Opciones para el manejo y comercializacin de escorias de cobre

Pedro Reyes, Gerente General Divisin Chagres, Angloamerican Chile

Armando Valenzuela, Director AL Prospecta Consultores, Chile

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

AGENDA
1.- Introduccin 2.- Origen y caracterizacin de las escorias 3.- Generacion de escorias, tratamiento y valorizacin 4.- Estudio de casos internacionales: Canad, India, Japn, Alemania, otros 5.- Comentarios finales

Principios
PARADIGMA = los Residuos Mineros son Desechos. y si consideramos estos desechos como RECURSOS?

Introduccin

Estos NUEVOS RECURSOS tienen varias ventajas: Se encuentran en SUPERFICIE (bajos costos mineros). Los VOLUMENES DISPUESTOS SON CONOCIDOS y por lo general caracterizados (bajos costos geolgicos). La RECUPERACION, RECICLAJE Y REUTILIZACIN de sus componentes tiene un EFECTO POSITIVO (transporte, disposicin, impacto ambiental).

Introduccin

La minera del cobre es la actividad ms importante en Chile. Aporta un porcentaje considerable del producto interno bruto. Sin embargo el impacto ambiental que ha producido ha sido una preocupacin permanente del Estado y de las Empresas. Del total de mineral extrado en una mina, slo el ~1% corresponde al metal, el resto es descartado como desechos:
Residuos Slidos Tasa de generacin (ton/ton Cu)

Escoria de fundicin Relave de flotacin Ripios de lixiviacin Estril de mina

~2

~ 100

~ 200

~ 400

Introduccin

Efluentes en Procesos Mineros-Metalrgicos

MINERA SUBTERRNEA MINERA RAJO ABIERTO
MINERAL FAENAS MINERAS
ESTERILES LASTRE MINERAL DE BAJA LEY AGUA DE MINAS

REDUCCIN DE TAMAO TRITURACIN MOLIENDA

MINERAL LIBERADO PROCESAMIENTO DE MINERALES
TRANQUES DE RELAVES LODOS REACTIVOS AGUAS DE DESECHOS

PROCESOS DE CONCENTRACIN SEPARACIN GRAVITACIONAL SEPARACIN MAGNTICA FLOTACIN

CONCENTRADO HMEDO

ESPESAMIENTO FILTRADO SECADO

CONCENTRADO SECO EXTRACCIN DE METAL
GASES DE FUNDICIN POLVOS RESIDUOS DE LIXIVIACIN AGUAS DE DESECHOS EFLUENTES

PROCESOS PIRO, HIDRO, ELECTROMETALRGICOS METAL

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

Introduccin

Situacin histrica => acumulacin de Escorias

Origen y caracterizacin de las escorias

CHUQUICAMATA (CODELCO) POTRERILLOS (CODELCO) ALTONORTE (XSTRATA) PAIPOTE (ENAMI) VENTANAS (CODELCO)

CHAGRES (ANGLOAMERICAN)
CALETONES (CODELCO)

POR QU LAS ESCORIAS?

7 Fundiciones: 4 de CODELCO, 1 de ENAMI, 2 Privadas Produccin anual: 1.8 millones ton cobre blister + aprox 4 millones ton de escorias Acumulado: Cerca de 40 millones de toneladas de escorias

Fundiciones de Concentrados enChile

Origen y caracterizacin de las escorias Composicin media de una escoria de descarte en Chile: 30-40 % hierro, 35-40% silice, ~ 10 % alumina oxido de calcio ~ 1 % cobre ~ 0.3 % molibdeno Cantidades importantes de zinc y metales preciosos (Au, Ag) los metales (materiales) que otorgan mayor valor a la escoria, en orden descendente, son el Molibdeno, el Cobre, el Hierro, la Slice

Generacion de escorias, tratamiento y valorizacin

Fuentes de generacin de escorias:

1. Etapa de Fusin 2% - 10% Cu 5% - 15% Cu 25% - 55% Cu > 50% Cu

2. Etapa de conversin
Soplado de Fe Soplado de Cu

3. Etapa de refino

Alternativas de Procesamiento:
1. Tratamiento Pirometalrgico 2. Flotacin de Escorias Fundamentalmente recuperar cobre

NO SE PONE ATENCION A OTROS COMPONENTES !!!

Q(+)
FUSION Necesidad de Calor
Concentrado+Fundentes+Q=Mata+Escoria+Gas

Q(-)
CONVERSION Generacin de Calor
FeS+3/2O2=FeO+SO2+

Cu2S+O2=2Cu+SO2+Q

Horno Electrico
Horno de Reverbero

Convertidor Peirce Smith

Convertidor Peirce Smith
Convertidor Peirce Smith
Convertidor Peirce Smith
Convertidor Peirce Smith

Flash Outokumpu

TB Isasmelt Bath El Teniente

Q(-)

Q(+)
~25% Cu
CONCENTRADO FeS + Cu2S Mata

80 % Cu

Cu2S Metal Blanco COBRE BLISTER

>95 % Cu

Generacion de escorias, tratamiento y valorizacin

Generacion de escorias, tratamiento y valorizacin

Generacion de escorias y propuestas de tratamiento

Estudio de casos internacionales

Estudio de casos internacionales

Typically it is composed of Ferro silicate material and metal oxides, formed when the molten slag is quenched in cold water. This cooling process fractures the slag into coarse, angular particles making it an ideal choice in many abrasive applications. Copper slag is a fast cutting, high quality, yet economical choice for shipyards and contractors. More than 20 years of history stand behind this type of abrasive grain. This copper slag was shown to be the best abrasive not only in cutting speed, but also in cost per sq. ft. It is also environmentally friendly, approved to be recycled into the manufacture of Portland cement.

Estudio de casos internacionales

Typical Chemical Analysis (%): Iron Oxide Fe203 - 57.0 Silicon Dioxide (total) SiO2 - 29.5 Aluminum Oxide AL203 - 5.0 Zinc - 3.5 Calcium Oxide CaO - 2.5 Magnesium Oxide MgO - 1.0 Copper Cu - 1.0

Typical Physical Properties: Grain Shape Angular Bulk Density (loose) 117 lbs./ft.3 Moh Hardness -7 Specific Gravity -3.8

Typical Gradation: COARSE: marine growth, cement buildup, heavy corrosion and concrete exposed aggregate blasting FINE: Selective coating removal, steelwork, tanks, pipes, brickwork and concrete EXTRA FINE: Wet blasting, motor bodywork, selective coating removal, timber cleaning

Estudio de casos internacionales

1000t

Production of Slag in Japan

45000 40000 35000 30000 25000 EF-production 20000 15000 10000 5000 0 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 LD-production BF-production

Estudio de casos internacionales

Slag Utilization
Uses of Slag in Japan(2007)
Total production Total Uses 40939000 t 41868000 t

Road Soil improvement Civil works Cement Fertilizer Others Land fill
Uses of BF Slag in Japan (2007)
Road Soil improbement Civil works Cement Concrete Aggregate

Estudio de casos internacionales

Iron silicate stone AURUBIS

Estudio de casos internacionales

>During the melting of copper concentrates an iron silicate melt is achieved by the addition of sand and is made into two basic products: iron silicate stone and granules. >These products are processed and sold by the subsidiary PEUTE BAUSTOFF GMBH. >In a crushing and screening plant the iron silicate stone is processed to construction materials, primarily for hydraulic construction purposes. >Hydraulic construction stone made of iron silicate stone is used for securing river embankments and for levees in ports, rivers and as coastal protection. >Due to its high weight compared with other stone it offers considerable advantages.

Estudio de casos internacionales

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

> Iron-silicate stone is a high-grade, extremely dense and hard mineral construction material with special technological properties such as: High apparent density, High strength, Optimal surface roughness, Full volume stability, Very low water absorption, Very good frost resistance, High resistance to weather

Iron-silicate granulate An amorphous granulate is produced after sudden cooling in a water jet, comparable with washed sand 0-4 mm.

Estudio de casos internacionales

Where are iron-silicate products used? These products play an important role in modern hydraulic construction work. > They secure embankments and the beds of rivers, canals and harbour basins against current and wave impact. They protect harbour moles and break the waves rushing to the coast. > Iron-silicate products are also used in track construction, horticulture and landscaping as well as in urban development and as a cement additive. Advantages of iron-silicate stone are: Consistent quality Availability throughout the year High weathering and long-term resistance Fulfils all requirements of application regulations Conservation of natural resources

Estudio de casos internacionales

Iron-silicate products in embankment construction

Clear advantages result in slope construction > Smaller layers are possible which also result in considerable savings in soil excavation work. > The use of smaller stones has significant advantages as regards interlocking, stability and adaptation to the existing bank protection.

> Basically, when using iron-silicate stone, the design engineer can arrange the structure with smaller types of stone and lower structure thickness.

Estudio de casos internacionales

Iron-silicate stone as an extra load and as harbour bottom protection

> Increasingly larger vessels and current action repeatedly cause erosion on the bottoms of harbours, canals, sluice areas and rivers that can be remedied or even avoided by the use of ironsilicate stone. > A hydraulic construction stone mixture for these applications is produced by optimal mixing of individual fractions of iron-silicate stone.

Estudio de casos internacionales

Iron-silicate stone in road construction

> Stone particles made of iron-silicate can be used as an anti-freeze layer and ballast as well as pavement beds in road construction. Special advantages: Very good load-carrying capacity Very good resistance to frost Good water permeability

Estudio de casos internacionales Further areas of application for iron-silicate products

Urban development
> Iron-silicate stone offers interesting design possibilities for urban construction objects as well as in horticulture and landscaping.. > Iron-silicate granulate is ideally suitable for drainages and in landfill construction due to its material-specific properties.

Estudio de casos internacionales EXAMPLES OF UTILIZATION Iron-silicate stone was used in the Mhlenberger Loch in Hamburg-Finkenwerder for bank protection, slopes and securing the harbour bottom along the new about 7 km long flood control system.

Iron-silicate hydraulic construction stone has been successfully used in the Kiel Canal for the canal extension. The bank protection has to withstand very high stress on account of the shipping traffic.

The deeper waterways in Hamburgs Harbour have made it necessary to secure the river beds over the Elbe Tunnel. This was performed with iron-silicate stone 80 cm thick layer with bordering sheet pile walls on both sides of the lowering tunnel.

Comentarios finales

Slags Desafios ambientales del futuro

Grandes Montaas de escorias en distintas partes del mundo Metales y materiales que pueden recuperarse y valorizarse Es utpico pensar en una prctica Zero Slag ?

Cada metro cbico de escoria ferro silicatada utilizada, significa no usar aproximadamente 1.4 m3 de roca, lo que resulta en una gran contribucin a no alterar la naturaleza circundante y por ende a hacer ms sustentable nuestros recursos naturales.

Quo vadis?

Comentarios finales

En relacin a los Metales y materiales presentes en las escorias (Mo, Fe, SiO2, etc.) : Usarlos o no? ~ Estabilizacin o Extraccin En relacin a las acciones de las Empresas: Fines Econmicos o Ecolgicos? ~ Situacin del Mercado Mundial de los Metales En relacin a la situacin de cada pas: Posible o imposible el zero waste? ~ Regulaciones y normativas

Fin