This document summarizes the design of a hydrometallurgical copper processing plant aimed at processing 15 tons of copper oxide ore per day. The plant utilizes a comminution circuit to grind the ore to an optimal size, followed by leaching to extract the copper. Solid-liquid separation then purifies the solution, which undergoes solvent extraction and electrowinning to produce copper cathodes. Laboratory experiments and theoretical calculations were used to design and size the equipment. The plant is estimated to recover over 80% of the copper at a capital cost of $1.5 million and produce around 583 tons of copper annually, making it a viable small-scale option. Recommendations include using design software and specialized engineers to

1. THE COPPERBELT UNIVERSITY
School of Mines and Mineral Sciences
Chemical Engineering Department
NAMES: BEELE WAMULUME 09198533
KALUMPILA MWANDILA 09196242
MULOSA JONATHAN 09194996
PROG: Beng Chemical 5
SUPERVISOR: MR C. BOTHA
© 2014

2. TITLE
HYDROMETALLURGICAL
COPPER PROCESSING
PLANT DESIGN

3. INTRODUCTION
 This project is about the design of a
Hydrometallurgical Copper Processing Plant
mainly for small scale miners.
 The project looks at a paradigm shift from the
conventional large scale processing of copper to
small scale processing of copper affordable to local
investors.

4. HYPOTHESIS
The plant to be designed will be able to
process 15 metric tonnes of copper ore per
day with 80% recovery. It will be economical,
cost effective and affordable for average local
investors.

5. AIM
The project was aimed at designing a
Hydrometallurgical Copper Processing
Plant on a small scale that would process
about 15 tons of copper oxide ore per day
and recover over 80% of copper.

6. SPECIFIC OBJECTIVES
1. To establish the most economical
hydrometallurgical technique for the treatment of
copper ore.
2. To carry out theoretical material balances of the
plant and to establish the feed rate required.
3. To carry out an energy balance of the
hydrometallurgical plant and establish the power
required to operate the plant.
4. To determine the types and sizes of the equipment
required.
5. To determine the capital cost of the plant.

7. Methodology
Part of the design work was based on the
laboratory experiments and the other part was
theoretical.
 The work was divided in the following phases:
 Data Collection
 Laboratory Experiments
 Process Design
 Mechanical Design
 Project Costing

8. Laboratory experiments
• Comminution –obtain optimum particle
size (75-100 microns)
• Leaching (determine leaching residence
time )
• Cu assays (determine extraction
efficiency)
• Batch settling tests (determine settling
rates for slurry)

9. Process design
The work in this stage involved;
• Determination of the appropriate feed rate
for a small scale plant.
• The theoretical material and energy
balances of the overall plant and the
individual units.
• Recovery, plant attainment and overall
efficiency

10. Mechanical design
The work involved in this stage included;
• Selection of appropriate equipment.
• Sizing of the equipment
• Selecting the appropriate materials of
construction to be used.

11. Mechanical design equations
• Reactor Volume…..
• Wall thickness of vessels
• Area of clarifier
• Power required for agitation

12. Project costing
• Cost of different equipment was obtained
from reliable internet vendors.
• The material costs for the equipment
fabricated on sight was also obtained
from the internet. 40% was added for
labor costs.

13. RESULTS

14. Summary of material and energy
balances
INPUT OUTPUT EFFICIENCY
Cu ore 1.5t/h (6wt%) 1.34t/h
(99.9wt%)
90%
Fresh water 35m3/hr 0 100%(assuming
no
spillages/leaks)
Sulphuric acid 1.6m3/hr 0.029m3/hr 98.2%
Organic solvent
(17.9% LIX
984N; 82.1%
diluent)
17m3 0 100% (recycle of
the organic)
Power
(13cents/kWh)
112kW - -

15. RESULTS
 Comminution Circuit
Model PE-150
Inlet Size (mm) 150×250
Maximum feeding size (mm) 125
Adjusting range of size (mm) 15-45
Capacity (t/h) 1.2-3.5
Motor (KW) 5.5
Weight (t) 0.8
Overall dimensions (L×W×H) (mm)
950x1100x1100
FOB Price (USD) 1650.00
Table 4.1 jaw crusher specifications

16. Cont…
Model 2YK 1237
Screen Spec (mm) 1200 × 3700
Maximum feeding size (mm) 200
Screen mesh size (mm) 4-50
Capacity (t/h) 15-86
Motor (KW) 15
Layers 2
Vibrating frequency (r/min) 960
FOB price (usd) 5000
Table 4.2 vibrating screen specifications

17. Cont…
Table 4.3 ball mill specifications

18. Cont.…
Model FX125
Diameter (mm) 125
Maximum feeding size
(mm)
0.6
Feeding Pressure
(MPa)
0.06-0.35
Capacity (m3) 8-15
Classification Size
(μm)
20-100
Weight (kg) 10
Overall dimensions
(L×W×H) (mm)
210x185x620
FOB price (usd) 100.00
Table 4.4 hydro cyclone specifications

19. Table 4.5 thickener design results
Parameter Dimensions
Diameter of thickener 10.0m
Height of cylindrical section 2.0m
Surface area of cylindrical section (m2) 62.8  63
Outlet diameter 1.0m
Volume of the cone 65.4m3
Surface area of the cone 25.868m2
Volume of the cylindrical section 157.1m3
Total surface are of thickener (m2)  90
Power requirement (kW) 0.12
Material of construction of shell Carbon steel
Thickness of shell 10mm
Material of construction of lining Vulcanized Latex
rubber
Thickness of lining (mm) 20
Total volume of shell (m3) 0.9 1
Total dead weight of thickener (t) 7.9 (steel shell) +
1.92 = 9.82  10
Total cost of rubber (mass of rubber (kg) × $2.50 (usd) 5000
Total cost of steel (hot rolled plate)(mass of steel (t) × $700
(usd)
5600
Total cost of thickener shell manufacture (usd) 15000

20. Cont.…
Mass of ore (Kg) 1500
Residence time (h) 3
Diameter of leach tank (m) 2
Height of leach tank (m) 2
Power (KW) 0.2
Torque (KW/rps) 0.03
Residue acid mass (pH=2) Kg 40.58
Tank thickness (mm) 9
Plate thickness (mm) 40
Impeller diameter (mm) 700
Table 4.6 Leaching Circuit

21. Cont.…
Over flow rate (m3/h) 1.5
Under flow rate (m3/h) 2.7
Copper Concentration In Overflow (g/l) 18.1
Average area (m2) 2.2
Diameter (m) 1.7
Cone angle (°) 30
Torque (Nm) 1530.2
Gearbox output speed (rpm) 0.378
Power (KW) 0.12
Clarifier thickness (mm) 10
Rubber lining thickness (mm) 5
Settling pond volume (m3) 302
Table 4.7 Solution Purification

22. Cont.…
Concentration of copper in PLS(g/l) 18.1
Extractant LIX 984N/LIX 973N
Mixing time (min) 15
Diameter of a mixer (m) 1
Height of a mixer (m) 2
Impeller diameter (mm) 330
Separation time (min) 30
Height of settler (m) 1
Length of settler (m) 6
Breadth of settler (m) 3
Mixer Construction material Carbon steel with PVC paint coating
Settler Construction material Concrete with PVC lining
Table 4.8 Solvent Extraction

23. Cont.…
Dimensions (L × W × H)m 4.2 × 1.25 × 1.5
Cost per cell K30 000
Total cost (15 cells) K154 000
Cost per stainless steel plate K16 800
Total cost (300 stainless steel plate) K5 040 000
Cost per anode plate K56
Total cost (315 anode plates) K K17 640
Cost of rectifier
Total cost (K) K5 300 000
OPERATION
Cathode production (tonnes /yr.) 518
Electrolytic cell
Total number 80
Construction material Polymer concrete
Length × width × depth(inside), m 4.8 × 1.25 × 1.5
Anodes, cathodes per cell 20/21
Spaces between anodes and cathodes, mm 95
Anode
Material % 98.4%Pb, 1.5%Sn, 0.08%Ca, 0.02%Al
Table 4.9 Electrowinning

24. Length × width × thickness, m 1.1 × 0.9 × 0.006
Center – to - center spacing in cell, mm 95
Life, yr. 5
Cathode
Type Stainless steel
Length × width × thickness, m 1.2 × 1.0 × 0.003
Side edge strip material PVC
Bottom strip material PVC/RUBBER
Plating time, days 10
Mass Cu plated on blank, Kg 60
Stripping method Hand stripping
Power and energy
Cathode current density, A/m2
280
Cathode current efficiency, % 98
Cell voltage, V 1.98-2
Cell current, kilo amperes 30
Power kW 60
Electrolyte
Cont.…

25. Cont.…
Cu, Kg/m3 45-55
H2SO4, Kg/m3 180-190
Temperature, °C 60-65
Out of cells
Cu, Kg/m3 40
H2SO4, Kg/m3 200
Temperature, °C 65
Addition rates, g/per tonne of cathode
Guar gum, ppm 250
Cobalt sulfate, ppm< 150
Chloride ions, ppm < 30
Electrolyte treatments before entering
tank house
Gamet / anthracite filtration, heat exchanger

26. Site location
• The overriding factor when selecting the
site for this plant was the proximity to the
main raw material- copper oxide ores.
• Other factors considered included source
of electricity, water and proximity to acid
source
• Areas suitable for this plant include
Kasempa, Mufumbwe and Mumbwa

27. DISCUSSION
Comminution Circuit
 Wet grinding was employed in this plant to reduce
energy usage, facilitate removal of material and to
suppress dust.
 Three hydrocyclones were used to increase efficiency of
the plant and also to allow room for expansion of the
plant.
 The thickener serves two purposes; allows the slurry to
be of required density for optimum extraction during
leaching and serves as a recycle line for the water to
minimize fresh water usage.

28. Cont…
Leaching Circuit
 pH was maintained between 1.8-2 to ensure proper extraction
of copper in the leach tank.
 Four tanks in parallel were used to achieve a continuous
process.

29. Cont…
Solid-Liquid Separation Circuit
 The separation of solids from the metal laden liquid was the
most difficult separation process to achieve. In the lab, the
separation was effectively using a leaf filter and the washing
done using hot water.
 However, on a commercial scale, the raffinate will be used to
wash the gangue solids
 The thickener will employed to facilitate the continuous
separation of solids from the metal laden liquid.

30. Cont…
Solvent Extraction Circuit
 The circuit is made up of 2 extraction stages and 1-
stripping stages.
 The PVC material will be used for lining the settler which
will be made of concrete.
Electrowinning
 The number of cathodes was determined for a 10 days
standard for electroplating 60 kg of copper on each
cathode to be 22 per cell.
 Polymer concrete cells were used.

31. Cont…
Summary
 The total cost of the plant was determined to be $1.1
million (K5.8million). Adding 40% for installation, civil
works and electrical works the total comes to about $1.5
million dollars (K8.5 million).

32. CONCLUSIONS
 A material balances and energy balances of the plant was
conducted and the plant was determined to have an
efficiency of at least 90%. The feed rate for the copper ore
was determined to be 1.5 tonnes per hour. The power
requirements of the plant was about 120kW (costing the
plant K2000/day on energy). The total copper output of the
plant is about 1,900kg copper per day giving an annual
output of 583 tonnes.
 The capital cost of the plant was determined to be
$1.5million dollars (K8.5 million).
 Small scale hydrometallurgical processing is a very viable
project for a developing country like Zambia. It will enable
empowerment of Zambians in an industry dominated by
foreign multinational companies.

33. RECOMMENDATIONS
 Small scale hydrometallurgical processing is a very
viable project. And This can easily be achieved if a team
of different specialists come together to start the plant.
 The use of plant design software will help optimize the
plant more accurately.
 The structural and mechanical design of the plant should
be carried out by more specialized structural and
mechanical engineers.
 Other areas which require specialists include
instrumentation, civil works, electrical works and detailed
costing.

34. REFERENCES
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New York, John Wiley and Sons, Inc.
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John Wiley publishers.
3. Davenport W.G. (2002) extractive metallurgy of copper, (4thed),
university of Missouri, USA.
4. Greenwood, N.N. and Earnshaw, A. (1984) Chemistry of the
Elements, (2nded), U.K., Reed Education and Profession Publishing
Ltd.
5. Kolthoff, Sandell, and Meehan. (1969) Quantitative Chemical Analysis,
(4th edition), U.S.A, The MacMillan Company.
6. Mark, E. eta’l (2004) Extractive Metallurgy of copper, (5thed),
Amsterdam, Netherlands: Elsevier.
7. Martin, R. (2008) Introduction to particle technology, (2nd edition),
Monash university, Australia: John Wiley & sons.

35. Cont…
8. Max, S.P., and Klaus D.T. (1991)Plant Design and Economics for
Chemical Engineers, (4thed),New York St. Louis, McGraw-Hill, Inc.
9. McCabe, W.L., Smith, J.C., and Harriott, P., (1987) Unit Operations of
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U.S.A., John Wiley and Sons, Inc.
11.Sinnot, R.K. (2005) Chemical Engineering Design, (volume 6), London,
Elsevier Butterworth Heinemann
12.Speight, J.G. (2002) Chemical and Process Design Handbook, New
York, McGraw - Hill.
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Perth, Australia: IDC Technologies
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USA, W.H. Freeman and Company.

36. THE END
Thank you…!