided by Coe and

Clevenger [6]. The choice of flocculant is performed by comparing the settling rate in the Domain (II). The

settling rate expressed in (m/h) in this domain II is obtained by equation (32). The settling test giving high

settling rate with low flocculent consumption is taken.

Vd = x 1.000 x 1.000

(tb −ta ) (32)

Where ha is the height (ml) in the point “a”, hb is the height (ml) in point “b”, t b is the time (min)

in the point “b”, t a is the time (min) in the point “a” and 348 is the height (mm) of the settling test cylinder at

1.000 ml.

The solid flux “G” expressed in (kg/m2.h) that a thickener can process per unit area and per unit

time is given by the equation (33).

Vd (

G= 1 1

( i − u) (33)

Cs Cs

where Csi is the initial solid concentration (kg/m3) of pulp and Csu is the concentration of solid

(kg/m3) in the underflow pulp.

The thickener area is obtained using the equation (34).

Ms (

S= x 1.2

G (34)

where Ms is the solid mass flow (kg/h) and G is solid flux (kg/m2.h).

5. Optimum number of thickener in the CCD circuit

There are two old methods for determining the number of thickener in the CCD circuit. These

two old methods require knowledge of the values of volume percentage of solid in the pulp fed in the CCD

circuit and in the underflows of thickeners.

When the volume percentage of solid in the pulp fed to the CCD circuit is the same as those of

underflows of CCD circuit, the mixing efficiency is 100 % and the flocculant is added only to the primary

thickener, the mathematical expression (35) gives the equation for calculating the concentration of an

element of index "k" in the liquid of underflow of thickener of rank "p".

p+1

T0u Ck −Tu Ck (

p p+1 = Ωp

Tu Ck −Tu Ck (35)

(

Ωp = 1+ β1 + β2 + …….. + βp

(36)

Tn+1

o VL (

β= Tn

u VL (37)

When the volume percentage of solid in the pulp fed to the CCD circuit is different from those of

underflows CCD circuit, the mixing efficiency is 100 % and the flocculant is added only to the primary

thickener, the mathematical expression (38) gives the equation for calculating the concentration of an

element of index "k" in the liquid of underflow of thickener of rank "n". The CCD circuit contains "n"

thickeners.

Tun Ck = γ

γ(n+1) −1

xTu0 Ck + [1- γ

γ(n+1) −1

]x Ton+1 Ck (

1 xγ2 xγ3 x….xγ(n+1) −1 1 xγ2 xγ3 x….xγ(n+1) −1 (38)

p

To VL (

γp = p−1

Tu VL (39)

Tn+1

o VL (

γ(n+1) = Tn

u VL (40)

5.2.1. Constraints

The old methods to calculate the number of thickener to upload the CCD circuit are no longer

used today because of:

When the control parameter of underflows in the CCD circuit becomes the specific gravity of pulp or

the weight percentage of solid in the pulp, the value of volume percentage of solid in the pulp becomes

a function of specific gravity of solid and specific gravity of liquid. It should also be noted that the

specific gravity of liquid is a function of the chemical composition.

In modern CCD circuits, the centrifugal pumps with variable speed are used for the underflow pulp to

improve the operability of the circuit. Under these conditions, the flocculant is also added in the CCD

circuit

Two examples of simulation of a CCD circuit will be made to illustrate the new method of

simulation

The CCD circuit is part of Copper and Cobalt production plant from flotation concentrates. The

configuration of Copper circuit is the conventional circuit. Accordingly, the overflow of the first thickener

in the CCD circuit is mixed with the overflow from the primary thickener and the mixture is the feed of

Copper tankhouse. The solution leaving the Copper tankhouse is pumped to the leach section after

bleeding excess water. This bleed solution is the feed of Cobalt circuit.

The pulp to be washed from the primary thickener has the following characteristics: the mass flow (MS )

of 26.250 kg/h, specific gravity of solid (dS ) 2,700 kg/m3, the volume percentage of solid in the pulp

after the settling test of 25%.

The concentrations of elements in the liquid are shown in the table (7)

Elements Cu Co Fe Zn Ca Mn Mg Al H2SO4

(kg/m3) 60.00 29.03 3.41 0.28 0.50 1.38 14.22 2.85 16.82

The consumption of flocculant in the primary thickener is 30 g/t. The value of "f1 " is 60% and the

value of "f2 " to "fn " is 40%. Note that centrifugal pumps are used for the underflows. The value of

weight percentage of flocculant in the solution fed to the thickener is 0.25 %.

The value of mixing efficiency is 95 %.

The type of thickener is the conventional.

C. Simulation results

First simulation

The control parameter of underflows is the specific gravity of pulp. The set value of the specific

gravity of underflow pulp is the value of specific gravity of underflow of thickener of rank “n” in the CCD

circuit having the volume percentage of solid of the underflow of primary thickener.

Table 8 shows the simulation results of the CCD circuit having the number of thickener ranging

from 1 to 5. The results of the simulation show that:

Wash efficiency increases with increasing the number of thickener in the CCD circuit. Figure 7 shows

the wash efficiency of the thickener of rank “n” in the CCD circuit as a function of number “n” of

thickener.

100,00

90,00

Wash efficiency (%)

80,00

70,00

60,00

50,00

0 1 2 3 4 5 6

Number of thickener in the CCD circuit

Figure 7: Wash efficiency of CCD circuit versus number of Thickener for the first simulation

The set value of specific gravity of underflows in the CCD circuit decreases with the increasing of

number “n” of thickener in the CCD circuit. This is due to the decreasing of specific gravity of

underflow liquid of the thickener of rank “n”.

For thickener of rank "p" in the CCD circuit containing "n" thickener, the weight and volume

percentages of solid in the underflow pulp decrease with the increasing the number of thickener "n".

This is due to the increasing of specific gravity of underflow liquid of thickener of rank “p”. This

increasing of specific gravity of underflow liquid of thickener of rank “p” is a consequence of liquid

enrichment.

For a CCD circuit containing "n" thickener, the values of weight and volume percentages of underflow

pulp increases from the thickener of rank “1” to the thickener of rank “n”. In our case, the increase in

the value of volume percentage from the first to the last thickener is 43.41 % for a CCD circuit

containing 5 thickeners.

Table 8: Simulation results of CCD circuit for the first example (specific gravity – control parameter)

Thickener

SGP kg/m3 1623.38 1516.22

Cw % 41.58 44.52

Cv % 25.00 25.00

1 SGL kg/m3 1264.50 1121.63

C2 kg/m3 60.00 23.57

Qt g/t 18.00

p

WE2 % 60.71

SGP kg/m3 1623.38 1478.20 1478.20

Cw % 41.58 38.79 45.66

Cv % 25.00 21.23 25

2 SGL Kg/m3 1264.50 1148.81 1070.93

C2 kg/m3 60.00 29.55 13.20

Qt g/t 30

p

WE2 % 55.52 78.00

SGP kg/m3 1623.38 1458.32 1458.32 1458.32

Cw % 41.58 35.73 41.52 46.29

Cv % 25.00 19.30 22.43 25.00

3 SGL kg/m3 1264.50 1161.44 1099.38 1044.43

C2 kg/m3 60.00 32.44 18.91 8.11

Qt g/t 42.00

p

WE2 % 52.55 75.13 86.48

SGP kg/m3 1623.38 1446.42 1446.42 1446.42 1446.42

Cw % 41.58 33.88 39.07 43.40 46.67

Cv % 25.00 18.15 20.93 23.25 25.00

4 SGL kg/m3 1264.50 1168.45 1114.56 1066.65 1028.56

C2 kg/m3 60.00 34.08 22.07 12.37 5.16

Qt g/t 54.00

p

WE2 % 50.70 73.29 84.96 91.41

SGP kg/m3 1623.38 1438.86 1438.86 1438.86 1438.86 1438.86

Cw % 41.58 32.71 37.55 41.61 44.71 46.91

Cv % 25.00 17.43 20.01 22.17 23.83 25.00

5 SGL kg/m3 1264.50 1172.61 1123.42 1079.59 1044.40 1018.49

C2 kg/m3 60.00 35.07 23.96 14.91 8.10 3.32

Qt g/t 66.00

p

WE2 % 49.52 72.09 83.94 90.60 94.47

Second simulation

Compared to the first simulation, the control parameter of underflows is the weight percentage of

solid in the pulp. The set value of the weight percentage of solid in the underflows is the value of the weight

percentage of solid in the underflow of primary thickener.

Table 9 shows the simulation results of CCD circuit having the number of thickener ranging from

1 to 5. The results of the simulation show that:

The wash efficiency increases with the increasing the number “n” of thickener in the CCD circuit.

Figure 8 shows the wash efficiency after the thickener of rank “n” in the CCD circuit as a function of

number “n” of thickeners

Table 9: Simulation results of CCD circuit for the first example (Weight percentage of solid – control

parameter)

Thickener

SGP kg/m3 1623.38 1481.53

Cw % 41.58 41.58

Cv % 25.00 22.82

1 SGL kg/m3 1264.50 1121.35

C2 kg/m3 60 23.52

Qt g/t 18

p

WE2 % 55.80

SGP kg/m3 1623.38 1518.77 1429.06

Cw % 41.58 41.58 41.58

Cv % 25.00 23.39 22.01

2 SGL Kg/m3 1264.50 1158.14 1070.44

C2 kg/m3 60 31.68 13.10

Qt g/t 30.00

p

WE2 % 55.68 74.20

SGP kg/m3 1623.38 1536.49 1462.53 1403.18

Cw % 41.58 41.58 41.58 41.58

Cv % 25.00 23.66 22.52 21.61

3 SGL kg/m3 1264.50 1175.84 1102.79 1045.71

C2 kg/m3 60 35.84 19.61 8.35

Qt g/t 42.00

p

WE2 % 55.58 74.12 83.17

SGP kg/m3 1623.38 1546.49 1481.46 1429.27 1388.17

Cw % 41.58 41.58 41.58 41.58 41.58

Cv % 25.00 23.82 22.81 22.01 21.38

4 SGL kg/m3 1264.50 1185.88 1121.29 1070.64 1031.48

C2 kg/m3 60 38.28 23.50 13.15 5.69

Qt g/t 54.00

p

WE2 % 55.51 74.06 83.11 88.36

SGP kg/m3 1623.38 1552.63 1493.17 1445.51 1407.99 1378.60

Cw % 41.58 41.58 41.58 41.58 41.58 41.58

Cv % 25.00 23.91 22.99 22.26 21.68 21.23

5 SGL kg/m3 1264.50 1192.09 1132.81 1086.29 1050.28 1022.46

C2 kg/m3 60 39.82 25.99 16.25 9.22 4.04

Qt g/t 66.00

p

WE2 % 55.48 74.03 83.09 88.33 91.68

For a Thickener of rank "p" in the CCD circuit containing "n" thickener, the volume percentage of

solid in the pulp of underflow increases with the increasing the number "n” of thickeners. This is due

to the increasing of specific gravity of underflow liquid of thickener of rank "p". This increasing of

specific gravity of underflow liquid is a consequence of enrichment of liquid.

For a CCD circuit containing "n" thickeners, the values of volume percentages of solid in the

underflow decrease from the thickener of rank “1” to the thickener of rank “n”. In this case, the

decrease in the value of volume percentage is 11.21 % for a CCD circuit containing "5" thickener.

100,00

80,00

70,00

60,00

50,00

0 1 2 3 4 5 6

Number of thickener in the CCD circuit

Figure 8: Wash efficiency of CCD circuit versus number of Thickener for the second simulation

The CCD circuit is part of Copper and Cobalt production plant from oxide ores. The

configuration of Copper circuit is the conventional circuit. So, the overflow of the first thickener in the

CCD circuit is mixed with the overflow from the primary thickener and the mixture is the PLS of Copper

solvent extraction. The raffinate from the Copper solvent extraction is pumped to the leach section of ores

after bleeding excess water. This bleed is the feed of Cobalt circuit.

The Pulp to be washed from the primary thickener has the following characteristics: the mass flow

(MS ) of 260,000 kg/h, the specific gravity of solid (dS ) of 2,600 kg/m3, the volume percentage of solid

in the pulp after the settling tests of 36.92 %.

The concentrations of elements in the liquid are shown in the table (10)

(kg/m3) 8.04 10.14 0.80 0,10 0,50 2.75 3.80 1.17 1.82 1.99

The flocculant consumption in the primary thickener is 40 g/t. The value of "f1 " is 60% and the value

of "f2 " to "fn " is 40%. Note that centrifugal pumps are used to pump underflows. The value of weight

percentage of flocculant in the solution fed to the thickener is 0.25 %.

The value of wash ratio is 1.8 m3/t.

The value of mixing efficiency is 95 %.

The type of thickeners is the High Grade Thickener.

C. Simulation results

First simulation

The control parameter of underflows is the specific gravity of pulp. The set value of the specific

gravity of underflows is the value of specific gravity of underflow of thickener of rank “n” having the

volume percentage of solid in the pulp of the underflow of primary thickener.

Table 11 gives the simulation results of CCD circuit with the number of thickeners ranging from 1

to 5. The results of simulation show that:

The Wash efficiency increases with the increasing the number of thickener in the CCD circuit. Figure 9

shows the wash efficiency of the thickener of rank “n” in the CCD circuit as a function of number “n”

of thickener.

100,00

95,00

Wash efficiency (%)

90,00

85,00

80,00

75,00

70,00

0 1 2 3 4 5 6

Number of thickener in the CCD

Figure 9: Wash efficiency of CCD circuit versus number of Thickener for the first simulation

The set value of specific gravity of underflows decreases with the increasing of number “n” of

thickener in the CCD circuit. This is due to the decreasing of specific gravity of underflow liquid of

thickener of rank “n”.

For thickener of rank "p" in the CCD circuit containing "n" thickener, the weight and volume

percentages of solid in the underflow pulp decrease with the increasing the number “n” of thickener in

CCD circuit. This is due to the increasing of specific gravity of underflow liquid. This increasing of

specific gravity of underflow liquid is a consequence of enrichment of liquid.

For a CCD circuit containing "n" thickener, the values of weight and volume percentages of solid in

the underflow pulp increase from the thickener of rank “1” to the thickener of rank “n”. In this case,

the increase of value of volume percentage from the first to the last thickener is 3.45 % for a CCD

circuit containing 5 thickeners.

Table 11: Simulation results of CCD circuit for the second example (specific gravity – control parameter)

Thickener

SGP kg/m3 1642.18 1605.61

Cw % 58.46 59.79

Cv % 36.93 36.93

1 SGL kg/m3 1081.46 1023.49

C2 kg/m3 8.04 2.22

Qt g/t 24.00

p

WE2 % 72.35

SGP kg/m3 1642.18 1596.02 1596.02

Cw % 58.46 58.82 60.12

Cv % 36.93 36.10 36.93

2 SGL Kg/m3 1081.46 1028.72 1008.27

C2 kg/m3 8.04 2.73 0.76

Qt g/t 40.00

p

WE2 % 71.60 90.36

SGP kg/m3 1642.18 1592.72 1592.72 1592.72

Cw % 58.46 58.48 59.77 60.28

Cv % 36.93 35.83 36.62 36.93

3 SGL kg/m3 1081.46 1030.41 1010.83 1003.04

C2 kg/m3 8.04 2.89 1.02 0.28

Qt g/t 56.00

p

WE2 % 71.39 90.18 96.47

SGP kg/m3 1642.18 1591.51 1591.51 1591.51 1591.51

Cw % 58.46 58.36 59.64 60.13 60.32

Cv % 36.93 35.73 36.51 36.81 36.93

4 SGL kg/m3 1081.46 1030.95 1011.70 1004.05 1001.13

C2 kg/m3 8.04 2.95 1.10 0.38 0.11

Qt g/t 72.00

p

WE2 % 71.36 90.15 96.43 98.69

SGP kg/m3 1642.18 1591.06 1591.06 1591.06 1591.06 15191.06

Cw % 58.46 58.33 59.59 60.08 60.27 60.34

Cv % 36.93 35.69 36.47 36.77 36.88 36.93

5 SGL kg/m3 1081.46 1031.09 1011.97 1004.4 1001.51 1000.42

C2 kg/m3 8.04 2.96 1.12 0.41 0.14 0.04

Qt g/t 88.00

p

WE2 % 71.39 90.17 96.43 98.68 99.52

Second simulation

Compared to the first simulation, the control parameter of underflows is the weight percentage of

solid in the pulp. The set value of weight percentage of solid in the underflows is the value of weight

percentage of solid in the underflow pulp of primary thickener.

Table 12 shows the simulation results of the CCD circuit having the number of thickener ranging

from 1 to 5. The results of simulation show that:

The Wash efficiency increases with the increasing of number of thickener in the CCD circuit. Figure 10

shows the wash efficiency of thickener of rank “n” in the CCD circuit as a function of the number “n”

of thickeners.

Table 12: Simulation results of CCD circuit for the second example (Weight percentage of solid – control

parameter)

Thickener

SGP kg/m3 1642.18 1585.52

Cw % 58.46 58.46

Cv % 36.93 35.65

1 SGL kg/m3 1081.46 1023.47

C2 kg/m3 8.04 2.22

Qt g/t 24

p

WE2 % 70.81

SGP kg/m3 1642.18 1591.18 1570.48

Cw % 58.46 58.46 58.46

Cv % 36.93 35.78 35.31

2 SGL Kg/m3 1081.46 1029.16 1008.48

C2 kg/m3 8.04 2.77 0.80

Qt g/t 40.00

p

WE2 % 70.77 89.40

SGP kg/m3 1642.18 1593.08 1573.25 1565.23

Cw % 58.46 58.46 58.46 58.46

Cv % 36.93 35.82 35.38 35.19

3 SGL kg/m3 1081.46 1031.08 1011.22 1003.28

C2 kg/m3 8.04 2.96 1.05 0.31

Qt g/t 56.00

p

WE2 % 70.79 89.38 95.90

SGP kg/m3 1642.18 1593.74 1574.25 1566.40 1563.23

Cw % 58.46 58.46 58.46 58.46 58.46

Cv % 36.93 35.84 35.40 35.22 35.15

4 SGL kg/m3 1081.46 1031.74 1012.21 1004.42 1001.29

C2 kg/m3 8.04 3.02 1.15 0.41 0.12

Qt g/t 72.00

p

WE2 % 70.85 89.41 95.89 98.38

SGP kg/m3 1642.18 1593.93 1574.58 1566.83 1563.70 1562.45

Cw % 58.46 58.46 58.46 58.46 58.46 58.46

Cv % 36.93 35.84 35.41 35.23 35.16 35.13

5 SGL kg/m3 1081.46 1031.93 1012.54 1004.84 1001.76 1000.51

C2 kg/m3 8.04 3.04 1.18 0.45 0.16 0.05

Qt g/t 88.00

p

WE2 % 70.91 89.45 95.91 98.38 99.35

For the thickener of rank "p" in the CCD circuit containing "n" thickener, the volume percentage of

solid in the underflow pulp increases with the increasing the number “n” of Thickener in the CCD

circuit. This is due to the increasing of specific gravity of underflow liquid of thickener of rank “p”.

This increasing of specific gravity of underflow liquid is a consequence of the enrichment of liquid.

In a CCD circuit containing "n" thickener, the values of volume percentages of solid in the underflow

decrease from the thickener of rank “n” to the thickener of rank “n”. In this case, the decrease in the

value of volume percentage is 1.98 % for a CCD circuit containing "5" thickeners.

100,00

90,00

80,00

70,00

60,00

50,00

0 1 2 3 4 5 6

Number of thickener in the CCD circuit

Figure 10: Wash efficiency of CCD circuit versus number of Thickener for the second simulation

5.2.4. Observations

The results of the four simulations of the two CCD circuits show that the use of pulp specific

gravity as control parameter of underflows gives high wash efficiency than the use of weight percentage of

solid in the underflows. This is true in the case of using a conventional or High Rate Thickener. On the

other hand, the value of pulp specific gravity does not give directly to the operator an accurate indication of

underflow pumping characteristics (the volume percentage of solid in the pulp).

The operability of the CCD circuit using the weight percentage as the control parameter of

underflow is high because the volume percentage of solid decreases from the first to the last thickener in

the CCD circuit. The decreasing of volume percentage of solid goes in the direction as the degradation of

flock in the underflow pulp. The decreasing in the value of volume percentage of solid in the underflow

pulp from the first to the last thickener is important when the value of specific gravity of underflow liquid

of the feed pulp is big.

6. Procedure of CCD circuit simulation

6.1. General

The simulation of a CCD circuit will be done on an Excel spreadsheet (Microsoft). Excel

spreadsheet gives numbers and formulas in the form of a table (rows and columns). The Excel spreadsheet is

made of lines (numbered with numbers) and of columns (numbered with letters). The intersection of a row

and a column is called "cell." A cell is identified by a letter and a number. The Excel spreadsheet can contain

up to 65,536 rows and 256 columns, more than 17 million cells. Each of the cells of the spreadsheet can

contain data (numbers, text, date,..) which are entered directly or automatically calculated.

The CCD circuit is part of Copper and Cobalt production plant from flotation concentrates. The

configuration of Copper circuit is the conventional circuit. Consequently, the overflow of first thickener in

the CCD circuit is mixed with the overflow from the primary thickener and the mixture is the feed of Copper

tankhouse. The solution leaving the Copper tankhouse is pumped to the leach section of Copper

concentrates after bleeding excess water. This bleed solution is the feed of Cobalt circuit.

The Preliminary data of the CCD circuit are the as the first example of CCD circuit simulation. The

only differences are:

The set value of control parameter of underflow is:

- The weight percentage of solid in the pulp. The set value of weight percentage of solid in the

underflows is the value of weight percentage of solid of the underflow of primary thickener.

- The specific gravity of the pulp. The set value of specific gravity of underflows is the value of the

underflow specific gravity of last thickener having the volume percentage of solid of underflow of

primary thickener.

The simulation table of CCD circuit is given by Table 13 as it appears on the Excel spreadsheet.

Table 13 is divided into four small tables. The first small table is the simulation table. The columns of this

first small show the names of the inlet and outlet pulps of thickeners in the CCD circuit. The lines show the

pulp parameters. On this first simulation table, the preliminary data attached to the pulp parameters of CCD

circuit are also included. The second small table shows preliminary data that are not the pulp parameters. The

third table shows the wash efficiency after each thickener in the CCD circuit. The fourth table shows data of

the "Solver" program of Excel.

A B C D E F G H I J K L

1

2 Table 13: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h

6 Ms kg/h 26,250.00

7 ML kg/h

8 Vp m3/h

9 Vs m3/h

10 VL m3/h

11 SGp kg/m3

12 SGs kg/m3 2,700.00 2,650.00 2,650.00

13 SGL kg/m3 1,000.00 1,000.00

14 Cw % 0.25 0.00 0.25 0.00 0.00

15 Cv % 25.00

16 Cts kg/m3 αk

17 H2SO4 kg/m3 16.82 0.00 1.000

18 Cu kg/m3 60.00 0.00 2.511

19 Co kg/m3 29.03 0.00 2.629

20 Fe kg/m3 3.41 0.00 2.719

21 Zn kg/m3 0.28 0.00 2.468

22 Ca kg/m3 0.50 0.00 3.395

23 Mn kg/m3 1.38 0.00 2.747

24 Mg kg/m3 14.22 0.00 4.949

25 Al kg/m3 2.85 0.00 6.337

26 H2SO4 kg/h

27 Cu kg/h

28 Co kg/h

29 Fe kg/h

30 Zn kg/h

31 Ca kg/h

32 Mn kg/h

33 Mg kg/h

34 Al kg/h

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE %

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables

45 Constraints

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables

48 Constraints

49

50

51

6.5. Procedure of CCD circuit simulation

- In the cell “D8”, type “ =D9/D15*100”

- In the cell “D10”, type “=D8-D9”

- In the cell “D16”, type “=$L17*D17+$L18*D18+$L19*D19

+$L20*D20+$L21*D21+$L22*D22+$L23*D23+$L24*D24+$L25*D25

- In the cell “D13”, type “=-6.139*10^-4*D16^2+0.9742*D16+1,000”

- In the cell “D7”, type “=D13*D6”

- In the cell “D5”, type “=D6+D7”

- In the cell “D11”, type “=D5/D8”

- In the cell “D14”, type “=D6/D5*100”

- In the cell “D26”, type “=D$10*D17”

- Copy the formula of cell “D26” into the cells of column “D” from “D27” to “D34”

- In the cell “K16”, copy the formula of cell “D16”

- In the cell “K13”, copy the formula of cell “D13”

- In the cell “K7”, type “=K10*K13”

- In the cell “K5”, type “=K7/(100-K14)*100”

- In the cell “K6”, type “=K5-K7”

- In the cell “K9”, type “=K6” because the value of To3 Ms is zero

- In the cell “K8”, type “=K9+K10”

- In the cell “K11”, type “=K5/K8”

- Copy the formula of cell “D26” into the cells of column “K” from “K26” to “K34”

- In the cell “E5”, type “=E6/E14*100”

- In the cell “E7”, type “=E5-E6”

- In the cell “E9”, type “=E6/E12”

- In the cell “E10”, type “=E7/E13”

- In the cell “E8”, type “=E9+E10”

- In the cell “E11”, type “=E5/E8”

- In the cell “H5”, type “=H6/H14*100”

- In the cell “H7”, type “=H5-H6”

- In the cell “H9”, type “=H6/H12”

- In the cell “H10”, type “=H7/H13”

- In the cell “H8”, type “=H9+H10”

- In the cell “H11”, type “=H5/H8”

- In the cell “F9”, type “=D9+E9”

The control parameter of underflows is the weight percentage of solid in the pulp. The set value of

weight percentage of solid in the underflows is the value of weight percentage of solid of the underflow of

primary thickener.

- In the cell “D44”, type the number “25.00”. this value is the started value of Tu1 CV for solver 1 variables

The control parameter of underflows is the specific gravity of pulp. The set value of specific gravity

of underflows is the value of specific gravity of underflow of last thickener having with the volume

percentage of solid of the underflow of primary thickener.

- In the cell “D44”, type the number “25.00”. this value is the started value of Tu1 CV for solver 1 variables

- In the cell “F8”, type “=F9/F15*100”

- In the cell “F10”, type “=F8-F9”

- In the cell “F16”, copy the formula of cell “D16”

- In the cell “F13”, copy the formula of cell “D13”

- In the cell “F7”, type “=F10*F13”

- In the cell “F5”, type “=F6+F7”

- In the cell “F12”, type “=F6/F9”

- In the cell “F11”, type “F5/F8”

- In the cell “I9”, type “=F9+H9”

The control parameter of underflows is the weight percentage of solid in the pulp. The set value of

weight percentage of solid in the underflows is the value of weight percentage of solid of the underflow of

primary thickener.

- In the cell “E44”, type the number “25.00”. this value is the started value of Tu2 CV for solver 1 variables

The control parameter of underflows is the specific gravity of pulp. The set value of specific gravity

of underflows is the value of specific gravity of underflow of last thickener having with the volume

percentage of solid of the underflow of primary thickener (because Tu2 is the underflow of the last Thickener).

- In the cell “I8”, type “=I9/I15*100”

- In the cell “I10”, type “=I8-I9”

- In the cell “I16”, copy the formula of cell “D16”

- In the cell “I13”, copy the formula of cell “D13”

- In the cell “I7”, type “=I10*I13”

- In the cell “I5”, type “=I6+I7”

- In the cell “I12”, type “=I6/I9”

Joseph Kafumbila Page 40

- In the cell “I11”, type “=I5/I8”

7. Calculation of mass and volume flows of the pulp 𝑻𝟐𝟎 (start with the overflow of the lost

thickener)

- In the cell “J10”, type “=F10+H10+K10-I10”

- In the cell “J5”, type “=J7/(100-J14)*100”

- In the cell “J6”, type “=J5-J7”

- In the cell “J9”, type “=J6” because the value of To2 Ms is zero

- In the cell “J8”, type “=J9-J10”

- In the cell “J13”, type “=J7/J10”

- In the cell “J11”, type “=J5/J8”

- In the cell “G10”, type “=D10+E10+J10-F10”

- In the cell “G5”, type “=G7/(100-G14)*100”

- In the cell “G6”, type “=G5-G7”

- In the cell “G9”, type “=G6” because the value of To1 Ms is zero

- In the cell “G8”, type “=G9-G10”

- In the cell “G13”, type “=G7/G10”

- In the cell “G11”, type “=G5/G8”

At this level, it appears table 14 giving the simulation table when the control parameter of

underflows is the weight percentage of solid and Table 15 gives the simulation table when the control

parameter of underflows is the specific gravity of pulp.

- In the cell “D47”, type the number “1.00”. This value is the started value of Tu2 C1 for solver 2 variables

- In the cell “E47”, type the number “1.00”. This value is the started value of Tu2 C2 for solver 2 variables

- In the cell “F47”, type the number “1.00”. This value is the started value of Tu2 C3 for solver 2 variables

- In the cell “G47”, type the number “1.00”. This value is the started value of Tu2 C4 for solver 2 variables

- In the cell “H47”, type the number “1.00”. This value is the started value of Tu2 C5 for solver 2 variables

- In the cell “I47”, type the number “1.00”. This value is the started value of Tu2 C10 for solver 2 variables

- In the cell “J47”, type the number “1.00”. This value is the started value of Tu2 C7 for solver 2 variables

- In the cell “K47”, type the number “1.00”. This value is the started value of Tu2 C8 for solver 2 variables

- In the cell “L47”, type the number “1.00”. This value is the started value of Tu2 C9 for solver 2 variables

- In the cell “I18”, type “=E47”

- In the cell “I19”, type “=F47”

- In the cell “I20”, type “=G47”

- In the cell “I21”, type “=H47”

- In the cell “I22”, type “=I47”

- In the cell “I23”, type “=J47”

- In the cell “I24”, type “=K47”

- In the cell “I25”, type “=L47”

A B C D E F G H I J K L

1

2 Table 14: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h 63,131.4 189.00 55,417.7 55,278.0 126.00 55,418.3 47,375.3 47,250.0

6 Ms kg/h 26,250.00 0.47 26,250.47 0.00 0.32 26,250.79 0.00 0.00

7 ML kg/h 36,881.4 188.53 29,167.2 55,278.0 125.69 29,167.6 47,375.33 47,250.0

8 Vp m3/h 38,89 0.19 38.89 47.56 0.13 38.89 47.38 47.25

9 Vs m3/h 9,72 0.00 9.72 0.00 0.00 9.72 0.00 0.00

10 VL m3/h 29,17 0.19 29.17 47.56 0.13 29.17 47.38 47.25

11 SGp kg/m3 1,623,38 1001.56 1,425.00 1,162.20 1,001.56 1,425.00 1,000.00 1,000.00

12 SGs kg/m3 2,700.00 2,650.00 2,700.00 2,650.00 2,700.00

13 SGL kg/m3 1,264.50 1,000.00 1,000.00 1,162.20 1,000.00 1,000.00 1,000.00 1.000.00

14 Cw % 41,58 0.25 0.00 0.25 0.00 0.00

15 Cv % 25.00 25.00 25.00

16 Cts kg/m3 347,69 0.00 0.00 αk

17 H2SO4 kg/m3 16.82 0.00 1.000

18 Cu kg/m3 60.00 0.00 2.511

19 Co kg/m3 29.03 0.00 2.629

20 Fe kg/m3 3.41 0.00 2.719

21 Zn kg/m3 0.28 0.00 2.468

22 Ca kg/m3 0.50 0.00 3.395

23 Mn kg/m3 1.38 0.00 2.747

24 Mg kg/m3 14.22 0.00 4.949

25 Al kg/m3 2.85 0.00 6.337

26 H2SO4 kg/h 490.58 0.00

27 Cu kg/h 1,750.00 0.00

28 Co kg/h 846.71 0.00

29 Fe kg/h 99.46 0.00

30 Zn kg/h 8.17 0.00

31 Ca kg/h 14.58 0.00

32 Mn kg/h 40.25 0.00

33 Mg kg/h 414.75 0.00

34 Al kg/h 83.13 0.00

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE %

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables 25.00 25.00

45 Constraints

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables

48 Constraints

49

50

51

A B C D E F G H I J K L

1

2 Table 15: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h 63,131.4 189.00 55,417.7 55,278.0 126.00 55,418.4 47,375.3 47,250.0

6 Ms kg/h 26,250.0 0.47 26,250.5 0.00 0.32 26,250.8 0.00 0.00

7 ML kg/h 36,881.4 188.53 29,167.2 55,278.0 125.69 29,167.6 47,375.3 47,250.0

8 Vp m3/h 38,89 0.19 38.89 47.56 0.13 38.89 47.38 47.25

9 Vs m3/h 9,72 0.00 9.72 0.00 0.00 9.72 0.00 0.00

10 VL m3/h 29,17 0.19 29.17 47.56 0.13 29.17 47.38 47.25

11 SGp kg/m3 1,623,38 1001.56 1,425.0 1.162.20 1,001.56 1,425.00 1,000.00 1,000.00

12 SGs kg/m3 2,700.00 2,650.00 2,700.0 2,650.00 2,700.00

13 SGL kg/m3 1,264.50 1,000.00 1,000.0 1,162.20 1,000.00 1,000.00 1.000.00 1.000.00

14 Cw % 41,58 0.25 0.00 0.25 0.00 0.00

15 Cv % 25.00 25.00 25.00

16 Cts kg/m3 347,69 0.00 0.00 αk

17 H2SO4 kg/m3 16.82 0.00 1.000

18 Cu kg/m3 60.00 0.00 2.511

19 Co kg/m3 29.03 0.00 2.629

20 Fe kg/m3 3.41 0.00 2.719

21 Zn kg/m3 0.28 0.00 2.468

22 Ca kg/m3 0.50 0.00 3.395

23 Mn kg/m3 1.38 0.00 2.747

24 Mg kg/m3 14.22 0.00 4.949

25 Al kg/m3 2.85 0.00 6.337

26 H2SO4 kg/h 490.58 0.00

27 Cu kg/h 1,750.00 0.00

28 Co kg/h 846.71 0.00

29 Fe kg/h 99.46 0.00

30 Zn kg/h 8.17 0.00

31 Ca kg/h 14.58 0.00

32 Mn kg/h 40.25 0.00

33 Mg kg/h 414.75 0.00

34 Al kg/h 83.13 0.00

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE %

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables 25.00 25.00

45 Constraints

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables

48 Constraints

49

50

51

- In the cell “I26”, type “=I$10*I17”

- In the cells of column “I” started from I27 to I34, copy the formula of cell “I26”

- In the cells of column “J” started from J18 to J25, copy the formula of cell “J17”

- In the cells of column “J” started from J26 to J34, copy the formula of cell “I26”

- In the cells of column “F” started from F27 to F34, copy the formula of cell “F26”

- In the cell “F17”, type “=F26/F$10”

- In the cells of column “F” started from F18 to F25, copy the formula of cell “F17”

- In the cells of column “G” started from G18 to G25, copy the formula of cell “G17”

- In the cells of column “G” started from G26 to G34, copy the formula of cell “I26”

The control parameter of underflows is the weight percentage of solid in the pulp. The set value of

weight percentage of solid in the underflows is the value of weight percentage of solid of the underflow of

primary thickener.

- In the Cell “E45”, type “=D14-I14”

The control parameter of underflows is the specific gravity of pulp. The set value of specific gravity

of underflows is the value of specific gravity of underflow of last thickener having with the volume

percentage of solid of the underflow of primary thickener.

- In the Cell “E48”, type “=D27+K27-G27-I27”

- In the Cell “F48”, type “=D28+K28-G28-I28”

- In the Cell “G48”, type “=D29+K29-G29-I29”

- In the Cell “H48”, type “=D30+K30-G30-I30”

- In the Cell “I48”, type “=D31+K31-G31-I31”

- In the Cell “J48”, type “=D32+K32-G32-I32”

- In the Cell “K48”, type “=D33+K33-G33-I33”

- In the Cell “L48”, type “=D34+K34-G34-I34”

At this level, it appears table 16 giving the simulation table when the control parameter of

underflows is the weight percentage of solid and Table 17 gives the simulation table when the control

parameter of underflows is the specific gravity of pulp.

A B C D E F G H I J K L

1

2 Table 16: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h 63,131.4 189.00 57,399.8 54,475.8 126.00 56,220.6 48,555.2 47,250.0

6 Ms kg/h 26,250.0 0.47 26,250.5 0.00 0.32 26,250.8 0.00 0.00

7 ML kg/h 36,881.4 188.53 31,149.3 54,475.8 125.69 29,969.8 48,555.2 47,250.0

8 Vp m3/h 38,89 0.19 38.89 47.56 0.13 38.89 47.38 47.25

9 Vs m3/h 9,72 0.00 9.72 0.00 0.00 9.72 0.00 0.00

10 VL m3/h 29,17 0.19 29.17 47.56 0.13 29.17 47.38 47.25

11 SGp kg/m3 1,623,38 1001.56 1,475.97 1,145.33 1,001.56 1,445.63 1,024.90 1,000.00

12 SGs kg/m3 2,700.00 2,650.00 2,700.00 2,650.00 2,700.00

13 SGL kg/m3 1,264.50 1,000.00 1,067.96 1,145.33 1,000.00 1,027.51 1,024.90 1.000.00

14 Cw % 41,58 0.25 45.73 0.00 0.25 46.69 0.00 0.00

15 Cv % 25.00 25.00 25.00

16 Cts kg/m3 347,69 73.13 28.76 αk

17 H2SO4 kg/m3 16.82 2.543 2.463 1.000 0.950 0.00 1.000

18 Cu kg/m3 60.00 2.543 2.463 1.000 0.950 0.00 2.511

19 Co kg/m3 29.03 2.543 2.463 1.000 0.950 0.00 2.629

20 Fe kg/m3 3.41 2.543 2.463 1.000 0.950 0.00 2.719

21 Zn kg/m3 0.28 2.543 2.463 1.000 0.950 0.00 2.468

22 Ca kg/m3 0.50 2.543 2.463 1.000 0.950 0.00 3.395

23 Mn kg/m3 1.38 2.543 2.463 1.000 0.950 0.00 2.747

24 Mg kg/m3 14.22 2.543 2.463 1.000 0.950 0.00 4.949

25 Al kg/m3 2.85 2.543 2.463 1.000 0.950 0.00 6.337

26 H2SO4 kg/h 490.58 74.17 117.17 29.17 45.01 0.00

27 Cu kg/h 1,750.00 74.17 117.17 29.17 45.01 0.00

28 Co kg/h 846.71 74.17 117.17 29.17 45.01 0.00

29 Fe kg/h 99.46 74.17 117.17 29.17 45.01 0.00

30 Zn kg/h 8.17 74.17 117.17 29.17 45.01 0.00

31 Ca kg/h 14.58 74.17 117.17 29.17 45.01 0.00

32 Mn kg/h 40.25 74.17 117.17 29.17 45.01 0.00

33 Mg kg/h 414.75 74.17 117.17 29.17 45.01 0.00

34 Al kg/h 83.13 74.17 117.17 29.17 45.01 0.00

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE %

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables 25.00 25.00

45 Constraints -4.153 -5.112

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables 1.000 1.000 1.0000 1.000 1.000 1.000 1.000 1.000 1.000

48 Constraints 344.2 1,603 700.3 -46.89 -138.2 -131.8 -106.1 268.4 -63.2

49

50

51

A B C D E F G H I J K L

1

2 Table 17: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h 63,131.4 189.00 57,399.8 54,475.8 126.00 56,220.6 48,555.2 47,250.0

6 Ms kg/h 26,250.0 0.47 26,250.5 0.00 0.32 26,250,8 0.00 0.00

7 ML kg/h 36,881.4 188.53 31,149.3 54,475.8 125.69 29,969.8 48,555.2 47,250.0

8 Vp m3/h 38,89 0.19 38.89 47.56 0.13 38.89 47.38 47.25

9 Vs m3/h 9,72 0.00 9.72 0.00 0.00 9.72 0.00 0.00

10 VL m3/h 29,17 0.19 29.17 47.56 0.13 29.17 47.38 47.25

11 SGp kg/m3 1,623,38 1001.56 1,475.97 1,145.33 1,001.56 1,445.63 1,024.90 1,000.00

12 SGs kg/m3 2,700.00 2,650.00 2,700.00 2,650.00 2,700.00

13 SGL kg/m3 1,264.50 1,000.00 1,067.96 1,145.33 1,000.00 1,027.51 1,024.90 1.000.00

14 Cw % 41,58 0.25 45.73 0.00 0.25 46.69 0.00 0.00

15 Cv % 25.00 25.00 25.00

s

16 Ct kg/m3 347,69 73.13 28.76 αk

17 H2SO4 kg/m3 16.82 2.543 2.463 1.000 0.950 0.00 1.000

18 Cu kg/m3 60.00 2.543 2.463 1.000 0.950 0.00 2.511

19 Co kg/m3 29.03 2.543 2.463 1.000 0.950 0.00 2.629

20 Fe kg/m3 3.41 2.543 2.463 1.000 0.950 0.00 2.719

21 Zn kg/m3 0.28 2.543 2.463 1.000 0.950 0.00 2.468

22 Ca kg/m3 0.50 2.543 2.463 1.000 0.950 0.00 3.395

23 Mn kg/m3 1.38 2.543 2.463 1.000 0.950 0.00 2.747

24 Mg kg/m3 14.22 2.543 2.463 1.000 0.950 0.00 4.949

25 Al kg/m3 2.85 2.543 2.463 1.000 0.950 0.00 6.337

26 H2SO4 kg/h 490.58 74.17 117.17 29.17 45.01 0.00

27 Cu kg/h 1,750.00 74.17 117.17 29.17 45.01 0.00

28 Co kg/h 846.71 74.17 117.17 29.17 45.01 0.00

29 Fe kg/h 99.46 74.17 117.17 29.17 45.01 0.00

30 Zn kg/h 8.17 74.17 117.17 29.17 45.01 0.00

31 Ca kg/h 14.58 74.17 117.17 29.17 45.01 0.00

32 Mn kg/h 40.25 74.17 117.17 29.17 45.01 0.00

33 Mg kg/h 414.75 74.17 117.17 29.17 45.01 0.00

34 Al kg/h 83.13 74.17 117.17 29.17 45.01 0.00

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE %

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables 25.00 25.00

45 Constraints 30.338

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000 1.000

48 Constraints 344.3 1603.7 700.4 -46.88 -138.2 -131.8 -106.1 258.4 -63.2

49

50

51

12. Solver 1 and 2 operations

1) On the ‘Data’, in the ‘Analysis group’ click solver (if the solver command is not available, you must

activate the solver add-in).

2) In the ‘Set objective’ box, enter the cell reference “D45” of Table 16 or Table 17 (first constraint of

solver 1).

3) Click “Value of” and then type the number “0” in the box.

4) In the “By Changing Variable Cells” box, enter the reference for each variable of solver 1 and 2

(blue color in Table 16 or Table 17). Separate the references with commas (English version).

5) In the ‘Subject to the constraints’ box, enter solver constraints by doing the following:

a) In the ‘Solver Parameters’ dialog box, click ‘Add’.

b) In the ‘Cell Reference’ box, enter the cell reference of constraints of solver 1 and 2 (green

color in Table 16 or Table 17)(do not take the first constraint of solver 1).

c) Click the ‘relationship’ ‘=‘, in the ‘Constraint’ box, type the number ‘0’. Click ‘Add’ for the

second solver constraint. When the last solver constraint is added (cell ‘L48’), click ‘OK’

6) Click ‘Solve’. To keep the solution values on the worksheet, in the ‘Solver Results’ dialog box, click

‘Keep solver solution’.

For both simulation having the control parameter of the underflow pulp the weight percentage of

solid in the pulp or the specific gravity of the underflow pulps.

- In the cell “E41”, type “=G10*(G18-K18)/(D10*(D18-K18))*100

At this level, it appears table 18 giving the table of optimized simulation when the control parameter

of underflows is the weight percentage of solid and Table 19 gives the table of optimized simulation when the

control parameter of underflows is the specific gravity of pulp.

A B C D E F G H I J K L

1

2 Table 18: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h 63,131.4 189.00 63,132.6 47,563.9 126.00 63,132.5 47,376.1 47,250.0

6 Ms kg/h 26,250.0 0.47 26,250.5 0.00 0.32 26,250.8 0.00 0.00

7 ML kg/h 36,881.4 188.53 36,882.1 47,563.9 125.69 36,881.7 47,376.1 47,250.0

8 Vp m3/h 38,89 0.19 41.57 42.28 0.13 44.18 44.77 47.25

9 Vs m3/h 9,72 0.00 9.72 0.00 0.00 9.72 0.00 0.00

10 VL m3/h 29,17 0.19 31.85 42.28 0.13 34.45 44.77 47.25

11 SGp kg/m3 1,623,38 1001.56 1,518.76 1,125.08 1,001.56 1,429.07 1,058.29 1,000.00

12 SGs kg/m3 2,700.00 2,650.00 2,700.00 2,650.00 2,700.00

13 SGL kg/m3 1,264.50 1,000.00 1,158.14 1,125.08 1,000.00 1,070.43 1,058.29 1.000.00

14 Cw % 41,58 0.25 41.58 0.00 0.25 41.58 0.00 0.00

15 Cv % 25.00 23.39 22.01

s

16 Ct kg/m3 347,69 183.56 75.93 αk

17 H2SO4 kg/m3 16.82 8.88 8.61 3.67 3.49 0.00 1.000

18 Cu kg/m3 60.00 31.68 30.72 13.10 12.45 0.00 2.511

19 Co kg/m3 29.03 15.33 14.86 6.34 6.02 0.00 2.629

20 Fe kg/m3 3.41 1.80 1.75 0.75 0.71 0.00 2.719

21 Zn kg/m3 0.28 0.15 0.14 0.06 0.06 0.00 2.468

22 Ca kg/m3 0.50 0.26 0.26 0.11 0.10 0.00 3.395

23 Mn kg/m3 1.38 0.73 0.71 0.30 0.29 0.00 2.747

24 Mg kg/m3 14.22 7.51 7.28 3.11 2.95 0.00 4.949

25 Al kg/m3 2.85 1.51 1.46 0.62 0.59 0.00 6.337

26 H2SO4 kg/h 490.58 282.79 364.02 126.57 156.22 0.00

27 Cu kg/h 1,750.00 1008.77 1,298.51 451.49 557.28 0.00

28 Co kg/h 846.71 488.08 628.26 218.45 269.63 0.00

29 Fe kg/h 99.46 57.33 73.80 25.66 31.67 0.00

30 Zn kg/h 8.17 4.71 6.06 2.11 2.60 0.00

31 Ca kg/h 14.58 8.41 10.82 3.76 4.64 0.00

32 Mn kg/h 40.25 23.20 29.87 10.38 12.82 0.00

33 Mg kg/h 414.75 239.08 307.75 107.00 132.08 0.00

34 Al kg/h 83.13 47.92 61.68 21.45 26.47 0.00

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE % 55.68 74.20

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables 23.39 22.01

45 Constraints 0.000 0.000

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables 3.673 13.104 6.340 0.745 0.061 0.109 0.301 3.106 0.622

48 Constraints 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

49

50

51

A B C D E F G H I J K L

1

2 Table 19: Simulation table for CCD circuit with two thickeners

3

4 Parameter Tu0 Tf1 Tu1 To1 Tf2 Tu2 To2 To3

5 Mp kg/h 63,131.4 189.00 67,680.7 53,209.2 126.00 57,487.2 57,569.6 47,250.0

6 Ms kg/h 26,250.0 0.47 26,250.5 0.00 0.32 26,250.8 0.00 0.00

7 ML kg/h 36,881.4 188.53 41,430.3 53,209.2 125.69 31,236.4 57,569.6 47,250.0

8 Vp m3/h 38,89 0.19 45.79 47.56 0.13 38.89 54.27 47.25

9 Vs m3/h 9,72 0.00 9.72 0.00 0.00 9.72 0.00 0.00

10 VL m3/h 29,17 0.19 36.06 47.56 0.13 29.17 54.27 47.25

11 SGp kg/m3 1,623,38 1001.56 1,478.20 1,118.70 1,001.56 1,478.20 1,060.76 1,000.00

12 SGs kg/m3 2,700.00 2,650.00 2,700.00 2,650.00 2,700.00

13 SGL kg/m3 1,264.50 1,000.00 1,148.81 1,118.70 1,000.00 1,070.93 1,060.76 1.000.00

14 Cw % 41,58 0.25 38.79 0.00 0.25 45.66 0.00 0.00

15 Cv % 25.00 21.23 25.00

16 Cts kg/m3 347,69 171.23 αk

17 H2SO4 kg/m3 16.82 8.28 8.05 3.70 3.52 0.00 1.000

18 Cu kg/m3 60.00 29.55 28.70 13.20 12.54 0.00 2.511

19 Co kg/m3 29.03 14.30 13.89 6.39 6.07 0.00 2.629

20 Fe kg/m3 3.41 1.68 1.63 0.75 0.71 0.00 2.719

21 Zn kg/m3 0.28 0.14 0.13 0.06 0.06 0.00 2.468

22 Ca kg/m3 0.50 0.25 0.24 0.11 0.11 0.00 3.395

23 Mn kg/m3 1.38 0.68 0.66 0.30 0.29 0.00 2.747

24 Mg kg/m3 14.22 7.00 6.80 3.13 2.97 0.00 4.949

25 Al kg/m3 2.85 1.40 1.36 0.63 0.60 0.00 6.337

26 H2SO4 kg/h 490.58 298.73 382.65 107.94 190.79 0.00

27 Cu kg/h 1,750.00 1,065.62 1,364.97 385.03 680.60 0.00

28 Co kg/h 846.71 515.58 660.42 186.29 329.29 0.00

29 Fe kg/h 99.46 60.56 77.58 21.88 38.68 0.00

30 Zn kg/h 8.17 4.97 6.37 1.80 3.18 0.00

31 Ca kg/h 14.58 8.88 11.37 3.21 5.67 0.00

32 Mn kg/h 40.25 24.51 31.39 8.86 15.65 0.00

33 Mg kg/h 414.75 252.55 323.50 91.25 161.30 0.00

34 Al kg/h 83.13 50.62 64.84 18.29 32.33 0.00

35

36 Data

37 Q 30.00 g/t f1 60 % f2 40 %

38 WR 1.80 m3/t ME 95 %

39

40 Results T1 T2

41 WE % 55.52 78.00

42

43 Solver 1 Tu1 CV Tu2 CV

44 Variables 21.23 25.00

45 Constraints 0.000

46 Solver 2 H2SO4 Cu Co Fe Zn Ca Mn Mg Al

47 Variables 3.701 13.201 6.387 0.750 0.062 0.110 0.304 3.129 0.627

48 Constraints 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000 0.000

49

50

51

7. Reference

1) ANONYME, Lavage des pulpes (théorie algébrique), Industrie Minérale – Les techniques, octobre 1981, p. 565-

590.

2) HOLLER h.d., Peffer E.L., Relation between composition and density of aqueous solutions of copper sulphate and

sulphuric acid, Bulletin of the bureau of standards, Vol. 13.

3) David R. Lide, CRC Handbook of chemistry and physics, Internet version 2005.

4) Joel B. Christian, Improve clarifier and thickener Design and operation, Chemical Engineering Progress, July

1994.

5) M.C. MULLIGAN, Soluble metal recovery improvement using high density thickeners in a CCD circuit: Ruashi II case

study, the journal of southern African institute of mining and metallurgy, Vol. 109, Johannesburg,

November 2009.

6) Kourosh Behrouzi, Majid Vafaei Fard, Anabito Raeiszadeh, Aida Faeghi nia, Water recycling at processing

plants in water scarce regions – a case study of thickener design for the Mansour Abad Processing plant, Proceeding

tailings and mine waste, Vancouver, 2011.

some pre-feasibility studies of your own or with help of consultant before evaluation feasibility study

done by engineering offices. If you find out early that the proposed plant design project idea is not

feasible, it will save your money. The paper is the metallurgical engineering paper that gives the

opportunity to do pre-feasibility study of copper hydrometallurgical plants of your own. The paper

gives the update of the design criteria and metallurgical constraints of copper solvent extraction and

the models of preliminary flow diagram mass balance of heap leaching, conventional, split circuits.

The models of preliminary flow diagram mass balance are executable on Microsoft Excel

spreadsheet.

https://fr.scribd.com/document/358056400/Pre-feasibility-Studies-of-Copper-

Hydrometallurgical-Plants

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