Recovery of metals from waste incinerator Institut für Umwelt- und Verfahrenstechnik bottom ash Prof. Dr. Rainer Bunge Author Prof. Dr. Rainer Bunge Institut für Umwelt- und Verfahrenstechnik UMTEC Hochschule für Technik Rapperswil Oberseestrasse 10 CH-8640 Rapperswil Switzerland [email protected]
Editor Verband der Betreiber Schweizerischer Abfallverwertungsanlagen (VBSA) Wankdorffeldstrasse 102 CH-3014 Bern Switzerland www.vbsa.ch
Copyright UMTEC and VBSA. All rights reserved. First edition 2016.
This publication will be updated periodically. The current version can be downloaded as Metals_from MWIBA.pdf from www.umtec.ch ; www.igenass.ch or www.vbsa.ch. 7DEOHRI&RQWHQWV ,QWURGXFWLRQ %DVLFVRI0XQLFLSDO:DVWH,QFLQHUDWLRQ *OREDODVSHFWV ,QFLQHUDWLRQ7HFKQRORJ\ &RPSRVLWLRQRI³SULPDU\´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« KHDY\1) +1) 1)ZLWKGHQVLW\!JFP HJ&X=Q3E6Q 66$X$J« SOXVDOOR\VVXFKDVEUDVVDQG EURQ]H QDWLYHPHWDO PHWDOSLHFHVIUHHRIPLQHUDODGKHVLRQV PHWDOWRWDO WRWDOPHWDODVVD\LQFOXGLQJWKHDPRXQWSUHVHQW LQFKHPLFDOFRPSRXQGVVXFKDVR[LGHV PHWDOSRWHQWLDO PHWDOWKDWFDQEHSRWHQWLDOO\UHFRYHUHGIURP%$ E\FRQYHQWLRQDOGU\SURFHVVLQJ LHQDWLYH PHWDOSLHFHV!PP IHUURPDJQHWLFSDUWLFOH WKHSDUWLFOHLVOLIWHGE\DPDJQHWZLWKVXUIDFH IOX[GHQVLW\7 /,06 SDUDPDJQHWLFSDUWLFOH WKHSDUWLFOHLVOLIWHGE\DPDJQHWZLWKVXUIDFH IOX[GHQVLW\«7 +,06 QRQPDJQHWLF WKHSDUWLFOHLVQRWOLIWHGE\DPDJQHWZLWK VXUIDFHIOX[GHQVLW\7 +,06
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Fig. 1.1: Bottom ash from a Municipal Waste Incinerator is excavated for processing. Exothermal chemical reactions lead to a marked increase in temperature which evaporates a significant amount of moisture.
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UHF\FOLQJ LQFLQHUDWLRQUHF\FOLQJODQGILOO Fig. 2.1: Incineration quota increases with Gross Domestic Product (top). In contrast to a common misconception, incineration does not compete with recycling, but with landfilling (bottom). Rich countries recycle and incinerate their wastes, while poor countries landfill (data EUROSTAT, IMF).
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*'3>&+)@ Fig. 2.2: The total amount of municipal waste generated increases with GDP. Fig. 2.3: Zinc and copper content of wastes from 6 cities in China (balanced from the chemical analyses of BA and filter ash) plus data from Switzerland. As GDP increases, so does metal content. $VVKRZQLQ)LJ0:,LVFRUUHODWHGZLWK*'35LFKFRXQWULHVQRWRQO\LQFLQHUDWHEXWDOVR UHF\FOH WKHLU ZDVWHV :DVWH LQFLQHUDWLRQ DQG GLUHFW UHF\FOLQJ RI VHSDUDWHO\ FROOHFWHG ZDVWHV UHF\FOLQJ FRQWDLQHUV IRU PHWDOV :((( EDWWHULHV«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Fig. 2.4: Simplified schematic of a “stoker type” Municipal Waste Incinerator (MWI). 6LQFHRFFDVLRQDOO\WKHUPDOGDPDJHWRWKHJUDWHHOHPHQWVLVRFFXUVLWLVUXPRUHGWKDWWKHUPLWH UHDFWLRQVOHDGWRWHPSHUDWXUHVH[FHHGLQJWKHPHOWLQJSRLQWRIVWHHO6XFKUHDFWLRQVRIDOXPLQXP ZLWK LURQ R[LGHV ± ERWK LQ SOHQW\VXSSO\ LQ 0:, DUH VWURQJO\ H[RWKHUPDO 2WKHU VRXUFHV VSHFXODWHWKDWWKHGDPDJHWRWKHJUDWHZKLFKVHHPVWRFRUUHODWHZLWKWKHLQSXWRILQFUHDVHG DPRXQWVRIDOXPLQXPPD\LQWUXWKEHWKHFRQVHTXHQFHRIPDJQHVLXPSUHVHQWLQLQGXVWULDO ZDVWHVZKLFKZDVHUURQHRXVO\LGHQWLILHGDVDOXPLQXP
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Fig. 2.5: Composition of the primary bottom ash 7KH³PLQHUDOIUDFWLRQ´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³JODVV\´DSSHDUDQFHDQGDEODFNLVKFRORU )LJ 7KH\FRQWDLQ DSSUR[LPDWHO\LURQR[LGHVDQGDUHZHDNO\PDJQHWLF7KH³JULW´LVPDWHULDO PPZKLFK LVZLWKUHVSHFWWRPHWDOVVODJDQG PLQHUDOFRQWHQWRIDVLPLODUFRPSRVLWLRQDVWKH%$LQ JHQHUDO,QFRQWUDVWWRWKHFRDUVHVL]HIUDFWLRQVWKHJULWFRQVLVWVRIDSSUR[LPDWHO\ZDWHU VROXEOHVSHFLHV7KHDONDOLQLW\RI%$LVLQWKHRUGHURIPRONJ HQGSRLQWS+ DQGPRONJ HQGSRLQWS+ $W\SLFDOSDUWLFOHVL]HGLVWULEXWLRQRILQFLQHUDWRUDVKLVVKRZQLQ)LJ$SSUR[LPDWHO\ RIWKH%$LVSUHVHQWLQVL]HVGLVWULEXWHGRYHUWKUHHRUGHUVRIPDJQLWXGHUDQJLQJIURPPP WRPP7KHPHDQSDUWLFOHVL]HLVW\SLFDOO\DURXQGG PP
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Fig. 2.7: Primary BA<32 mm. Fig. 2.8: Slag 8-32 mm.
Fig. 2.9: Glass in BA: 4-8 mm Fig. 2.10: Glass and ceramics in BA: 8-32 mm.
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ZDWHUUHWHQWLRQFDSDFLW\ SDUWLFOHVL]HPP Fig. 2.11: The water retention capacity for fine size fractions of BA is much higher than for coarse size fractions.
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Fig. 2.12: Solidification of free flowing bulk solid after wet extraction. )LJ OHIW VKRZVWKHUHVXOWVRI%$ PPZKHQVHSDUDWHGLQDKHDY\OLTXLGDWNJ/DIWHU JLYHQ WLPH LQWHUYDOV ,QLWLDOO\ MXVW DERXW RI WKH %$ IUDJPHQWV IORDW :KHQ WKH VDPH SURFHGXUHLVUHSHDWHGSHULRGLFDOO\GXULQJWKHFXULQJSURFHVVWKHIUDFWLRQRI%$ZLWKGHQVLW\ NJ/LQFUHDVHVDVSDUWLFOHVRIKHDY\PHWDOV )(FRSSHUEUDVV WKDWKDGSUHYLRXVO\UHSRUWHG WRWKH³VLQNV´KDYHPHDQZKLOHEHHQHPEHGGHGLQVXIILFLHQWO\ODUJHOXPSVRIVROLGLI\LQJ OLJKW PLQHUDOPDWHULDOVRWKHZKROHOXPSUHSRUWVWRWKH³IORDWV´ )LJ ULJKW VKRZVWKHLUUHYHUVLEOHZDWHUXSWDNHRIIRXUVL]HIUDFWLRQVRI%$FXUHGRYHUWKH FRXUVHRIZHHNV6DPSOHVRIHDFKJGU\H[WUDFWHG%$ZHUHPRLVWHQHGDQGWKHQVWRUHGLQ
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Fig. 3.1: Copper is often present in the form of wire which is oxidized on the surface (left). Fig. 3.2: Brass is mostly encountered in the form of mountings and fittings (right).
Fig. 3.3: Aluminum melt solidified as “nugget”. Fig. 3.4: Approximately 2/3 of the batteries pass the incinerator intact. This sample was taken from magnetic scrap recovered by BA-processing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Fig. 3.5: After 1h exposure to 900°C: steel (left) and copper (right) have developed an oxidation layer of approximately 0.08 mm thickness.
Fig. 3.6: Oxidation progress on steel (left) and copper (right) as functions of temperature and time.
Fig. 3.7: Oxidation progress on aluminum (left) and brass (right) as functions of temperature and time.
Fig. 3.8: Copper plated pieces of steel recovered from BA (after removal of the oxide scales by shredding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Fig. 3.9: As temperature increases, the steel surface oxidizes and the liquid copper penetrates the boundary between steel and iron oxide thus plating the steel (left). Front and back after cutting the steel dish in half (right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
coppermassbalance gCupertonofMW
MW 20kgfilterash@0.2%Cu MWI landfill 2000g=100% 40g=2% 200kgBA@1%Cu 1960g=98% 173kgprocessedBA@0.2% landfill BAprocessing 350g=17%
7kgNFmetal 20kgFEscrap 3.5kgFEͲoxides @1.4%Cu landfill scrap@19%Cu scrap 20g=1% 1330g=67% 280g=14% processing 140g=7% scrapmetal 0.5kgCu/FEcomposites 16kgsteel@0.75%Cu (e.g.solenoids) 120g=6% smelter steelworks Fig. 3.10: The copper-balance of a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±SHUWRQRI%$W\SLFDOO\DURXQG/SHUGD\ZLWKLQWKHILUVWGD\VRIGLVSRVDO
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³W\SLFDO´IRU0:,LQFHQWUDO(XURSHIRUH[DPSOHLQ*HUPDQ\)UDQFHWKH%HQHOX[ DQG WKH 1RUGLF FRXQWULHV 7KH GDWD SUHVHQWHG DSSO\ WR D SULPDU\ ERWWRP DVK RU D IUHVKO\ GLVFKDUJHG ZHW %$ ,I WKH %$ KDG EHHQ ODQGILOOHG EHIRUH SURFHVVLQJ VHFRQGDU\ %$ FRUUHFWLRQVPXVWEHPDGHIRUORVVRIPHWDOWKURXJKR[LGDWLRQDQGFRUURVLRQ 7DEOHZDVJHQHUDWHGIURPGDWDSXEOLVKHGLQ>@ZKLFKLVDYHU\WKRURXJKDQDO\VLVRIWKH PHWDOLQYHQWRU\LQWKHZDVWHDQGWKHUHVLGXHVRIDSDUWLFXODU0:,LQ6ZLW]HUODQG2I¶W ZDVWHDQQXDOO\SURFHVVHGLQWKLVLQFLQHUDWRU¶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
Table 3.2: Data from a Swiss MWI [2]
FRQFLQZDVWH WUDQVIHUWR%$ FRQFLQ%$ FRQFLQZDVWH WUDQVIHUWR%$ FRQFLQ%$ PJNJ PJNJ PJNJ PJNJ $OXPLQXP $O 1LRELXP 1E %DULXP %D 3ODWLQXP 3W %HU\OOLXP %H 3UDVHRG 3U %LVPXWK %L 5KRGLXP 5K &DGPLXP &G 5XELGLXP 5E &KURPLXP &U 5XWKHQLXP 5X &REDOW &R 6FDQGLXP 6F &RSSHU &X 6HOHQLXP 6H *DGROLQLXP *G 6LOYHU $J *DOOLXP *D 6WURQWLXP 6U *HUPDQLXP *H 7DQWDOXP 7D *ROG $X 7HOOXULXP 7H +DIQLXP +I 7KDOOLXP 7O ,QGLXP ,Q 7LQ 6Q ,URQ )H 7XQJVWHQ : /HDG 3E 9DQDGLXP 9 /LWKLXP /L 10.0% fraction>2mm fraction<2mm BA of 1.0% weight % 0.1% steel aluminum copper zinc stainless Fig. 3.11: Total mass fractions of metals in BA. Potentially recoverable with conventional technology are only metals >2 mm. Fig. 3.12: The total mass of potentially recoverable metals >2mm in BA is 10.4% of which approximately a quarter is NF. $QRWKHU JURXS RI PHWDOV QRW \HW GLVFXVVHG LV SUHFLRXV PHWDOV QDPHO\ JROG DQG VLOYHU 3RWHQWLDOO\ UHFRYHUDEOHFRDUVH SLHFHV !PP RI WKHVH PHWDOV ZLOOHLWKHU FRPH DV VHSDUDWH SDUWLFOHV MHZHOU\ FRLQV«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³VLOYHUZDUH´ ZKLFKDUHDFFXPXODWHGLQWKHFRDUVHIUDFWLRQ ,QDGGLWLRQWRWKHPHWDOVDOUHDG\GLVFXVVHGRQHZLOODOVRILQGDVXUSULVLQJQXPEHURIFRLQVLQ %$DSSUR[LPDWHO\KDOIRIWKHPLQIRUHLJQFXUUHQF\$OWKRXJKWKHQXPEHUDQGYDOXHRIFRLQV LQ%$YDULHVFRQVLGHUDEO\RQHPD\DVVXPHWKDWDSSUR[LPDWHO\FRLQRIJKDYLQJDQRPLQDO YDOXHRI¼LVIRXQGSHUHDFKNJRI%$LHDSRWHQWLDOYDOXHRI¼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ig. 3.13: Size distribution of metal particles in BA. SS and FE occur as much bigger pieces than aluminum, brass and copper. Fig. 3.14: Concentrations of selected metals in BA 0.5-2mm. The relative masses of the fractions were: Mferromag=20 %), Mparamag=20 %, Mnonmag=60 %. 100% %$PP 80% QRQPDJ!7 recovery SDUD7 60% "nonmagnetic" IHUUR 7 mass 40% concentrate to 20% PHWDO\LHOG>@ cumulative 0% 0 0.1 0.2 0.3 0.4 0.5 0.6 magneticfluxdensityofseparator,T )H &X $X $J Fig. 3.15: BA <6mm was separated into classes of magnetic susceptibility by increasing the magnetic flux density of the separator. (left) With strong magnets, up to half of the BA <6mm is attracted. (right) Surprisingly, only around 55-65% of the metals Cu, Au, Ag are recovered in the nonmagnetic fraction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¶*DXVV SDUDPDJVWRDPDJQHWZLWKIOX[GHQVLW\RI7DQG QRQPDJVDUHFRQVLGHUHGDOOSDUWLFOHVWKDWDUHQHLWKHUIHUURQRUSDUDPDJQHWLF7KHGDWDRQPHWDO \LHOGVKRZQLQ)LJ ULJKW ZHUHGHULYHGIURPWKHGDWDVHWLQ)LJ8QVXUSULVLQJO\LURQ LVKLJKO\FRQFHQWUDWHGLQWKH³IHUURPDJQHWLFIUDFWLRQ´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mags ferromags paramags 0.2T=2'000G 0.6T=6'000G feed0.2T=2'000G nonmags Fig. 3.16: Illustration of our definitions for magnetic particles. matrix matrix matrix matrix Cu FE FE+Cu SS +FE +FE+Cu +CuͲoxides (nonmag) (nonmag) (ferromag) (ferromag) (paramag) (paramag) (paramag) (nonmag) gravityconcentr. light + mags at5.5g/cm3 + Ͳ heavy + mags gravityconcentr. light at5.5g/cm3 Ͳ + heavy Fig. 3.17: Copper and iron species in BA and their fate when subjected to magnetic and gravity separation processes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x 0DJQHWLFVXVFHSWLELOLW\ x (OHFWULFDOFRQGXFWLYLW\ x 'HQVLW\ ,QWKHVHSDUDWRUWKHSDUWLFOHVWUHDPLVVXEMHFWHGWRDIRUFHDFWLQJSHUSHQGLFXODUWRWKHJHQHUDO GLUHFWLRQRIWUDQVSRUW7KHPHWDOSDUWLFOHVDUHWKXVIRUFHGRQWRWUDMHFWRULHVGLIIHUHQWIURPWKRVH RIWKHPLQHUDOSDUWLFOHVDQGDUH±DIWHURYHUFRPLQJWKHHGJHRIDVSOLWWHUUHFRYHUHGLQWKH FRQFHQWUDWH GLUHFWLRQRI WUDQVSRUW Fig. 4.1: Principle of mechanical separation processes. Fig. 4.2: Simplified flow sheet of a BA processing plant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±FRQVLGHULQJWKHVWULQJHQWHQYLURQPHQWDOOHJLVODWLRQLQFRXQWULHVWKDWHPSOR\0:,±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³YHUWLFDOVKDIWLPSDFWFUXVKHUV´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mineral fraction matrix= solidifiedgrit slag metal Fig. 4.3: After comminution the metals are fully liberated. Note that the particle size of the all mineral matter has been reduced while the size of the metal pieces remains unaltered. Fig. 4.4: Liberation of pieces of FE and SS embedded in slag: (left) before comminution and (right) after. :KHQFUXVKLQJ%$³VHOHFWLYHFRPPLQXWLRQ´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±LQSDUWLFXODU ZKHQLPSDFWFUXVKHUVRUUHODWHGGHYLFHVDUHXVHGDVWKHVHZLOOFDXVHORVVHVE\DEUDVLRQRIVRIW PHWDOVVXFKDVDOXPLQXPDQGFRSSHU,QFRXQWULHVZKHUHWKHSURFHVVHG%$LVXVHGWRVXEVWLWXWH IRUJUDYHOLQURDGFRQVWUXFWLRQH[FHVVLYHFRPPLQXWLRQLVQRWDQRSWLRQDVSXOYHUL]HGPLQHUDO PDWHULDO FDQQRW EH XVHG IRU FRQVWUXFWLRQ SXUSRVHV :KLOH HQHUJ\ FRQVXPSWLRQ LV D FRQVLGHUDWLRQLWLVQRWDPDMRUIDFWRULQHFRQRPLFWHUPVZKHQSURFHVVLQJ%$*ULQGLQJDOO%$ WRIRUH[DPSOHPPVL]HZRXOGUHTXLUHRQO\VRPHN:KW LPSDFW EDUV URWRU Fig. 4.5: Impact crusher: The rotor with the impact bars revolves at approximately 1000 rpm. The material is crushed by the impact bars and also by impact on the baffle plates. The photo shows the interior after opening the lid with the baffle plates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³FODVVLILFDWLRQ´LVDVHSDUDWLRQDFFRUGLQJWR SDUWLFOH VL]H ZKHUHDV ³FRQFHQWUDWLRQ ³VRUWLQJ´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ig. 4.6: Equipment for the coarse classification of BA: (left) a bar-sizer (drawing by Mogensen) and (right) a trommel screen. 7KHPRVWFRPPRQVFUHHQXVHGLQ%$SURFHVVLQJLVWKHYLEUDWLQJVFUHHQDQH[DPSOHRIZKLFK LVVKRZQLQ)LJ7KHVFUHHQUHVWVRQVSULQJVDQGLVVHWLQWRFLUFXODUPRWLRQE\DURWDWLQJ HFFHQWULFWDSSHW7KHGHFNSURYLGHVDPXOWLWXGHRIDSHUWXUHVRIHTXDOGLPHQVLRQV7KHDSHUWXUHV PD\EHURXQGUHFWDQJXODURU±DVVKRZQLQ)LJULJKWHORQJDWH$VWKHPDWHULDOKRSVRYHU WKHGHFNRIWKHLQFOLQHGVFUHHQWKHILQHVSDVVWKHDSHUWXUHVDQGFROOHFWDWWKHERWWRPZKLOHWKH FRDUVHSDUWLFOHVVWD\RQWRSRIWKHGHFN3UREOHPVPD\DULVHIURPSDUWLFOHVJHWWLQJVWXFNDQG EOLQGLQJWKHVFUHHQDSHUWXUHV7KLVLVDTXLWHFRPPRQHIIHFWZKHQORQJLVKPHWDOSLHFHVGLYH LQWRWKHDSHUWXUHV:KHQYLEUDWLQJVFUHHQVDUHXVHGPXOWLSOHGHFNVFUHHQVVKRXOGEHDYRLGHG DVWKHVFUHHQVPXVWEHHDVLO\DFFHVVLEOHIRUWKHSHULRGLFUHPRYDORISLQFKHGSDUWLFOHV 6FUHHQEOLQGLQJFDQEHDYRLGHGZLWKVWDUVFUHHQVDVVKRZQLQ)LJ7KH³VWDUV´DUHIOH[LEOH SRO\XUHWKDQHHOHPHQWVZKLFKDUHVWUXQJRQWRURWDWLQJVSLQGOHV7KHVWDUHOHPHQWVRQDGMDFHQW VSLQGOHVDUHSRVLWLRQHGLQDVWDJJHUHGDUUDQJHPHQWLQRUGHUWRHQDEOHPXWXDOFOHDQLQJ:KLOH EOLQGLQJ LV DYRLGHG WKH VFUHHQV PXVW EH RFFDVLRQDOO\ FKHFNHG IRU ZLUHV VSRROHG RQWR WKH VSLQGOHV 6FUHHQLQJ%$DWVL]HVEHORZPPLVGLIILFXOW,QDGGLWLRQWRVLHYHEOLQGLQJWKH%$PD\EH VWLFN\7KLVFDQEHDYRLGHGZKHQWKH%$ZKLFKLVGULSSLQJZHWDIWHUH[WUDFWLRQLVILUVWFXUHG IRUDIHZZHHNVDQGWKHQFUXVKHGIRUOLEHUDWLRQRIWKHPHWDOV$VDOUHDG\GLVFXVVHGWKH%$ ³GULHV´GXULQJWKHVROLGLILFDWLRQSURFHVVDVWKHPRLVWXUHFRQWHQWLVHYDSRUDWHGRUXVHGXSLQ FKHPLFDOUHDFWLRQV Fig. 4.7: Vibrating screen: in principle (left) and production scale (right). Fig. 4.8: In order to avoid blinding, sizes 10-100 mm are often processed on star-screens. ,IWKH%$LVSURFHVVHGULJKWDIWHUH[WUDFWLRQRUWKHFXULQJLVQRWFDUULHGRXWXQGHUDURRIWKH%$ PD\EHZHWDQGVWLFN\ZKLFKUXOHVRXWILQHVFUHHQLQJRQFRQYHQWLRQDOYLEUDWRU\VFUHHQV,QWKLV FDVH ³IOLSIORZ´ VFUHHQV DUH XVHG $V VKRZQ LQ )LJ D WKH IOH[LEOH VFUHHQ PDWV H[HUW D ³WUDPSROLQHHIIHFW´RQWKHPDWHULDOZKLFKOHDGVWRVKHDUIRUFHVVWURQJHQRXJKWROLEHUDWHILQH SDUWLFOHV VWLFNLQJ WR WKH VXUIDFHV RI FRDUVH SDUWLFOHV $OWKRXJK %$ FRQWDLQV YHU\ DEUDVLYH SDUWLFOHV ZLWK VKDUS HGJHV HJ EURNHQ SRUFHODLQ WKH IOH[LEOH VLHYH PDWV DUH VXUSULVLQJO\ UHVLVWDQWWRZHDU7KHPLQLPXPVSOLWVL]HDWWDLQHGRQVXFKVFUHHQVLVLQWKHRUGHURIPP7KH DSHUWXUHVDUHRIWHQQRWUHFWDQJXODUEXWVORWWHG Fig. 4.9a: Schematic of “flip-flow” screen, used for the classification of moist and “sticky” BA. Fig. 4.9b: (left) Installation of a “flip flow” screen. (right) BA on a 16 mm deck. IHHG KRSSHU URWRUZLWK ,PSDFWEDUV ILQHIUDFWLRQ FRDUVHIUDFWLRQ Fig. 4.10: “ADR” technology for separating moist BA. 7KHGLIILFXOW\WRVHSDUDWHZHW³VWLFN\´%$DWVPDOOSDUWLFOHVL]HVRQVFUHHQVKDVEURXJKWDERXW XQFRQYHQWLRQDOGHYLFHVVXFKDVWKH³$'5´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³DLUNQLIH´ WHFKQRORJ\ZKHUHWKHPDWHULDOSDVVHVXQGHUDQDLUEORZHUWRUHPRYHWKHILQHV ,IGU\%$LVSURFHVVHGRQHPD\EHDEOHWRFODVVLI\DWVSOLWVL]HV DV ORZ DV PP $V PHQWLRQHG DERYH VLHYH EOLQGLQJ E\ HORQJDWH SDUWLFOHV PD\ EHFRPH D PDMRU SUREOHP ZLWK FRQYHQWLRQDO YLEUDWLQJ VFUHHQV $Q DOWHUQDWLYH PD\ EH J\UDWRU\ VFUHHQV )LJ $V WKH VFUHHQLVPRYHGKRUL]RQWDOO\WKHPDWHULDOGRHVQRW³KRS´EXWUDWKHUJOLGHVRYHUWKHVFUHHQPDW 7KLVSUHYHQWVORQJLVKSDUWLFOHVIURPYHUWLFDOO\GLYLQJLQWRDSHUWXUHVWRRVPDOOIRUWKHLUSDVVDJH *\UDWRU\VFUHHQVKDYHEHHQIRXQGYHU\HIIHFWLYHLQUHFRYHULQJVPDOOSLHFHVRIFRSSHUZLUHIURP %$ ZKHQ LQVWDOOHG GRZQVWUHDP RI D YLEUDWLQJ VFUHHQ ZLWK DSSUR[LPDWHO\ WKH VDPH VFUHHQ DSHUWXUHVL]H2QWKHYLEUDWLQJVFUHHQWKHZLUHVVOLSWKURXJKWKHDSHUWXUHVEXWWKH\DUHWKHQ UHFRYHUHGRQWKHJ\UDWRU\VFUHHQRIHTXDODSHUWXUHVL]H Fig. 4.11: Gyratory screens are employed, if the feed contains fibrous and elongate particles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x )HUURPDJV VWURQJO\PDJQHWLFSDUWLFOHV )( x 3UDPDJV ZHDNO\PDJQHWLFSDUWLFOHV 66LURQR[LGHV x 1RQPDJV QRQPDJQHWLFSDUWLFOHV JODVVQRQIHUURXVPHWDOV« :KLOHVWURQJO\PDJQHWLFSDUWLFOHVFDQEHUHFRYHUHGZLWKORZLQWHQVLW\PDJQHWV /,06 WKH UHFRYHU\ RI WKH ZHDNO\ PDJQHWLF IUDFWLRQ UHTXLUHV KLJK LQWHQVLW\ PDJQHWV +,06 7KH ³PDJQHWLFIOX[GHQVLW\´LVXVHGIRUGHVFULELQJWKH³VWUHQJWK´RIPDJQHWVDQGLVPHDVXUHGLQ 7HVOD 7 ¶*DXVV ,QWKHFRQWH[WRI%$SURFHVVLQJ/,06DUHGHILQHGDV06ZLWK VXUIDFHIOX[GHQVLWLHV 7DQGDV+,06GHYLFHVDUHGHILQHGZLWKIOX[GHQVLWLHVH[FHHGLQJ 7LQSDUWLFXODU73DUWLFOHVWKDWDUHQRWUHFRYHUHGE\+,06ZLWK7DUHFRQVLGHUHG ³QRQPDJQHWLF´ $OOPDJQHWLFVHSDUDWRUVHPSOR\HGLQ%$SURFHVVLQJDUHRIWKH³ODWHUDOSROH´NLQGZKHUHWKH PDJQHWLF SROHV DUH DUUDQJHG QH[W WR HDFK RWKHU DV VKRZQ LQ )LJ ,Q FRQWUDVW WR WKH ³RSSRVLQJSROH´GHVLJQZKHUHWKHPDWHULDOSDVVHVEHWZHHQIDFLQJPDJQHWLFSROHV HJWKURXJK WKHJDSRID³KRUVHVKRH´PDJQHW WKHPDWHULDOFDQQRWEHFRPHMDPPHGLQWKHVHSDUDWLRQJDS ,QPRGHUQ06LWLVTXLWHFRPPRQWRLQVWDOOSHUPDQHQWPDJQHWV DVRSSRVHGWRHOHFWURPDJQHWV )RU/,06IHUULWHPDJQHWVDUHRIWHQSUHIHUUHG EHFDXVHFKHDSHU ZKLOHIRU+,06³UDUHHDUWK´ PDJQHWVEDVHGRQ1HRG\PLXPDUHXVHG 6 1 6 6 1 6 1 6 1 1 6 1 JODVVSDQH Fig. 4.12: Schematic of the “lateral pole” design of magnetic separators. D is the outer boundary of the zone of attraction for a particular material (e.g. steel). As the magnet approaches the steel spheres, the bigger sphere is attracted first (top). Upon withdrawing the magnet from the glass pane, the big sphere drops first (bottom). ,WLVLPSRUWDQWWRQRWHWKDWWKHDWWUDFWLRQGHFUHDVHVH[SRQHQWLDOO\ZLWKGLVWDQFHIURPWKHVXUIDFH RIWKHPDJLFSROHV$JLYHQPDJQHWKDVDGHILQHG³]RQHRIDWWUDFWLRQ´IRUDJLYHQPDWHULDOVD\ )(±UHJDUGOHVVRIWKHVL]HRIWKHREMHFW2QO\LIWKHFHQWHURIJUDYLW\RIDJLYHQ)(REMHFWOLHV ZLWKLQWKLV]RQHRIDWWUDFWLRQLWZLOOEHDWWUDFWHGDJDLQVWJUDYLW\ )LJ WRS VKRZV±LQDYHU\VLPSOLILHGPDQQHUZKDWKDSSHQVLIDPDJQHWZLWKDQRXWHU OLPLWRIWKH]RQHRIDWWUDFWLRQ'DSSURDFKHVWZRVWHHOVSKHUHVSRVLWLRQHGQH[WWRHDFKRWKHURQ DWDEOHIURPDERYH'GHSHQGVRQWKHPDWHULDOWREHDWWUDFWHG HJVWHHO DQGWKHFRPSRVLWLRQ RIWKHPDJQHW HJ1G)H% %HWZHHQWKHPDJQHWDQGWKHVSKHUHVDJODVVSDQHLVLQVWDOOHG7KH PDJQHWDSSURDFKHVIURPDERYHXQWLOWKHFHQWHURIJUDYLW\RIWKHODUJHVSKHUHOLHVZLWKLQ'$W WKLVSRLQWWKHVSKHUHLVDWWUDFWHGDQGSLQQHGWRWKHJODVVSDQH2QO\ZKHQWKHPDJQHWLVIXUWKHU DSSURDFKHGWREHFORVHHQRXJKIRUWKHFHQWHURIJUDYLW\RIWKHVPDOOVSKHUHWROLHZLWKLQ'ZLOO WKHVPDOOVSKHUHDOVREHDWWUDFWHG2QZLWKGUDZLQJWKHPDJQHWDJDLQ )LJERWWRP WKH ODUJHVSKHUHZLOOGURSILUVWDQGRQO\LIWKHGLVWDQFHRIWKHPDJQHWLVIXUWKHULQFUHDVHGZLOOWKH VPDOOVKHUHDOVRGURS7KHILUVWSDUWRIWKHH[SHULPHQW DSSURDFK ZRXOGVXJJHVWWKDWODUJHVWHHO SDUWLFOHV DUH ³PRUH VWURQJO\ DWWUDFWHG´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±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x GUXPPDJQHWGHIOHFWLQJ x GUXPPDJQHWH[WUDFWLQJ x RYHUKHDGPDJQHW Fig. 4.13: Drum magnets: (left) deflection magnet, (right) extraction magnet. 2YHUKHDGPDJQHWVDUHHLWKHUHTXLSSHGZLWKHOHFWURPDJQHWVRUZLWKSHUPDQHQWPDJQHWV7KH GHVLJQRIDQRYHUKHDGPDJQHWLVVKRZQLQ)LJ7KHPDWHULDOWUDYHOVRQWKHFRQYH\RUEHOW DQGIROORZV±DIWHUKDYLQJSDVVHGWKHKHDGSXOOH\±WKHIUHHIDOOWUDMHFWRU\SDUDEROD)(LV DWWUDFWHGE\WKHPDJQHWJHWVSLQQHGRQWRWKHEHOWWKDWUXQVDURXQGWKHPDJQHWLVWKHQGUDZQ E\WKHEHOWRXWRIWKHPDJQHWLFILHOGDQGIDOOVLQWRWKHFRQFHQWUDWHELQ7KHRYHUKHDGPDJQHWLV XVXDOO\LQVWDOOHGDV/,06XSVWUHDPRIWKHFUXVKHUIRUUHPRYLQJRYHUVL]H)(RIVL]H!PP Fig. 4.14: Overhead magnet: schematic and photo. A “crossbelt design” (lower left corner on drawing) must be avoided if coarse BA is processed. )UHTXHQWO\WKHRYHUKHDGPDJQHWLVLQVWDOOHGDV³FURVVEHOWPDJQHW´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« E\KDQGSLFNLQJWKHFRQFHQWUDWLRQRIFRSSHULQWKHVWHHOVFUDS ZDVVWLOOJ&XNJ)( VHHDOVR)LJ (GG\&XUUHQW6HSDUDWRUV (&6 ,QDGGLWLRQWRPDJQHWLFVHSDUDWRUVHGG\FXUUHQWVHSDUDWRUVDUH³ZRUNKRUVHV´RI%$SURFHVVLQJ SODQWVDVWKH\DUHDEOHWRUHFRYHUHOHFWULFDOO\FRQGXFWLYHPDWHULDOVVXFKDVQRQIHUURXVPHWDOV 1) 0DMRUSDUWVRI(&6DUHDFRQYH\RUEHOWZKLFKWUDYHOVDWPVDKHDGSXOOH\DURWRUZLWK VWURQJPDJQHWVDWWDFKHGWRLWVVXUIDFHDQGDVSOLWWHU )LJ 7KHURWRULVRIWHQSRVLWLRQHG RIIFHQWHUZLWKLQWKHSXOOH\VKHDYH 67(,1(57GHVLJQ DQGURWDWHVDWPXFKIDVWHUVSHHGVWKDQ WKHVKHDYH HJ¶USP 7KHPDJQHWVRQWKHURWRUVXUIDFHJHQHUDWHDQHGG\FXUUHQWLQVLGH HOHFWULFDOO\FRQGXFWLYHSDUWLFOHV7KLVFXUUHQWLQWXUQSURGXFHVDPDJQHWLFILHOGWKDWFDXVHVWKH SDUWLFOHVWREHUHSHOOHGE\WKHURWRU1RQFRQGXFWLYHSDUWLFOHVUHPDLQXQDIIHFWHGDQGIROORZWKH WUDMHFWRU\SDUDEROD$VSOLWWHULVSRVLWLRQHGEHWZHHQWKHWUDMHFWRULHVRIWKHQRQFRQGXFWLYHDQG WKHFRQGXFWLYHSDUWLFOHV conductive URWRU KHDGSXOOH\ VKHDYH non- conductive Fig. 4.16: Eddy Current Separator ECS: Schematic of principle (left). View from diagonally above into the separation chamber (right). 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2YHUORDGLQJPXVWEHDYRLGHG7KHEHOWPXVWQRWEHFRYHUHGZLWKPRUHWKDQDPRQROD\HU RIPDWHULDO7KLVLPSRVHVVLJQLILFDQWOLPLWDWLRQVWRWKURXJKSXW x 7KH EHOW DQG WKH IHHG KRSSHU PXVW EH NHSW FOHDQ DV WKH EXLOGXS RI GHSRVLWV LQ SDUWLFXODU LI WKH\ FRQWDLQ PDJQHWLF SDUWLFOHV LV GHWULPHQWDO WR VHSDUDWLRQ HIILFLHQF\ &RQVHTXHQWO\±ZKHQSURFHVVLQJPRLVW%$±VFUDSHUVDQGEUXVKHVPXVWEHLQVWDOOHGIRU FOHDQLQJWKHEHOW x $OWKRXJKVRPH(&6WKDWXVHFRQFHQWULFURWRUV ZLWKUHVSHFWWRWKHD[LVRIWKHKHDG SXOOH\VKHDYH WKHGRPLQDQWGHVLJQLVWKHRIIFHQWHUDUUDQJHPHQWZKLFKRIIHUVYDULRXV DGYDQWDJHV7KHRSWLPXPDQJOHRIWKHD[LVRIWKHURWRULQUHODWLRQWRWKHD[LVRIWKHKHDG SXOOH\VKHDYHGHSHQGVDPRQJRWKHUWKLQJVRQSDUWLFOHVL]H*HQHUDOO\WKHURWRULVVHW DWDSSUR[LPDWHO\WKH³RQHR¶FORFNSRVLWLRQ´LHDWDVVKRZQLQ)LJULJKW)RU FRDUVH SDUWLFOHV D VHWWLQJ RI DURXQG KDV EHHQ VKRZQ WR EH IDYRUDEOH ZKLOH ILQH SDUWLFOHVWHQGWREHWWHUVHSDUDWHDWDURWRUVHWWLQJRIDSSUR[LPDWHO\,QDQ\FDVHWKH EHOWVSHHGPXVWEHDGMXVWHGVXFKWKDWWKHSDUWLFOHVGRQRWVOLSRQWKHEHOWZKLOHSDVVLQJ RYHUWKHURWRU x 7KHVSOLWWHUVHWWLQJPXVWEHRSWLPL]HGDQGFRQWUROOHGLQUHJXODULQWHUYDOV6RPHH[SHUWV FODLPWKDWWKHVSOLWWHUPXVWEHVHWVXFKWKDWLWVHGJHLVRQOHYHOZLWKWKHD[LVRIWKHKHDG SXOOH\ VKHDYH RU HYHQ EHORZ LQ RUGHU IRU WKH ³FORXGV´ RI FRQGXFWLYH DQG QRQFRQGXFWLYHSDUWLFOHVWRVHSDUDWH2WKHUVDUJXHWKDWWKHVSOLWWHUPXVWEHSRVLWLRQHG PXFKKLJKHUWRFDSWXUHWKHGHIOHFWHGVPDOOFRQGXFWLYHSDUWLFOHVEHIRUHWKHLUWUDMHFWRU\ LQWHUVHFWVWKDWRIFRDUVHQRQFRQGXFWLYHSDUWLFOHV7KHRSWLPXPVSOLWWHUVHWWLQJGHSHQGV RQWKHVHSDUDWLRQLVVXHDWKDQGDQGLVEHVWGHWHUPLQHGH[SHULPHQWDOO\ Fig. 4.18: NF recovered by ECS: (left) mostly aluminum. (right) NF concentrate from a sensor sorter (after ECS): mostly SS. IHHG FRQGXFWLYH VHQVRU DLU QR]]OH QRQ FRQGXFWLYH FRPSXWHU Fig. 4.19: (left) Functional principle of sensor sorting. (right) View into the separation chamber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x $OOPHWDOVFDQEHUHFRYHUHGUHJDUGOHVVRIPDJQHWLFSURSHUWLHVDQGVKDSH x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ig. 4.20: Handpicking station. Fig. 4.21: Transformers and electric motors handpicked from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³RGG´ SDUWLFOH VKDSHV DUH SURFHVVHG )RU H[DPSOH ³VSLUDO FRQFHQWUDWRUV´DUHQRWDEOHWRVXFFHVVIXOO\UHFRYHUVPDOOSLHFHVRIFRSSHUZLUHGHVSLWHWKHUDWKHU KLJKGHQVLW\RIFRSSHU2QWKHRWKHUKDQGVKDNLQJWDEOHVMLJVDQGFHQWULIXJDOGHYLFHVKDYH EHHQVKRZQWRVXFFHVVIXOO\H[WUDFWKHDY\PHWDOVIURP%$'XHWRWKHIDFWWKDWDOXPLQXPKDV DSSUR[LPDWHO\WKHVDPHGHQVLW\DVWKHPLQHUDOPDWHULDO JODVVVODJ« WKLVPHWDOFDQDVD PDWWHURISULQFLSOHQRWEHVHSDUDWHGE\JUDYLW\FRQFHQWUDWLRQSURFHVVHV ,QJUDYLW\FRQFHQWUDWLRQSURFHVVHVLQYROYLQJ%$ PPWKHUDWLRRIFRSSHU VLOYHU JROGSUHVHQW LQWKH%$RIDSSUR[LPDWHO\ ¶ « « LVPDLQWDLQHGDOVRLQFRQFHQWUDWHV DQGUHVLGXHV7KLVLVDQLQGLFDWLRQRIJROGDQGVLOYHUEHLQJSUHVHQWHLWKHULQQDWLYHIRUPRUDW OHDVWLQFRPSRVLWHZLWKKHDY\PLQHUDOVRUPHWDOVWKDWEHKDYHLQJUDYLW\FRQFHQWUDWLRQSURFHVVHV VLPLODUWRFRSSHU2QFHWKHDFWXDOUDWLR&X $J $XKDVEHHQGHWHUPLQHGIRUDSDUWLFXODU%$WKH DQDO\VLVIRUFRSSHUFDQEHXVHGIRUHVWLPDWLQJWKHFRQFHQWUDWLRQVRIWKHSUHFLRXVPHWDOVLQD JLYHQSURGXFW'LUHFWDQDO\VHVRIJROGDQGVLOYHUDUHGLIILFXOWWRGHWHUPLQHGLUHFWO\GXHWRWKH ³QXJJHWHIIHFW´ DVGLVFXVVHGLQFKDSWHU Fig. 4.22: Metals recovered from BA by gravity concentration: gold originating from ball bonded contacts (left), contact foils (middle) and copper from litz wire (right). Even the longest dimensions of these objects are approximately only 0.5 mm. 8QFRQYHQWLRQDO(TXLSPHQW $WOHDVWRQHFRPSDQ\ LQ*HUPDQ\ LVVSHFLDOL]HGLQH[WUDFWLQJFRLQVZKLFKDUHDFFXPXODWHGLQ VL]HIUDFWLRQVPPRIWKH1)FRQFHQWUDWHV)LUVWWKHFRLQVDUHIXUWKHUFRQFHQWUDWHGZLWK VSHFLDOL]HGHTXLSPHQWWKDWXVHVWKHGLVFVKDSHRIFRLQVDVDVHSDUDWLRQFULWHULRQ7KHFRLQVDUH WKHQFOHDQHGDQGSROLVKHGDQGUXQWKURXJKDQDXWRPDWLFVRUWHU7KLVGHYLFHVFDQVWKHIURQWDV ZHOODVWKHIOLSVLGHRIHDFKFRLQWKHQFRPSDUHVWKHVFDQZLWKLPDJHVRIFRLQVVWRUHGLQLWVGDWD EDVHDQGDFFRUGLQJO\WUDQVIHUVWKHFRLQVLQWRUHFHSWDFOHV Fig. 4.23: Coins recovered from the NF fraction of BA: (left) after extraction from the NF concentrate; after polishing (Photos: Georg Schons/GS-GmbH). :KDWSHUFHQWDJHRIWKHFRLQVSUHVHQWLQWKH%$LVDFWXDOO\UHFRYHUHGGHSHQGVRQWKHSURSHUWLHV RIWKHFRLQVWKHIORZVKHHWRIWKHSODQWDQGWKHHTXLSPHQWLQXVH,IWKH%$LVVFUHHQHGIRU H[DPSOHRQGHYLFHVZLWKORQJLWXGLQDODSHUWXUHVVXFKDVVL]HUVVWDUVFUHHQVDQGWKHOLNHWKH FRLQVPD\VOLSLQWRWKHUHVLGXHDQGFDQQRWEHUHFRYHUHG%XWLIFRQYHQWLRQDOYLEUDWLQJVFUHHQV ZLWK VTXDUH RSHQLQJV DUH XVHGWKH FRLQV KDYH D JRRG FKDQFH WRHQGXS LQ WKH 1) IUDFWLRQ UHFRYHUHGE\(&6RUVHQVRUVRUWHU6RPHFRLQVDUHZHDNO\PDJQHWLFIRUH[DPSOH¼DQG¼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±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able 5.1: Taxonomy of BA processing operations %$WKURXJKSXWWD H[WUDFWLRQPHWKRG ORFDWLRQRISODQW SURFWHFKQRORJ\ IDWHRIUHVLGXH ZHWH[WUDFWLRQ RQVLWH0:, GU\SURFHVVLQJ ODQGILOO GU\H[WUDFWLRQ RQVLWHODQGILOO ZHWSURFHVVLQJ EXLOGLQJPDWHULDO ! 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YLEUDWLQJVFUHHQ PP /,06 VWHHOPP HGG\FXUUHQW QRQIHUURXVPP VHSDUDWRU YLEUDWLQJVFUHHQ PP /,06 VWHHOPP GHVOLPLQJDW HGG\FXUUHQW QRQIHUURXVPP PP VHSDUDWRU ZHW/,06 JUDYLW\ QRQIHUURXVPP FRQFHQWUDWLRQ IUHVKZDWHULQ GHZDWHULQJ VDQGPP VROLGOLTXLG VHGLPHQWDWLRQ VOXGJH FDNH VHSDUDWLRQ ILOWUDWH ZDVKHG%$IRU ODQGILOO EULQHRXW URDGFRQVWUXFWLRQ Fig. 5.2: Simplified flowsheet of a wet BA processing plant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ategory 1.x/2.2/3.x/4.x/5.x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³SULPDU\%$´$VWKHPDWHULDOLVQRWZHWWHG WKHGHWULPHQWDOFRUURVLRQDQGVROLGLILFDWLRQSURFHVVHVFKDUDFWHULVWLFIRU³VHFRQGDU\%$´DUH WKHUHIRUHVXSSUHVVHGDQGPHWDOSLHFHVWKDWZRXOGRWKHUZLVHEHORFNHGLQWRWKHQHZO\IRUPHG PLQHUDOVUHPDLQOLEHUDWHG2QHZRXOGWKHUHIRUHH[SHFWDFRPPLQXWLRQSULRUWRWKHVHSDUDWLRQ VWDJHVWREHXQQHFHVVDU\7KLVLVQRWWKHFDVHKRZHYHUEHFDXVHVRPHPHWDOSLHFHVDUHFRQWDLQHG LQWKHVODJ )LJ ,QRUGHUWROLEHUDWHWKHVHPHWDOVWKHSULPDU\%$QHHGVWREHFRPPLQXWHG Fig. 5.3: Metals 10-40 mm recovered from dry extracted BA: NF (left) and FE (right). Even thin foils of aluminum have been successfully recovered as a pure product with virtually no corrosion and adhesions of mineral material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x ³*UDGH´LVWKHFRQFHQWUDWLRQRIWKHPHWDOLQWKHFRQFHQWUDWH&F x ³5HFRYHU\´LVWKHUHODWLYHDPRXQWRIPHWDOSUHVHQWLQWKHIHHGWKDWKDVEHHQVXFFHVVIXOO\ WUDQVIHUUHGLQWRWKHFRQFHQWUDWH5F non-conductive conductive % F JUDGH& $ % residue concentrate VSOLWWHU PHWDOUHFRYHU\5F Fig. 5.4: The ECS splitter setting (A) results in 100% recovery but only 45% grade. Splitter setting (B) results in 100% grade but only 60% recovery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³RQ WKHVDIHVLGH´7KHFRQVHTXHQFHVDUHREYLRXVIURP)LJ ULJKW ,IWKHFRQFHQWUDWHJUDGHLV LQFUHDVHGWR LQVWHDGRIWKHUHTXLUHG WKHUHFRYHU\ZLOOGURSIURPWR7KLV PD\DSSHDULQFRQVSLFXRXVEXWFRXOGWUDQVODWHLQWRDUHGXFHGRYHUDOOSURILWRIDSSUR[LPDWHO\ DVGLVFXVVHGLQFKDSWHU :KHQDVVHVVLQJSODQWSHUIRUPDQFHPXFKFRQIXVLRQLVFDXVHGE\WKHODFNRIUHIHUHQFHZLWK UHVSHFWWRWHFKQLFDOWHUPVOLNH³PHWDOFRQWHQW´³JUDGH´RU³PHWDOUHFRYHU\´$FDVHLQSRLQWLV WKH WHUP ³PHWDO \LHOG´ :KHQ SODQW RSHUDWRUV UHIHU WR ³PHWDO \LHOG´ WKH\ XVXDOO\ PHDQ WKH FRQFHQWUDWHPDVVUHFRYHU\EHFDXVHWKLVLVWKHSURGXFWWKH\VHOOE\ZHLJKW±PLQHUDOPDWUL[ LQFOXGHG$QRWKHUVRXUFHRIFRQIXVLRQLVWKHWHUP³JUDGH´,QVFLHQWLILFSXEOLFDWLRQVRQHZLOO RIWHQILQGWKH³JUDGH´EHLQJGHWHUPLQHGE\DFKHPLFDODQDO\VHV7KLVZRXOGLQFOXGHQRWRQO\ YDOXDEOH QDWLYH PHWDOV EXW DOVR PLQHUDOL]HG PHWDOV VXFK DV PHWDO R[LGHV ZKLFK KDYH QR FRPPHUFLDOYDOXH:HWKHUHIRUHVXJJHVWWKDWWKHGHILQLWLRQVLQ7DEOHEHXVHG Table 5.2: definitions for grade, recovery and related terms ʹ PHWDOSRWHQWLDO&I PDVVUHFRYHU\WRFRQFHQWUDWH50F PHWDOUHFRYHU\WRFRQFHQWUDWH5F ʹ FRQFHQWUDWHJUDGH&F VPHOWHU\LHOG5V EXOOLRQJUDGH&V Note that in the above definitions the term „metal“ refers to „native metal“. And keep in mind that all data on metal content or yield should be given with respect to dry mass (i.e. the mass of the material after drying at 105°C). IHHG NJ ZDWHU &I NJ PLQHUDOPDWWHU %$ &U5 U UHVLGXH SURFHVVLQJ PHWDOR[LGHV NJ QDWLYHPHWDO PP &F5F50F FRQFHQWUDWH QDWLYHPHWDO NJ !PP SROLVKLQJ VODJ NJ VPHOWHU 120 kg 57 kg &V5V %$ FRQFHQWUDWH EXOOLRQ EXOOLRQ %$SURFHVVLQJ VPHOWHU Fig. 5.5: (left) Simplified flow sheet of a BA processing operation plus downstream metal concentrate refining. (right) Example: Graphic representation of the composition of a BA, the metal concentrate and the product after smelting. )LJ ULJKW LOOXVWUDWHVWKHGHILQLWLRQVIURP7DEOHE\ZD\RIDQH[DPSOH x WRWDOPHWDOJUDGHRIWKHIHHG x QDWLYHPHWDOJUDGHRIWKHIHHG x PHWDOSRWHQWLDORIWKHIHHG &I x PDVVUHFRYHU\WRFRQFHQWUDWH 50F x PHWDOUHFRYHU\WRFRQFHQWUDWH 5F x FRQFHQWUDWHJUDGH &F x VPHOWHU\LHOG 5V *reference: dry mass (105°C) 7KH³WRWDOPHWDOJUDGHRIWKHIHHG´FRUUHVSRQGVZLWKWKHUHVXOWRIDFKHPLFDODQDO\VLV7KLV LQFOXGHV YDOXDEOH QDWLYHPHWDODVZHOODV YDOXHOHVV PLQHUDOL]HGPHWDO :KHQDVVHVVLQJWKH³PHWDOSRWHQWLDO´RID%$RQO\WKHSLHFHVRIQDWLYHPHWDO!PPDUHRI LQWHUHVWDVWKHSLHFHV PPDUHRQO\PDUJLQDOO\UHFRYHUHGZLWKFRQYHQWLRQDO%$SURFHVVLQJ WHFKQRORJ\ FKDSWHU 2QH PD\ DUJXH WKDW ZLWK DSSURSULDWH WHFKQRORJ\ HJ ZHW SURFHVVLQJ DWOHDVWVRPHRIWKHPHWDO PPFDQDOVREHUHFRYHUHGDQGWKHUHIRUHWKH³PHWDO UHFRYHU\WRWKHFRQFHQWUDWH´5FFRXOGWKHRUHWLFDOO\H[FHHGWKH³PHWDOSRWHQWLDO´+RZHYHULQ SUDFWLFH5FLVDOZD\VVLJQLILFDQWO\ORZHUWKDQWKH³PHWDOSRWHQWLDO´(YHQLIVRPHPHWDO PP KDGVXFFHVVIXOO\EHHQUHFRYHUHGPXFKPRUHRIWKHPHWDO!PPLVORVWLQWRWKHUHVLGXH,Q SUDFWLFHWKH³PHWDOSRWHQWLDO´EHLQJDFFRUGLQJWRRXUGHILQLWLRQQDWLYHPHWDOSLHFHV!PPLV QHYHUH[FHHGHGE\5F $VPHQWLRQHGDERYHWKH³PDVVUHFRYHU\WRFRQFHQWUDWH´50FLQFOXGHVPLQHUDODGKHVLRQVDQG LVWKHUHIRUHXVHOHVVIRUDVVHVVLQJWKHSHUIRUPDQFHRIDJLYHQSODQWRUIRUFRPSDULQJGLIIHUHQW SODQWV,QWKHVHFDVHV³PHWDOUHFRYHU\WRFRQFHQWUDWH´5FVKRXOGEHXVHGLQVWHDG/LNHZLVH ³FRQFHQWUDWH JUDGH´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ig. 5.6: (left) As the trajectories of coarse nonconductive particles and small conductive particles overlap, separation efficiency is low when processing wide particle size distributions. (right) If the metals were not sufficiently liberated, separation efficiency is low. F LPSURYHGVHSDUDWLRQSHUIRUPDQFHGXHWR x QDUURZHUSDUWLFOHVL]HIUDFWLRQV JUDGH& x EHWWHUOLEHUDWLRQ x OHVVWKURXJKSXW PHWDOUHFRYHU\5 F Fig. 5.7: Influence of various parameters on improving the grade/recovery curve. Ideally, the plant would operate at 100% metal recovery and 100% grade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xample (fictional): Plant Optimization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±IRUVLPSOLFLW\±WKDWWKHUHYHQXHIRUWKHFRQFHQWUDWHEH¼WDQGRSHUDWLQJFRVWEH ¼K LQGHSHQGHQWRIWKURXJKSXW RQHDUULYHVDWWKHGDWDVKRZQLQ)LJ:KLOHLQLWLDOO\ LQFUHDVHG WKURXJKSXW EULQJV DERXW DQ LQFUHDVHG DPRXQW RI FRQFHQWUDWH DW JUDGH H[FHVVLYHLQFUHDVHVLQWKURXJKSXWGHFUHDVHWKHDPRXQWRIFRQFHQWUDWHDQGWKHUHIRUHSURILW .HHS LQ PLQG WKDW WKH SODQW SHUVRQQHO ZLOO WHQG WR RSHUDWH DW ORZHU WKURXJKSXW WKDQ LV HFRQRPLFDOO\DGYLVDEOHDVWKLVUHTXLUHVOHVVDWWHQWLRQE\WKHSHUVRQQHOWKDQUXQQLQJWKHSODQW ³QHDU WKH WLSSLQJ SRLQW´ $VVXPH WKH SODQW LQ WKH H[DPSOH VKRZQ LQ )LJ ZRXOG EH ³QRUPDOO\´UXQDWWK$QLQFUHDVHRIPHUHO\WKURXJKSXW !WK ZRXOGLQFUHDVH SURILWE\ !¼K WKURXJKSXW PDVVUHFRYHU\ PDVVRI UHYHQXH SURILW WRFRQFHQWUDWH50F FRQFHQWUDWH t/h % t/h €/h €/h SURILW¼K assumptions: concentrate grade is always 80% operating cost is 60€/h (independent of throughput) WKURXJKSXWWK revenue for concentrate is 20€/t Fig. 5.8: Optimization of an ECS. Optimum throughput is approximately 53t/h. 2QHPHWKRGIRULQFUHDVLQJSODQWSHUIRUPDQFHLVWRUXQWKHPDWHULDOQRWWKURXJKRQHVHSDUDWRU RQO\EXWWKURXJKWZRRUHYHQWKUHHLGHQWLFDOVHSDUDWRUVLQVHULHV7KLVPD\LPSURYHVHSDUDWLRQ UHVXOWV FRQVLGHUDEO\ LQ SDUWLFXODU ZKHQ RGG VKDSHG SDUWLFOHV DUH WR EH VHSDUDWHG E\ (&6 3DUWLFOHVWKDWZHUHQRWLGHDOO\SRVLWLRQHGIRUVHSDUDWLRQRQWKHILUVW(&6JHWD³VHFRQGFKDQFH´ WRILQGWKHLUZD\LQWRWKHFRQFHQWUDWHRQWKHQH[W(&6GRZQVWUHDP7KLVSKLORVRSK\PD\DOVR EHHPSOR\HGIRULPSURYLQJORZVHSDUDWLRQHIILFLHQF\GXHWRRYHUORDGLQJ $VDUXOHRIWKXPERQHPD\DVVXPHWKDWWKHUHFRYHU\RQWKHGRZQVWUHDPGHYLFHLVDWWKHVDPH VHWWLQJ SDUDPHWHUV IRU H[DPSOH VSOLWWHU HGJH DSSUR[LPDWHO\ RI WKH UHFRYHU\ RI WKH XSVWUHDPGHYLFH7KHUHFRYHU\GHFUHDVHVIURPVWDJHWRVWDJHEHFDXVHWKHSDUWLFOHVWKDWDUHPRUH HDVLO\VHSDUDWHGIRUH[DPSOHEHFDXVHWKH\KDYHDIDYRUDEOHVKDSHKDYHDOUHDG\EHHQUHFRYHUHG E\WKHXSVWUHDPGHYLFHV Example: multiple ECS in series The BA fed to the first ECS contained 2% (20 kg/t) fully liberated aluminum particles of which 60% were successfully separated, i.e. metal recovery ECS1=60% (12 kg). On the second device ECS2 one may expect a recovery of 65% of the recovery of ECS1 i.e. 0.65*0.6=39%. At the remaining head grade of 0.8% (=8kg/t) one may therefore expect another 0.39*8=3.1 kg to be recovered to the concentrate. Running the material through ECS2 would increase aluminum recovery from 12 to 15.1 kg per ton of BA processed. A third separation step would add another (20-15.1)*0.39*0.65=1.24 kg. Note, that this algorithm applies only if the metal particles are fully liberated – a small aluminum particle locked in a big slag particle will never be recovered into the concentrate, regardless of the number of ECS in series. )RULPSURYLQJSODQWSHUIRUPDQFHLWPXVWEHILUVWHVWDEOLVKHGZKDWPHFKDQLVPLVOLPLWLQJWKH SHUIRUPDQFH ZLGHSDUWLFOHVL]HGLVWULEXWLRQLQVXIILFLHQWOLEHUDWLRQRYHUORDGLQJWKHHIILFLHQF\ RI VHSDUDWRU LWVHOI SDUWLFOH VKDSH DJJORPHUDWLRQ GXH WR PRLVWXUH« 7KLV UHTXLUHV D JRRG XQGHUVWDQGLQJQRWRQO\RIWKHSURFHVVEXWDOVRRIVHSDUDWLRQWKHRU\8QIRUWXQDWHO\PDQ\SODQWV GR QRW HPSOR\ TXDOLILHG SHUVRQQHO ZLWK D VXIILFLHQW WKHRUHWLFDO EDFNJURXQG HJ LQ EDVLF SK\VLFVWREHDEOHWRLGHQWLI\WKHXQGHUO\LQJUHDVRQRIDQREVHUYHGVHSDUDWLRQSUREOHPDQG GHYLVHDSURSHUDPHOLRUDWLYHVWUDWHJ\,QVWHDGSODQWRSHUDWRUVREWDLQWKHLUNQRZOHGJHDOPRVW H[FOXVLYHO\E\³WULDODQGHUURU´ZKLFKPD\SURYHWREHYHU\FRVWO\WRWKHLUHPSOR\HUV7KH RIWHQKHDUGUHPDUN³2XUSODQWLVSURILWDEOH±VRZK\KLUHDQ H[SHQVLYH« HQJLQHHU"´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³UHFLSHV´KRZRQHPXVW SURFHHGLQRUGHUWRDUULYHDWPHDQLQJIXOUHVXOWV7KHSUREOHPVDVVRFLDWHGZLWKVDPSOLQJDUH x 6DPSOLQJLQWKHILHOG 2EWDLQLQJDUHSUHVHQWDWLYHVDPSOH x 6DPSOHSUHSDUDWLRQDQGDQDO\VLV DUULYLQJDWWKHFRUUHFWUHVXOW 6DPSOLQJSURFHGXUHVIRUEXONVROLGVKDYHEHHQGHYLVHGPRVWO\IRUWKHPLQLQJLQGXVWU\ZKHUH SUHFLVHUHVXOWVDUHRIXWPRVWLPSRUWDQFH7DNLQJLQWRDFFRXQWWKHKXJHPDVVIORZVDVVRFLDWHG ZLWK PLQLQJ VDPSOLQJ LV DQ H[WUHPHO\ HODERUDWH SURFHGXUH ZKLFK LV FDUULHG RXW E\ KLJKO\ VSHFLDOL]HGSHUVRQQHO6XFKSURFHGXUHVDUHQRWSUDFWLFDOIRUVDPSOLQJWKHIHHGDQGSURGXFWVRI D%$SURFHVVLQJSODQW)RUWKHFRQVLGHUDWLRQVLQWKLVFKDSWHULWLVDVVXPHGWKDWWKHIROORZLQJ ERXQGDU\FRQGLWLRQVDSSO\ x 7KHVDPSOHLVEHLQJGUDZQIURPDSLOHRIEXONVROLG x 2QO\WKHFRQWHQWRIQDWLYHPHWDO!PPLVRILQWHUHVW x 7KHDQDO\]HGPHWDOFRQWHQWVKRXOGOLHZLWKLQRIWKHWUXHYDOXH 7KHFHQWUDOREMHFWLYHRIVDPSOLQJEXONVROLGVLVWRREWDLQD³UHSUHVHQWDWLYH´VDPSOHDQGWR SUHSDUHWKHVDPSOHIRUODWHUDQDO\VLVLQVXFKPDQQHUWKDWLWUHPDLQVUHSUHVHQWDWLYH,QWKHFRQWH[W RI%$SURFHVVLQJ³UHSUHVHQWDWLYH´PHDQVWKDWWKHVDPSOHPXVWZLWKLQDVWDQGDUGGHYLDWLRQRI FRQWDLQDVPXFKRIWKHPHWDOLQTXHVWLRQDVWKHZKROHVWRFNSLOHWKDWZDVVDPSOHG 6DPSOLQJRQVLWH :KHQ SUHSDULQJ D VWUDWHJ\ IRU RQVLWH VDPSOLQJ WKH IROORZLQJ WZR TXHVWLRQV QHHG WR EH DGGUHVVHG x +RZPXFKVDPSOHVKRXOGEHREWDLQHG" x ,QZKLFKZD\VKRXOGWKHVDPSOHEHGUDZQ" 2QH RI WKHPRVW FUXFLDO IDFWRUV IRUGHWHUPLQLQJ WKH SUHFLVLRQ RI WKH DQDO\WLFDO UHVXOWLV WKH ³PLQLPXPVDPSOHPDVV´0607KLVLVWKHPDVVRIWKHVDPSOHWREHGUDZQLQRUGHUWREH UHSUHVHQWDWLYHIRUWKHPHWDOFRQWHQWRIWKHVWRFNSLOHDVDZKROH ZLWKLQWKHJLYHQPDUJLQRIHUURU RI 7KLV060GHSHQGVVWURQJO\RQWKHIROORZLQJIDFWRUV x 0D[LPXPVL]HRIWKHPHWDOSDUWLFOHVLQWKHVWRFNSLOH x 0DVVIUDFWLRQRIWKHPHWDOSDUWLFOHVLQWKHVWRFNSLOH x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³7DNHDVPXFKVDPSOHDVIHDVLEOH$QGWKHQVRPHPRUH´ :KHQVDPSOLQJ%$IRUPHWDOFRQWHQWDWDSUHFLVLRQRIRQHFDQGHULYHIURPVDPSOLQJ WKHRU\WKHIROORZLQJHTXDWLRQV ZKLFKLVDOVRSORWWHGLQ)LJ U Z MSM dPD[ HTD d MSM HTE Z PD[ U MSM minimum sample mass [kg] dmax maximum size of metal pieces [m] U density of the metal [kg/m3] Z mass fraction of the metal [-] 7KH060GHSHQGVYHU\VWURQJO\RQSDUWLFOHVL]H 060aGPD[ /DUJHSDUWLFOHVUHTXLUHPXFK PRUH 060 WKDQ VPDOO SDUWLFOHV 'XH WR WKH ³QXJJHW HIIHFW´ WKH 060 DOVR LQFUHDVHV ZLWK GHFUHDVLQJPDVVIUDFWLRQRIWKHPHWDOLQTXHVWLRQ DVDPSOHRI%$UHSUHVHQWDWLYHIRU UDUH JROG FRLQVLVPXFKODUJHUWKDQDUHSUHVHQWDWLYHVDPSOHIRU IDLUO\IUHTXHQW QLFNHOFRLQV EDVHGRQGHQVLW\NJP VDPSOLQJ%$ 060LQNJ PLQLPXPVDPSOHPDVV060LQNJ PD[LPXPVL]HRIPHWDOSDUWLFOHLQPP PD[LPXPVL]HRIPHWDOSDUWLFOHLQPP Fig. 6.1: The minimum sample mass MSM as a function of the maximum size of the metal particles at various mass fractions of metal w=0.1%...10%. For a given metal the MSM read from the graph must be multiplied with the density of the metal in multiples of 1’000 kg/m3. The MSM for copper (density=9’000 kg/m3) with maximum particle size 10 mm and a mass fraction of 1% the MSM would be 2.5kg*9’000/1000=22.5kg (left). Assuming typical concentrations of metals in BA, the required MSM can be estimated from the graph (right). Example 1: A size fraction 0-16 mm of BA needs to be sampled for aluminum. It is estimated that the BA contains approximatelyZ=2% aluminum particles. The density of aluminum is U=2’700 kg/m3. The minimum sample mass MSM is calculated as MSM = 25*2’700*0.0163/0.02=13.8 kg. Example 2: The residue of a processed BA 0-64 mm is to be sampled for residual copper potential (i.e. pieces >2mm). The density of copper is 9’000 kg/m3. Assuming that all copper pieces >6 mm have been successfully recovered by the eddy current separators, the maximum size of copper particles in the residue is 6 mm (despite the maximum size of the mineral material being 64 mm). Further assuming that, of the 0.5% copper present in the feed an estimated 50% had been recovered in the NF concentrate, leads to approximately 0.25% native copper in the residue. The minimum sample mass is therefore MSM=25*9’000*0.0063/0.0025=19.4 kg. ,IWKHDFWXDOVDPSOHPDVV0 GLIIHUVIURPWKH060WKHHUURUWREHH[SHFWHGLVHVWLPDWHGDV IROORZV HT ͲǤͳכ כܯȀܯܵܯߝൌඥ MSM minimum sample mass with implicit error H=10% [kg] M* sample mass actually drawn [kg] H error to be expected $VVXPLQJWKDWLQWKHDERYH([DPSOHLQVWHDGRI060 NJIRUH[DPSOH0 NJKDG ͲǤͳ ൌ ǤͺΨ 9LFH YHUVD כ DFWXDOO\ EHHQ GUDZQ WKH HUURU ZRXOG EH UHGXFHG WR ඥͶȀͳͲͲ SUHFLVLRQGHFUHDVHVZLWKWKHVTXDUHURRWRIWKHVDPSOHPDVV Fig. 6.2: Segregation according to particle size. Big particles fly farther than small particles of same initial horizontal velocity (left). Big particles accumulate at the foot of the pile and small ones in the center (right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³PLQLPXP VDPSOHPDVV´060 7KLV SURFHGXUH LV UHSHDWHG SHULRGLFDOO\DVWKHSLOH JURZVIRUH[DPSOH LQ LQWHUYDOV 7KH VDPSOHVWKXVREWDLQHGDUHFRPELQHGWKRURXJKO\KRPRJHQL]HGDQGWKHQJUDGHGWRIRUPDEHG DSSUR[LPDWHO\PPKLJK)URPWKLVEHGVDPSOHVZLWKHDFKRIWKH060DUHGUDZQ DWUDQGRPWRSURGXFHRQHUHSUHVHQWDWLYHVDPSOHRI0602EYLRXVO\RYHUVL]HPHWDOSLHFHV ZLWKUHJDUGWRWKHFRUUHVSRQGLQJ060 DUHUHPRYHGHLWKHUE\VFUHHQLQJRUE\KDQGSLFNLQJ DQGGLVFDUGHG7KLVVDPSOHLVUHIHUUHGWRDVWKH³VWRFNSLOHVDPSOH´ZKLFKLVIXUWKHUSURFHVVHG LQWKHODERUDWRU\,ISRVVLEOHDWDOODVHFRQGVDPSOHRIHTXDOPDVVVKRXOGEHGUDZQDVDUHWDLQLQJ VDPSOHLQFDVHWKHUHVXOWVRIWKHILUVWVDPSOHDUHLQFRQFOXVLYHRULWLV±DIWHUDQDO\VLV±GLVFRYHUHG WKDWWKHVDPSOHPDVVZDVWRRORZWRPHHWWKHPLQLPXPSUHFLVLRQGHPDQGHG $QDO\VLVRIWKHVWRFNSLOHVDPSOH 2QFHDUHSUHVHQWDWLYHVWRFNSLOHVDPSOHLVGUDZQ IRUH[DPSOHNJ LWQHHGVWREHIXUWKHU SURFHVVHGLQWKHODEIRUGHWHUPLQLQJPHWDOFRQWHQW7KHUHDUHWKUHHGLIIHUHQWDSSURDFKHV x &KHPLFDODQDO\VLV LQFOXGLQJILQHJULQGLQJ x )LUH$VVD\ VPHOWLQJ x 6HOHFWLYHFRPPLQXWLRQ ³807(&´PHWKRG &KHPLFDODQDO\VLV ,QDPRGHUQODEIRUDQDO\WLFDOFKHPLVWU\PHWDOFRQWHQWLVDQDO\]HGE\IRUH[DPSOH;5),&3 RU$$6ZKLFKUHTXLUHDSSUR[LPDWHO\JPDWHULDORQO\7KHSUREOHPLQWKLVFDVHLV³VDPSOH UHGXFWLRQ´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±LIDSSOLHGWR%$ ±DFRSSHUFRQWHQWWKDWLVRQO\RIWKHWUXHYDOXHLHWKH\ZRXOGEHFRPSOHWHO\RIIWKHPDUN 7KHUHDVRQEHLQJWKDWFRSSHU±LQWKHIRUPRIQDWLYHPHWDO±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³EDFNJURXQGFRQFHQWUDWLRQ´ RIFRSSHUEHLQJSUHVHQWDVR[LGH LQ%$W\SLFDOO\DURXQG¶PJNJ DFFRUGLQJWR)LJ DQGRFFDVLRQDOH[WUHPHO\KLJKYDOXHVLIDSLHFHRIQDWLYHFRSSHURIIRUH[DPSOHPP LQVL]HZDVLQFRUSRUDWHGLQWKHJVDPSOH HJ¶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kg 600g jawcrusher ballmill sieve sieve discmill discmill 2mm 0.3mm fireassay chemicalanalysis 2g chemicalanalysis Fig. 6.3: Reduction of a 20 kg sample for chemical analysis. The coarse fractions from the sieves can be either ground in special mills and then remixed into the fine fraction or they can be analyzed as a whole, for example by fire assay or chemical analysis. $OWHUQDWLYHO\WKHFRDUVHPHWDOIUDFWLRQ !PP FRXOGEHGLJHVWHGDVDZKROHLQDFLGVDQG WKHQWKHVROXWLRQEHDQDO\]HG7KLVLVJHQHUDOO\IHDVLEOHRQO\IRUTXDQWLWLHVOHVVWKDQJ)RU ODUJHUTXDQWLWLHVRQHPD\VXEMHFWWKHVDPSOHWRDILUHDVVD\DVGLVFXVVHGEHORZ7KLVKDVWKH DGGHGDGYDQWDJHRIPHDVXULQJWKHFRQWHQWRIPHWDOVLQWKHLUQDWLYHIRUP DQGQRWIRUH[DPSOH R[LGHV ,QVXPPDU\FRQYHQWLRQDOVDPSOHUHGXFWLRQSURFHGXUHVIRUSURYLGLQJDQDO\VLVVDPSOHVIURP %$DUHXQVXLWDEOHDQGZLOOSURGXFHZURQJUHVXOWV0RUHRYHUDFRQYHQWLRQDOFKHPLFDODQDO\VLV FDQQRWGLVWLQJXLVKEHWZHHQ³QDWLYHPHWDO´DQG³FKHPLFDOO\ERXQGPHWDO R[LGH ´EXWZLOO\LHOG D³WRWDOPHWDO´UHVXOW$VKDVDOUHDG\EHHQSRLQWHGRXW )LJ RQO\WKHQDWLYHPHWDOFRQWHQW LV RI LQWHUHVW 7KH WRWDO PHWDO DQDO\VLV LV ± IURP WKH WHFKQLFDOHFRQRPLF SRLQW RI YLHZ ± LUUHOHYDQW )LUHDVVD\ ,IFDUULHGRXWFRUUHFWO\ILUHDVVD\VDUHDUREXVWPHWKRGIRUGHWHUPLQLQJWKHFRQFHQWUDWLRQRI PHWDOVEHLQJSUHVHQWLQWKHLUQDWLYHIRUP+RZHYHUILUHDVVD\VDUHQRWSUDFWLFDOZLWKVDPSOHV RI±IRUH[DPSOHWHQVRUHYHQKXQGUHGVRINLORJUDPVRIPLQHUDOPDWWHUFRQWDLQLQJDIHZSHUFHQW RIQDWLYHPHWDO 6PHOWLQJLVWKHUHIRUHOLPLWHGWRDVVD\VRIFRQFHQWUDWHVZKHUHWKHPHWDOVDUHSUHVHQWLQDKLJKO\ HQULFKHGIRUP$VVXPHJRIDFRQFHQWUDWHRI+1)LVWREHDQDO\]HGIRUWKHFRQWHQWVRI FRSSHU]LQFVLOYHUDQGJROG7KHPDWHULDOLVILUVWPL[HGZLWKDIOX[ HJERUD[ DQGWKHQKHDWHG LQDFUXFLEOHWRDSSUR[LPDWHO\¶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ig. 6.4: Fire assay of 250g HNF concentrate from BA. The slag collects on top of the metal regulus (right). After the regulus has been sawed in half the surface can be analyzed for example by spark emission spectroscopy. 6HOHFWLYHFRPPLQXWLRQ 7KLV PHWKRG ± DOVR NQRZQ DV WKH ³807(&PHWKRG´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³VHOHFWLYHFRPPLQXWLRQ´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nd sample stage reduction 2nd sample Fig. 6.5: Simplified schematic of metal analysis making use of selective comminution. 1)PPLVVHSDUDWHGZLWKJUDYLW\FRQFHQWUDWLRQSURFHVVHVIRUH[DPSOHRQDMLJ1)PP FDQEHOLNHZLVHVHSDUDWHGE\JUDYLW\FRQFHQWUDWLRQLQDJROGSDQRUE\ZD\RIKHDY\PHGLD VHSDUDWLRQ LQ D VRGLXP WXQJVWDWH VROXWLRQ DW D GHQVLW\ RI JFP ,I WKH FRQWHQW RI WKH LQGLYLGXDOPHWDOVLQWKH+1)LQSDUWLFXODUWKDWRISUHFLRXVPHWDOVQHHGVWREHGHWHUPLQHGD UHSUHVHQWDWLYHVDPSOHRIWKH+1)LVVXEMHFWHGWRDILUHDVVD\ )( 1) Fig. 6.6: Metals from selective comminution of BA: FE and NF 8-32 mm (left). NF on a 2 mm sieve (right). Note that the NF particles were flattened when passed through the jaw crusher (left) or roll mill (right). VDPSOLQJ+1)IRUSUHFLRXVPHWDOV 060LQNJ PD[LPXPVL]HRIPHWDOSDUWLFOHLQPP Fig. 6.7: The minimum masses required when sampling HNF concentrates for precious metals. 'XHWRWKHQXJJHWHIIHFWWKH060IRUGHWHUPLQLQJSUHFLRXVPHWDOVLQ%$LVPXFKKLJKHUWKDQ WKDWIRUWKH³PDVVPHWDOV´ VHH)LJULJKW $QHVWLPDWHRIWKH060IRUD1)FRQFHQWUDWH ZLWK UHVSHFW WR JROG FRQWHQW FDQ EH GHULYHG IURP WKH IROORZLQJ FRQVLGHUDWLRQV $V VWDWHG SUHYLRXVO\ WKH UDWLR RI FRSSHU VLOYHU JROG LQ %$ PP LV W\SLFDOO\ LQ WKH RUGHU RI ¶ « «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xample: How much sample of HNF<1 mm (from BA) needs to be drawn if an error of ±20% in the result for gold analysis by fire assay is tolerated? Taking eq. 5.2 leads to MSM/M*=(0.2/0.1)2=4. Reading from Fig. 6.7 MSM=10 kg it is calculated that M* = 2.5 kg. ,IWKH1)PHWDOFRQWHQWRIDUDZ%$QHHGVWREHGHWHUPLQHGWKH060LVLQWKHRUGHURINJ RUPRUH,QWKLVFDVHLWPD\EHSUHIHUDEOHWRSURFHHGZLWKWKHILUVWVWHSRIVDPSOHUHGXFWLRQRQ VLWH7KHPDWHULDO HJNJ LVVSUHDGRXWDQGUXQRYHUVHYHUDOWLPHVZLWKDZDONEHKLQG FRPSDFWRU HJYLEUDWLQJSODWHWDPSHURUUROOHU 7KHQLWLVFODVVLILHGDWDSSUR[LPDWHO\PP HLWKHUZLWKDVLHYHRUZLWKDUDNHDQGWKHFRDUVHIUDFWLRQLVUHSHDWHGO\UXQRYHUDJDLQZLWKWKH FRPSDFWRUXQWLODOOPLQHUDOPDWHULDOLVFRPPLQXWHGWR PP7KHPDWHULDO!PP±FRPSULVHG HVVHQWLDOO\RIPHWDOV±LVUHFRYHUHGIRUODWHUVHSDUDWLRQLQWRLQGLYLGXDOVL]HIUDFWLRQV7KH060 RIWKHPDWHULDO PPLVGHWHUPLQHG HJNJ DQGDUHSUHVHQWDWLYHVDPSOHGUDZQIRUIXUWKHU VDPSOHUHGXFWLRQLQWKHODE $OWKRXJKWKHGHWHUPLQDWLRQRI1)FRQWHQWRIWKHUHVLGXHIURPD%$SURFHVVLQJRSHUDWLRQLV FUXFLDOIRUDVVHVVLQJSODQWSHUIRUPDQFHWKLVLVUDUHO\GRQHEHFDXVHRQO\IHZODERUDWRULHVKDYH ERWKWKHNQRZKRZDQGWKHKDUGZDUHWRFDUU\RXWVXFKWHVWV$WOHDVWWKHRSHUDWRUVRIKLJK YROXPHSODQWVVKRXOGFRQVLGHUGHYHORSLQJWKHLURZQ³ILHOGSURFHGXUHV´DORQJWKHOLQHVRIWKH GLVFXVVHG ³VHOHFWLYH FRPPLQXWLRQ´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¼DQG86DUHDSSUR[LPDWHO\DWSDULW\ (VWLPDWHRIUHYHQXHIRU1)FRQFHQWUDWHV 7DEOH LV DQ RYHUYLHZ RI WKH PHWDO FRQWHQWV DQG YDOXHV DVVXPHG IRU WKH HFRQRPLF FRQVLGHUDWLRQVGLVFXVVHGLQWKLVFKDSWHU7KHRYHUDOOYDOXHRIWKHPHWDOVLQ%$LVLQWKHRUGHU RI¼WRIZKLFKVWHPVIURPWKH1):KLOHWKH+1)FRQWULEXWHRQO\E\ZHLJKWWR WKHWRWDOPHWDOFRQWHQWDSSUR[LPDWHO\RIWKHWRWDOPHWDOYDOXHFRQWDLQHGLQWKH%$OLHVLQ WKH+1) Table 7.1: Contents and values of metals in BA (pieces >2mm) PHWDO %$ NJW%$ ¼NJ YDOXH¼W%$ RIWRWDOPHWDOYDOXH /1) DOXPLQXP FRSSHU VWDLQOHVV ]LQF +1) OHDG JROG VLOYHU total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¼JLYHVWKHYDOXHRI+1)DV¼NJ1RWHWKDWWKLVDSSOLHVWRWKHYDOXHRI WKH+1)SURYLGHGLWVFRPSRVLWLRQLVDVVKRZQLQ7DEOH7KH+1)FRQFHQWUDWHDFWXDOO\ GHULYHGIURP%$SURFHVVLQJKDVDGLIIHUHQWFRPSRVLWLRQ%HFDXVHWKHKLJKHUYDOXHPHWDOV &X $X DUHVRPHZKDWGHSOHWHGLQWKHFRDUVHVL]HUDQJHZKLOHORZYDOXH+1)OLNH66DQGEUDVVDUH HQULFKHGWKHYDOXHSHUNJRI+1)UHFRYHUHGLQWKHFRQFHQWUDWHLVORZHUWKDQWKDWSHUNJRI+1) RULJLQDOO\SUHVHQWLQWKH%$7KHUHIRUHRQHFDQXVHWKHPDUNHWSULFHRIWKHFRSSHU LQ7DEOH WKLVLV¼NJ DVDIDLUO\SUHFLVHHVWLPDWRUIRUWKHDYHUDJHPHWDOYDOXHFRQWDLQHGLQD+1) FRQFHQWUDWH 7KHVDOHVSULFHRIWKH1)LVJHQHUDOO\OLQNHGWRWKHPHWDOSULFHVSXEOLVKHGE\WKH/0( /RQGRQ 0HWDO([FKDQJH %XWVLQFHWKHFRQFHQWUDWHQHHGVWREHIXUWKHUSURFHVVHG LQVLQNIORDWSODQWV DQGVPHOWHUV WRGHOLYHUWKHPHWDOVLQWKHIRUPRIEXOOLRQWKHSULFHDFWXDOO\SDLGE\WKHVLQNIORDW SODQWVRUVPHOWHUVIRUWKHPHWDOFRQWHQWRIWKH1)FRQFHQWUDWHLVRQO\DSSUR[LPDWHO\RIWKH /0(QRWDWLRQ7KHVDOHVSULFHWREHH[SHFWHGSHUNJ1)FRQFHQWUDWH DVVXPLQJ/1) +1) LVWKHUHIRUHHVWLPDWHGDVIROORZV 0DVVEDODQFH NJ1) NJPLQHUDOV NJFRSSHUNJDOXPLQXP /0(SULFHV /0(1) /0(FRSSHU /0(DOXPLQXP VDOHVSULFH VDOH1) /0(1) /0(FRSSHU /0(DOXPLQXP Example: Estimate the sales price for 100t NF concentrates (LNF+HNF) from a BA processing operation on the basis of LMEcopper=6’000 €/t and LMEaluminum=2’000€/t. The estimate is 0.11*6’000+0.34*2’000 = 134’000 €. PHWDOSULFHV/0( 86NJ FRSSHU DOXPLQXP ]LQF Fig. 7.1: The development of metal prices over the past 16 years. &RVWVWUXFWXUHVRIGU\DQGZHWSURFHVVLQJSODQWV $QH[DPSOHIRUWKHFRVWVWUXFWXUHRIDGU\%$SURFHVVLQJSODQWLVVKRZQLQ7DEOH XSSHU WDEOH ,WLVDVVXPHGWKDWWKHODQGILOOIHHLV¼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able 7.2: cost/revenue structure of BA processing operations dryprocessing&landfill basedata cost annualthroughput 90'000 t/a payoffcapex 500'000 €/year contentFEmetal>2mminBA 7.0% interest(0.5×capex×interest) 150'000 €/year contentNFmetal>2mminBA 2.6% maintenace(8%ofcapex) 240'000 €/year recoveryFEmetal>2mminconcentrate 80% energy(10kWh/t@0.15€/kWh) 135'000 €/year recoveryNFmetal>2mminconcentrate 45% labor 540'000 €/year revenueFEmetal 100 €/t overhead,chem.analyses… 450'000 €/year revenueNFmetal* 1'800 €/t 2'015'000 €/year landfillfeeforrawBA(incl.transport) 28 €/t 22.4 €/ton disposalofprocessedBA(incl.transport) 28 €/t capex:10'000îthroughput^0.5 3'000'000 € revenue payoffperiod(linear) 6 years saveddisposalfees 227'472 €/year interestrate 10% revenueFEmetal 504'000 €/year costlabor;6×throughput 540'000 €/year revenueNEmetal 1'895'400 €/year costoverhead…:1500×throughput^0.5 450'000 €/year 2'626'872 €/year 29.2 €/ton *Basedon"metalrecovery"i.e.1tpuremetal(nominerals).Thisis profit 611'872 €/year equivalentto1'800*0.75=1'350€/tof1.33tconcentrateincl.25%minerals) 6.8 €/ton wetprocessing&recycle basedata cost annualthroughput 90'000 t/a payoffcapex 750'000 €/year contentFEmetal>2mminBA 7.0% interest(0.5×capex×interest) 225'000 €/year contentNFmetal>2mminBA 2.6% maintenace(8%ofcapex) 360'000 €/year recoveryFEmetal>2mminconcentrate 80% energy(10kWh/t@0.15€/kWh) 135'000 €/year recoveryNFmetal>2mminconcentrate 45% labor 540'000 €/year revenueFEmetal 100 €/t overhead,chem.analyses… 450'000 €/year revenueNFmetal 1'800 €/t disposalof10%sludge 252'000 €/year landfillfeeforrawBA(incl.transport) 28 €/t add.operatingcostwetproc. 1'260'000 €/year disposalofprocessedBA(incl.transport) 5 €/t 3'972'000 €/year capex:15'000×throughput^0.5 4'500'000 € 44.1 €/ton payoffperiod(linear) 6 years revenue interestrate 10% saveddisposalfees 2'155'620 €/year costlabor:6×throughput 540'000 €/year revenueFEmetal 504'000 €/year costoverhead…:1500×throughput^0.5 450'000 €/year revenueNEmetal 1'895'400 €/year additionaloperatingcostwetprocessing 14.0 €/t 4'555'020 €/year 50.6 €/ton profit 583'020 €/year 6.5 €/ton 7KH LQWHUUHODWLRQ EHWZHHQ WKURXJKSXW DQG SURILW LV VKRZQ LQ )LJ SURILW LQFUHDVHV ZLWK WKURXJKSXW$WDWKURXJKSXWRI ¶WDDSURILWRI¼WPD\EHH[SHFWHG$SODQWZLWK GRXEOHWKHWKURXJKSXWPD\H[SHFWWKHSURILWWRLQFUHDVHE\WR¼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x FRQWHQW1)LQWKHIHHG x 1)PHWDOUHFRYHU\ x /0(1) ¶¼W )RUDSODQWZLWKDQDQQXDO ¶WWKURXJKSXWWKHLQFUHDVHRIDPHUHLQDQ\RIWKHVH SDUDPHWHUVZRXOGERRVWSURILWE\DSSUR[LPDWHO\,IDOOWKUHHSDUDPHWHUVDUHVLPXOWDQHRXVO\ LQFUHDVHGE\WKHSURILWZRXOGPRUHWKDQGRXEOH7KHWUHDWPHQWFRVWIRUWKHSODQWSURGXFLQJ ¶WDLV¼WRIZKLFKDSSUR[LPDWHO\LVIL[HGFRVWV:LWKIL[HGFRVWVWKLVKLJKWKH SODQWVKRXOGEHUXQLQDWOHDVWWZRVKLIWVLQRUGHUWRPD[LPL]HSURILW 7KHORZHUSDUWRIWDEOHLVDEUHDNGRZQRIFRVWDQGUHYHQXHIRUDZHWSURFHVVLQJSODQWZKHUH PRVWRIWKHUHVLGXHLVXVHGIRUURDGFRQVWUXFWLRQDQGRQO\QHHGVWREHODQGILOOHG WKHILOWHU FDNH ,WLVDVVXPHGWKDWWKH%$UHVLGXH DIWHUSURFHVVLQJ LVGHOLYHUHGWRWKHFXVWRPHUDWQR FRVW ¼W EHLQJ WKH FRVW RI WKH WUDQVSRUW )RU D ZHW SURFHVVLQJ SODQW ERWK FDSLWDO DQG RSHUDWLRQDOH[SHQGLWXUHDUHKLJKHUWKDQIRUDGU\SURFHVVLQJSODQW&RQVHTXHQWO\WKHFRVWSHU WRQRISURFHVVHGPDWHULDOLVDERXWGRXEOHDVKLJK ¼YV¼ )LJ VXJJHVWV WKDW JHQHUDOO\ D ZHW SURFHVVLQJ RSHUDWLRQ LV PRUH IDYRUDEOH DW KLJK WKURXJKSXWVZKLOHORZWKURXJKSXWZRXOGIDYRUDGU\SURFHVVLQJRSHUDWLRQ1RWHWKDWWKHZHW SURFHVVLQJRSHUDWLRQUHFRYHUVDSSUR[LPDWHO\KDOIRIWKHUHYHQXHIURPDYRLGHGGLVSRVDOFRVW :HWSURFHVVLQJPD\WKHUHIRUHEHIDYRUDEOHZKHUHODQGILOOLQJLVH[SHQVLYH 12 2.6%NF 45%NFrecovery 10 1350€/tNFconc. 8 €/t 6 profit, 4 wetprocessing&recycle 2 dryprocessing&landfill 0 50 100 150 200 annualthroughput,1'000t Fig. 7.2 The profit gained from BA processing depends considerably on the throughput of the plant. 5HOHYDQFHRIPHWDOSULFHVIRUWKHUHFRYHU\RIPHWDOVIURP%$ :LWK D JLYHQ %$ ERWK PHWDO UHFRYHU\ DQG /0( SULFH DIIHFW WKH SURILWDELOLW\ RI WKH %$ SURFHVVLQJRSHUDWLRQVLJQLILFDQWO\:KLOHSODQWRSHUDWRUVKDYHQRLQIOXHQFHRQWKH/0(PHWDO SULFHVWKH\FDQ±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¼NJ /RZUHFRYHULHVDUHWKHFRQVHTXHQFHRIORZWHFKHTXLSPHQWIRUH[DPSOHWKHLQVWDOODWLRQRIMXVW RQHRYHUKHDGPDJQHW7KLVGHYLFHPD\UHFRYHURIWKH)(DWDFRVWRIRQO\¼W EXWQR 1) ,ILQVWHDGDORZWHFKPRELOHSURFHVVLQJXQLWZDVXVHG RQHGUXPPDJQHWRQH(&6VRPH KDQGSLFNLQJ RQHPD\H[SHFWD)(UHFRYHU\RIDQGD1)UHFRYHU\RIDWDFRVWRI ¼W)RUDSODQWDVVKRZQLQWKHXSSHUSDUWRI7DEOHWKHUHFRYHU\RI1)KDGEHHQDVVXPHG DQGWKDWRI)(DWDFRVWRI¼W$KLJKWHFKSODQWWKDWIRUH[DPSOHHPSOR\VD VHQVRUVRUWHUDVVKRZQLQ)LJ DGYDQFHGIORZVKHHW PD\UHFRYHURIWKH1)DQG )(DWDFRVWRI¼W*RLQJWRWKHH[WUHPHWKHUHFRYHU\RI 1)ZRXOGUHTXLUHLQDGGLWLRQ WRWKHVHQVRUVRUWHUDWZRVWHSFRPPLQXWLRQDQGVHYHUDOSDUDOOHOWUDLQVRI/,06+,06DQG (&6 LQ VHULHV UDLVLQJ WKH FRVW WR ¼W RI %$ SURFHVVHG :LWK LQFUHDVHG UHFRYHU\ WKH FRPSOH[LW\RIWKHSODQWDQGWKHUHVSHFWLYHFRVWSHUWRQSURFHVVHGLQFUHDVHVLQLWLDOO\LQDPRUH RUOHVVOLQHDUIDVKLRQEXW±DVUHFRYHU\LVDSSURDFKHG±H[SRQHQWLDOO\ 7KHUHYHQXHIURPWKHVDOHRIWKH1)FRQFHQWUDWHLQFUHDVHVLQDOLQHDUIDVKLRQZLWKWKHDPRXQW RI1)H[WUDFWHGLHOLQHDUO\ZLWK1)UHFRYHU\&RQVHTXHQWO\WKHSURILWEHLQJUHYHQXHPLQXV FRVWLQLWLDOO\LQFUHDVHVXQWLODPD[LPXPLVUHDFKHGDQGWKHQUDSLGO\GHFOLQHV7KHPD[LPXP RIWKHSURILWFXUYHLVWKHUHFRYHU\WKDWWKHSODQWVKRXOGEHGHVLJQHGIRU LHDURXQGLQ)LJ OHIW 50 45 40 40 35 30 30 25 revenue 3.2€/kgNF BA BA 20 cost 20 1.8€/kgNF €/t profit €/t 15 0.9€/kgNF 10 10 0 5 0 Ͳ10 Ͳ5 0% 20% 40% 60% 80% 100% 0% 20% 40% 60% 80% 100% recoveryNFmetals recoveryNFmetals Fig. 7.3: Development of cost and revenue depending on the recovery of NF (left). The profit optimum is at approximately 50%. This optimum not only increases with increasing NF prices but also shifts towards higher recoveries (right). Table 7.3: The data plotted in Fig. 7.3 12 345 6789 10 costpertmetalcontent metalcontent 0.1€/kg 0.028€/kg 1.8€/kgNF total profit profit profit processed NF:26kg/tBA FE:70kg/tBA revenueFE saveddisp.fee revenueNF revenue at1.8€/kgNF at0.9€/kgNF at3.6€/kgNF €/tBA NFrecovery FErecovery €/tBA €/tBA €/tBA €/tBA €/tBA €/tBA €/tBA 1 0% 50% 3.50 1.31 0.00 4.81 3.81 3.8 3.8 11 20% 70% 4.90 2.02 9.36 16.28 5.28 0.6 14.6 22.4 45% 80% 5.60 2.53 21.06 29.19 6.79 Ͳ3.7 27.8 38 70% 90% 6.30 3.03 32.76 42.09 4.09 Ͳ12.3 36.9 65 93% 98% 6.86 3.46 43.52 53.85 Ͳ11.15 Ͳ32.9 32.4 ,WLVLPSRUWDQWWRQRWHWKDWWKHVHFRQVLGHUDWLRQVSHUWDLQWRWKHGHVLJQRIDnewSODQW)RUDQ H[LVWLQJSODQWWKDWKDGEHHQGHVLJQHGIRUDKLJKHUUHFRYHU\LWZRXOGRQO\PDNHVHQVHWRUXQ WKLV SODQW DW ORZHUWKDQ GHVLJQ UHFRYHULHV LIWKH YDULDEOH FRVWV ZHUH VLJQLILFDQWO\ GHFUHDVHG ZKLFKLVUDUHO\WKHFDVHRQFHWKHHTXLSPHQWKDVEHHQLQVWDOOHG 1)UHYHQXHQRWRQO\GHSHQGVRQ1)UHFRYHU\EXWDOVRRQ/0(SULFHV)LJ ULJKW VKRZV ZKDWZRXOGKDSSHQLIWKHDVVXPHGUHYHQXHRI¼NJ1)ZDVLQFUHDVHGRUGHFUHDVHGE\D IDFWRURI,IWKH1)SULFHZDVDVORZDV ¼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Ä3UHFLRXVPHWDOVDQGUDUHHDUWKHOHPHQWVLQPXQLFLSDOVROLGZDVWH±6RXUFHV DQGIDWHLQD6ZLVVLQFLQHUDWLRQSODQW³ :DVWH0DQDJHPHQW SS >@ =HOWQHU&K ³(LVHQLQ.9$6FKODFNHQ´'LSORPDUEHLW(7+ >@ 0XFKRYD/ :HWSK\VLFDOVHSDUDWLRQRI06:,ERWWRPDVK'LVVHUWDWLRQ ,6%1 >@ 0HLQIHOGHU 7 5LFKHUV 8 (QWVRUJXQJ GHU 6FKODFNH DXV GHU WKHUPLVFKHQ 5HVWDEIDOOEHKDQGOXQJ³ )RUVFKXQJV]HQWUXP .DUOVUXKH :LVVHQVFKDIWOLFKH %HULFKWH )=.$-XOL >@ 3 /HFKQHU 3 0RVWEDXHU . %|KP Ä*UXQGODJHQ IU GLH 9HUZHUWXQJ YRQ 09 5RVWDVFKH³%2.8:LHQ >@ $OZDVW+5LHPDQQ$ Ä9HUEHVVHUXQJGHUXPZHOWUHOHYDQWHQ4XDOLWlWHQYRQ6FKODFNHQ DXV$EIDOOYHUEUHQQXQJVDQODJHQ³8%$)% ,661 PERFORMANCE neutral Drucksache No. 01-16-942492 – www.myclimate.org © myclimate – The Climate Protection Partnership