PROJECT METALLURGIST

Comparison between
conventional and split
circuits: Iron behaviors,
Reagent consumptions
and Equipment sizes

KAFUMBILA KASONTA JOSEPH

2022
Comparison between conventional and split circuits: Iron behaviors, Reagent
consumptions and Equipment sizes
© Joseph Kafumbila 2022
[email protected]

Joseph Kafumbila Page 1

 Process simulation
Chemical engineering can be defined from many different aspects. However, all
the scientists and professionals agree that the process is the center of it. To make a
distinction from any other discipline, the role of chemical engineering could be defined
with its purpose to develop, design, construct, control, optimize and mange any process
involving physical and/or chemical changes and make this process profitable.

Process simulation as discipline uses mathematical models as basis for analysis

prediction, testing, detection of a process behavior unrelated to whether the process is
existing in reality or not. Process simulation is there to increase the level of knowledge
for a particular process and chemical engineering in general.

So, when those two concepts are put together, we can look into the chemical
engineering as a discipline defining how the process should be developed and
simulation as the tool helping us to explore the options. Chemical engineering needs to
know how the process should be designed while chemical engineers use the simulation
to explore all the process design options and define the optimal one.

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 Abstract
The region of Copper-belt areas of Zambia and the Democratic Republic of
Congo (DRC) remains an important resource for copper and cobalt for future years. The
production plant of copper and cobalt follows the hydrometallurgical route. The
mineralogy of ores in this area is typically associated with high gangue acid
consumption during the leaching process. The idea is to minimize the acid concentration
in the water balance bleed to decrease plant acid consumption. One of the ways for acid
concentration minimization in this bleed stream is to use the split circuit.

The goal of this publication is to compare the conventional circuit and two split
circuits (with different and same organic phase for HG and LG circuits). The simulation
is done by using Realistic Simulation Model (RSM) that can simulate the saturation
concentrations of Gypsum and Copiapite and the effect of other ions, phosphate anion
and dithionate anion on Copper and Iron solvent extraction recoveries. The simulation
constraint is that Equipment sizes of unit operations having the same functionality are
the same all plant configurations.

The simulation results show that the sulfate in the leach circuit comes from
concentrated acid and SO2. The increase of extractant volume percent in the organic in
HG circuits of split circuits comparatively to conventional circuit increases the solvent
extraction efficiency of Fe(3). Therefore the copper electrowinning acid consumption
increases. There is an increase of lix984N and Kerosene consumptions in split circuits
comparatively to conventional circuit. These erase the reduction in acid consumption
cost provided by the split circuit. Split circuits comparatively to conventional circuit
have low CAPEX.

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 SUMMARY
Table A: Iron behaviors the configurations

Conventional Split circuit Split circuit

circuit with different with same
organic phase organic phase
Saturation concentration No Yes Yes
Leach circuit Fe(2) g/L 1.131 1.511 1.505
Fe(3) g/L 0.062 0.084 0.085
Fe(3) g/L 0.050 0.090 0.091
PO4 g/L 0.994 1.803 1.798
S2O6 g/L 9.041 19.811 19.740
HGPLS Ac g/L 2.834 3.821 3.956
Extractant v/v% 18.34 22.95 27.16
LO/ML 0.700 0.715 0.800
Cu/Fe 1453 1022 847
Fe(3) g/L 0.040
PO4 g/L 0.861
S2O6 g/L 9.468
LGPLS Ac g/L 1.828
Extractant v/v% 13.47
LO/ML 0.745
Cu/Fe 1023
Leach Kg/ton feed 53.22 50.59 50.68
Acid consumption
CuEW Kg/ton feed 1.86 3.04 3.36

 Cu/Fe in HGE1 increases with the increase of v/v% of extractant.

 Cu/Fe in LGE1 increases with the decrease of Ac, S2O6 and PO4 concentrations.
 Acid consumption in CuEW increases with the decrease of Cu/Fe.

Table B: Annual Copper production and reagent consumptions for all plant
configurations

Conventional Split circuit with Split circuit with

circuit different organic same organic
phase phase
Copper production 92 055 92 431 92 836 Ton/year
Elementary sulfur 173 707 168 215 168 984 Ton/year
Flocculants 928 928 928 Ton/year
Lix984N 190 201 287 Ton/year
Kerosene 725 742 663 Ton/year
Guar 18 18 19 Ton/year

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 Table C: Number of unit operations in the plant configurations and the first fill

Conventional Split circuit with Split circuit with

circuit different organic same organic
phase phase
Mixers and settler unit operation 16 14 12
Aqueous coalescing tank 4 4 2
Organic surge tank 4 4 2
Lix984N - first fill 730 710 779 ton
Kerosene - first fill 2 792 2 636 1801 ton

 Other unit operations have the same number in plant configurations

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 Contents

1. Introduction 8
1.1. Concept and advantageous 8
1.2. Copper and cobalt projects 9
1.3. Publication goals 10
2. Split circuit configurations 12
2.1. Type of wash solution 12
2.2. Type of Copper SX configuration 12
3. Split circuit parameters 15
3.1. Split value 15
3.2. High grade transferred copper percent 15
4. Realistic Simulation Model (RSM) 16
4.1. Characterization of pulp 16
4.2. Specific gravity 16
4.2.1. Solid specific gravity 16
4.2.2. Liquid specific gravity 18
4.3. Soluble compounds 19
4.3.1. Activity of soluble species 19
4.3.2. Concentration of soluble species 20
5. Conventional circuit 29
5.1. Configuration 29
5.1.1. Flow diagram 29
5.1.2. Plant description 31
5.2. Mass balance 31
5.2.1. Design criteria 31
5.2.2. Mass balance results 37
5.3. Reagent consumption 38
5.3.1. Design criteria 38
5.3.2. Results 40
5.4. Equipment size 41
5.4.1. Design criteria 41

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 5.4.2. Equipment sizing 48
6. Split circuit – different organic phase 50
6.1. Configuration 50
6.1.1. Flow diagram 50
6.1.2. Plant description 53
6.2. Mass balance 54
6.2.1. Design criteria 54
6.2.2. Mass balance results 57
6.3. Reagent consumption 59
6.3.1. Design criteria 59
6.3.2. Results 60
6.4. Equipment size 61
6.4.1. Design criteria 61
6.4.2. Equipment sizing 62
7. Split circuit – same organic phase 66
7.1. Configuration 66
7.1.1. Flow diagram 66
7.1.2. Plant description 68
7.2. Mass balance 69
7.2.1. Design criteria 69
7.2.2. Mass balance results 70
7.3. Reagent consumption 71
7.3.1. Design criteria 71
7.3.2. Results 72
7.4. Equipment size 73
7.4.1. Design criteria 73
7.4.2. Equipment sizing 74
8. References 77

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1. Introduction

1.1. Concept and advantageous

Recently, split circuit has been introduced as copper production circuit for oxide
ores having high gangue acid consumption instead of conventional circuit (Nisbett A. et
al, 2009 and Miller G.M. et al, 2005). The big change between the conventional circuit
and the split circuit is that overflow from primary thickener and rich solution from solid
washing unit operation are not combined prior to copper solvent extraction. In
consequence, water balance bleed of the high grade circuit is now liquid of the
underflow of primary thickener which has a lower flow rate than that of conventional
circuit. Figures (1.1) and (1.2) give respectively the conventional configuration and the
split configuration. The Cu SX linked to overflow of primary thickener is called high
grade Cu SX and the Cu SX linked to rich solution from wash residue circuit is called low
grade Cu SX.

Figure 1.1: Conventional configuration

The economic advantageous of the split circuit economics is due to notable

reduction in operating costs from the lower acid consumption and lower tails
neutralization costs. The reductions of operating cost come from:

 High grade raffinate containing high acid concentration is totally

recycled to the leach.

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 Figure 1.2: Split Configuration

 The low concentration of copper in low grade PLS produces low

concentration of copper in low grade raffinate. Therefore there is
reduction of the copper soluble lost.
 The low concentrations of copper and free acid in low grade PLS produce
low concentration of free acid in low grade raffinate. Therefore there is
reduction of acid lost and cost of neutralization of plant water balance
bleed.

1.2. Copper and cobalt projects

In the Copper-belt areas of Zambia and the Democratic Republic of Congo

(DRC), the production plants utilize an agitation leach followed by solvent extraction
and electrowinning to recover both copper and cobalt. The mineralogy of ores in the
area is typically associated with high gangue acid consumption during the leaching
process. The use of split circuit decreases acid consumption by 12.1% (Nisbett A. et al,
2009).

In the DRC and to some extent in Zambia, the copper and cobalt oxide ores are
leached in atmospheric systems. The dominant Copper mineralization is Malachite with
accessory Azurite and Chrysocolla and minor other secondary copper minerals. The
cobalt is present as Heterogenite with cobalt in both the Co(II) and Co(III) oxidation
state. The cobaltic minerals are about 50 per cent of the total cobalt; and are not direct

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acid leachable at normal temperatures and pressures. Alternate methods of enhancing
the cobalt leaching are required.

Copper leaching is generally taken close to completion in four hours. Those

projects that do not have significant secondary copper minerals can achieve high
leaching efficiencies in as little as two hours from the rapidly leaching malachite and
azurite. About 50 per cent of the cobalt is leached (along with the copper) mainly from
the Co(II) minerals. The other cobaltic minerals need to be reduced to the 2+ state in
order for them to leach. This is achieved with controlled reductive leaching. The main
reductant used to date has been sodium meta bi-sulfite (SMBS: Na2S2O5). A more recent
development has been the use of gas from a sulfur burning acid plant (SO2 and N2) as a
direct Eh management tool. Other newer projects are considering the use of liquefied
SO2 to remove the voluminous nitrogen (Miller G. M., 2009).

Sulfite compounds are only partially utilized for cobalt (III) reduction during
copper-cobalt leaching. This low utilization is due to the secondary reactions of sulfur
dioxide and the sulfur dioxide gas lost in outlet leach tank gases due to low solubility of
sulfur dioxide gas in water. The secondary reactions are the reduction reactions of iron,
manganese from ore and the production of sulfate and dithionate with surface oxygen
catalyzed by Co, Mn and Fe ions. (Kafumbila J., 2020a and Kafumbila J., 2022a).

1.3. Publication goals

The goals of the publication are:

 To reevaluate the reduction in acid consumption by using split circuit

comparatively the conventional circuit in the condition of reductive
leaching of Cobalt using SO2 as reducing agent.
 To take account of the presence of dithionate and phosphate in the
solution in the simulation of copper solvent extraction (Kafumbila J.
2022b).
 To take account of ferric solvent extraction on organic phase (Kafumbila J.
2022b).

The goals are realizable by using:

 The new realistic simulation model of hydrometallurgical plant that uses

the thermodynamic equilibrium of soluble species in solution. This
simulation model allows the find the saturation concentrations of gypsum
and Copiapite.
 The new realistic simulation model of copper solvent extraction
configuration that uses the thermodynamic equilibrium of soluble species

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 in solution to determine the concentration of free hydrogen and copper
ions and uses the new equilibrium correlation on extraction and stripping
between copper concentration in aqueous and organic phases (Kafumbila
J. 2022b).

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2. Split circuit configurations

2.1. Type of wash solution

Figure (1.2) (Tenke Fungurume plant configuration) and Figure (2.1)

(Kansanshi plant configuration) show the split circuits where the wash solutions are
respectively water and low grade raffinate. The split circuit in which low grade raffinate
is used as wash solution works when there is not build-up of Magnesium and Aluminum
in the low grade raffinate that can decrease the decantation rate of leach residue in CCD
train. The advantageous of this split configuration is that lost acid from liquid of primary
thickener underflow is used to leach the remaining copper in the residue.

Figure 2.1: Split Configuration with low grade raffinate as wash solution

2.2. Type of Copper SX configuration

There are two configurations of split circuit compared to solvent extraction

configuration. In the first split circuit, HG and LG Cu SX have different organic phase.
Figure (2.2) (Mutanda Mining configuration) gives the split circuit in which HG and LG
Cu SX circuits have different organic phase. The advantageous of this configuration is HG
and LG work independently. But LG circuit must works with organic saturated in copper
for iron rejection from organic phase. The consequence is high concentration of Copper
in LG raffinate.

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 Figure 2.2: Split circuit – different organic phase between HG and LG SX

Figure 2.3: Split circuit – the same organic phase – HG and LG Cu extraction in series

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 Figure (2.3) (Usoke chemaf configuration) gives the split circuit in which HG
and LG Cu SX circuits have the same organic phase. The advantageous of this
configuration is to work with organic phase saturated in copper and to have low
concentration of copper in LG raffinate. HG and LG circuits cannot work separately.

Figure (2.4) gives the proposal of split circuit in which HG and LG Cu SX have
the same organic inspired from Mt Gordon Copper Process (Shaw D. R., 2004). The
advantageous of this configuration is HG extraction can work independently to LG
extraction.

Figure 2.4: Split circuit – the same organic phase – LG work with a stripped organic
bleed

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3. Split circuit parameters

3.1. Split value

Split value is a ratio of flowrate of primary thickener overflow onto the flowrate
of outlet liquid of the leaching unit operation (Miller G.M. et al, 2005). In industrial
practice, split value ranges from 60 to 90%. Split value depends on solid percentages in
leach pulp and in primary thickener underflow. Equation (3.1) gives the relationship
between solid percent in leach pulp, solid percent in the primary thickener underflow
and split value.

100 100 (100−%SU)

=1+( )* (3.1)
%SL %SU (100−SP)

Where “%SL” is solid percent in leach pulp, “%SU” is solid percent in the
primary thickener underflow and “SP” is split value (%)

3.2. High grade transferred copper percent

High grade transferred copper percent is the percentage of transferred copper

from the high grade circuit to the copper electrowinning unit operation (Miller G.M. et al,
2005). Equation (3.2) gives the value of the high grade transferred copper percent
“HGTCu”.

HGPLSFx(HGPLS−HGRaf)
HGTCu = * 100 (3.2)
HGPLSFx(HGPLS−HGRaf) +LGPLSFx(LGPLS−LGRaf)

Where “HGPLSF” is the high grade PLS flowrate (m3/h), “HGPLS” is the high
grade PLS copper concentration (g/L), “HGRaf” is the high grade raffinate
copper concentration (g/L), “LGPLSF” is the low grade PLS flowrate (m3/h),
“LGPLS” is the low grade PLS copper concentration (g/L), and “LGRaf” is the low
grade raffinate copper concentration (g/L).

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4. Realistic Simulation Model (RSM)

4.1. Characterization of pulp

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.

4.2. Specific gravity

4.2.1. Solid specific gravity

4.2.1.1. 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:

 Dry the crushed solid in an oven at 80 ° C for 24 hours,

 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.

After the practical operations, the other data is determined as follows:

 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 (4.1) 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.

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 Table 4.1: Specific gravity of solid from the laboratory method

Description Units Equations 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

4.2.1.2. 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:

 Knowing the weight percentage of minerals in the solid.

 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 (4.2) shows an example for obtaining the specific gravity of solid by using
the mineralogical composition method. The result from Table (1.2) 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.

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 Table 4.2: Specific gravity of solid from the mineralogical composition

Minerals Grade weight Specific gravity Volume of Specific

of mineral mineral gravity 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

4.2.2. Liquid specific gravity

4.2.2.1. 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.

4.2.2.2. Chemical composition method

Equation (4.1) gives the approximate value of specific gravity of liquid in as

function of liquid chemical composition (Kafumbila J., 2017a).

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 SGL = -6.139 * 10−7 x [GT ]2 + 9.742 * 10−4 * GT + 1 (4.1)

Where “ 𝑆𝐺𝐿 ” is liquid specific gravity (t/m3) and “𝐺𝑇 ” is total concentration of
soluble compounds (g/L)

4.3. Soluble compounds

4.3.1. Activity of soluble species

 Ionic strength

The ionic strength of the system is given by Equation (4.2). Where “Ci ” is the
concentration (mol/L) of soluble compounds “i” and “Zi ” is electrical charge of the
soluble compounds “i”.

1
I = 2x∑ Ci ∗ Zi2 (4.2)

 Water activity

The activity of water (solvent) (𝑎𝑤 ) is given by Equation (4.3). “ϕ” is the
osmotic coefficient, “W” is the molecular weight of water (18.016) and “𝑚𝑖 ” is the
concentration (mol/kg water) of soluble compounds (Charles E. Harvie et al, 1984). In
this case, the concentrations of soluble compounds are very low; in consequence the
molarity is close to the molarity. Equation (4.3) becomes Equation (4.4).

W
ln (aw ) = - 1000 *ϕ *∑i mi (4.3)

W
ln (aw ) = - 1000 *ϕ *∑i Ci (4.4)

The calculations of osmotic coefficient have been approximated by Equation

(4.5) (H.C. Helgeson, 1969). The value of “u” is given by Equation (4.6). Table (4.3) gives
values of parameters “a”, “b”, “c” and “d” at 298.15 K. “A” comes from Debrye-Huckel
Equation for activity coefficient and is function of temperature. The value of “A” is
0.5092 at 298.15K. “I” is the ionic strength (mol/kg of water). In this case, the ionic
strength is given in mol/L.

2.303∗A 1 b∗I 2c∗I2 3d∗I3

ϕ=1- [u -2ln(u) - u] + + + (4.5)
a3 ∗I 2 3 4

u=1+a*√I (4.6)

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 Table 4.3: values of a, b, c and d parameter at 298.15K

a b c d
1.454 0.02236 9.38 x10−3 -5.362x10−4

 Activity coefficients

Activity of soluble compound “i” in water is given by Equation (4.7). “γi ” is

activity coefficient and Ci is the concentration (mol/L) of soluble compound.

ai = γi * Ci (4.7)

The calculations of individual ion activity coefficient have been approximated by

Equation (4.8) in concentrated as well as dilute electrolyte solutions involved in
geochemical processes at high temperatures and pressures (H.C. Helgeson et al, 1981)
and suitable for overall equilibrium diagram calculations. “γi ” is the activity coefficient of
soluble compound “i”, “Zi ” is the electrical charge of compound “i” and “I” is the ionic
strength (mol/kg of water) (in this case ionic strength is given in mol/L). “A”, “B” and
“b” are temperature-dependent parameters. Table (4.4) gives values of parameters “A”,
“B” and “b” at 298.15 K (B. Beverskog et al, 1998). “ä” is a distance of closest approach,
which may be taken to be equal to that of NaCl (3.72 10−10m).

Z2 A√I
Log(γi )= - (1+Bä√I)
i
– log(1+0.018015*I)+b*I (4.8)

Table 4.4: values of A, B and b parameter at 298.15K

A B x 10−10 b
0.509 0.328 0.064

For neutral aqueous species it is usually approximated that the activity

coefficients are unity at all values of ionic strength and temperature. The approximate
applicability is up to value of ionic strength around 5 (mol/kg of water) (H.C. Helgeson
et al, 1981).

4.3.2. Concentration of soluble species

In the case of the simulation of Copper circuit: pH (1-3) and Eh (0.56-0.6V):

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  Hydrogen ion

Predominate water soluble compound is H + in solution. The molarity of H +

(C(H+ ) ) is given by Equation (4.9).

C(H+) =10(−pH) *(γ1 )(−1) (4.9)

 Sulfate

Sulfate soluble compounds are SO−2 −

4 , HSO4 and H2 SO4 . Equilibrium chemical
reactions between sulfate soluble compounds are given by the chemical reactions (4.a)
and (4.b).

SO−2 + −
4 + H =HSO4 (4.a)

SO−2 +
4 + 2H =H2 SO4 (4.b)

C(SO−2
4 )
is the molarity of SO−2
4 and C(SO−2
4 )
is fixed by electrical neutrality of
solution. The molarities of HSO−
4 (C(HSO−
4)
) and H2 SO4 (C(H2 SO4 ) ) are given by Equations
(4.10) and (4.11).

C(HSO−4 ) =10(1.99) *C(SO−2

4 )
*C(H+ ) *γ2 (4.10)

C(H2 SO4 ) =10(−0.053) *C(SO−2

4 )
*(C(H+) ∗ γ1 )2 *γ2 (4.11)

Equation (4.12) gives the molarity of free sulfuric acid.

C(Ac) =C(H+) +C(H2 SO4 ) (4.12)

 Dithionate

Dithionate soluble compound is S2 O−2

6 . C(S2 O−2
6 )
is the molarity of S2 O6−2.

 Phosphate

Predominate phosphate compounds are:H2 PO− 4 , H3 PO4 and AlH2 PO4

+2
.
Equilibrium chemical reactions between phosphate soluble compounds are given by the
chemical reactions (4.c) and (4.d).

H2 PO− +
4 +H =H3 PO4 (4.c)

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 Al+3 +H2 PO− +2
4 =AlH2 PO4 (4.d)

C(H2 PO−4 ) is the molarity of H2 PO− +3

4 and C(Al+3 ) is the molarity of Al . The
molarities of H3 PO4 (C(H3 PO4 ) ) and AlH2 PO+2
4 (C(AlH2 PO+2
4 )
) are given by Equations (4.13)
and (4.14). Total molarity of P (C(PT) ) is given by Equation (4.15).

C(H3 PO4 ) =10(2.15) *C(H2 PO−4 ) *C(H+ ) *(γ1 )2 (4.13)

C(AlH2 PO+2
4 )
=10(1.94) *C(H2 PO−4 ) *C(Al+3 )*γ1 *γ3 *(γ2 )(−1) (4.14)

C(PT) =C(H2 PO−4 ) +C(H3 PO4) +C(AlH2 PO+2

4 )
(4.15)

 Copper

Predominate Copper soluble compounds are Cu+2 and CuSO4 . Equilibrium

chemical reaction between Copper soluble compounds is given by the chemical reaction
(4.e).

Cu+2 + SO−2
4 = CuSO4 (4.e)

C(Cu+2 ) is the molarity of Cu+2 and the molarity of CuSO4 (C(CuSO4 ) ) is given by
Equation (4.16). The total molarity of soluble Cu (C(CuT) ) is given by Equation (4.17).

C(CuSO4 ) =10(2.36) *C(Cu+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.16)

C(CuT) =C(Cu+2 ) +C(CuSO4) (4.17)

 Cobalt

Predominate Cobalt soluble compounds are Co+2 and CoSO4 . Equilibrium

chemical reaction between Cobalt soluble compounds is given by the chemical reaction
(4.f).

Co+2 + SO−2
4 = CoSO4 (4.f)

C(Co+2 ) is the molarity of Co+2 and the molarity of CoSO4 (C(CoSO4 ) ) is given by
Equation (4.18). The total molarity of soluble Co (C(CoT)) is given by Equation (4.19).

C(CoSO4) =10(2.30)*C(Co+2 )*C(SO−2

4 )
*(γ2 )(2) (4.18)

C(CoT) =C(Co+2 )+C(CoSO4) (4.19)

Joseph Kafumbila Page 22

  Zinc

Ppredominate Zinc soluble compounds are Zn+2 and ZnSO4 . Equilibrium

chemical reaction between Zinc soluble compounds is given by the chemical reaction
(4.g).

Zn+2 + SO−2
4 = ZnSO4 (4.g)

C(Zn+2 ) is the molarity of Zn+2 and the molarity of ZnSO4 (C(ZnSO4 ) ) is given by
Equation (4.20). The total molarity of soluble Zn (C(ZnT)) is given by Equation (4.21).

C(ZnSO4) =102.46*C(Zn+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.20)

C(ZnT) =C(Zn+2 )+C(ZnSO4 ) (4.21)

 Nickel

Ppredominate Nickel soluble compounds are Ni+2 and NiSO4 . Equilibrium

chemical reaction between Nickel soluble compounds is given by the chemical reaction
(4.h).

Ni+2 + SO−2
4 = NiSO4 (4.h)

C(Ni+2 ) is the molarity of Ni+2 and the molarity of NiSO4 (C(NiSO4 )) is given by
Equation (4.22). The total concentration of soluble Ni (C(NiT) ) is given by Equation
(4.23).

C(NiSO4 ) =10(2.30) *C(Ni+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.22)

C(NiT) =C(Ni+2 ) +C(NiSO4 ) (4.23)

 Manganese

Predominate Manganese soluble compounds are Mn+2 and MnSO4. Equilibrium

chemical reaction between Manganese soluble compounds is given by the chemical
reaction (4.i).

Mn+2 + SO−2
4 = MnSO4 (4.i)

Joseph Kafumbila Page 23

 C(Mn+2 ) is the molarity of Mn+2 and the molarity of MnSO4 (C(MnSO4 ) ) is given
by Equation (4.24). The total molarity of soluble Mn (C(MnT)) is given by Equation
(4.25).

C(MnSO4) =10(2.25) *C(Mn+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.24)

C(MnT) =C(Mn+2 ) +C(MnSO4 ) (4.25)

 Aluminum

Ppredominate Aluminum soluble compounds are Al+3 , AlSO4+ , Al(SO4 )− 2,

+2 +2
AlHSO4 and AlH2 PO4 . Equilibrium chemical reactions between Aluminum soluble
compounds are given by the chemical reactions (4.j), (4.k), (4.l) and (4.d).

Al+3 + SO−2 +
4 = AlSO4 (4.j)

Al+3 +2SO−2 −
4 = Al(SO4 )2 (4.k)

Al+3 +H + + SO−2 +2
4 = AlHSO4 (4.l)

Al+3 +H2 PO− +2

4 =AlH2 PO4 (4.d)

C(Al+3 ) is the molarity of Al+3 and the molarities of AlSO+

4 (C(AlSO+
4 )
), Al(SO4 )−
2
(C(Al(SO4 )−2 ) ), AlHSO+2
4 (C(AlHSO+2
4 )
) and AlH2 PO+2
4 (C(AlH2 PO+2
4 )
) are given by Equations
(4.26), (4.27), (4.28) and (4.14). The total molarity of soluble Al (C(AlT)) is given by
Equation (4.29).

C(AlSO+4 ) =10(3.59) *C(Al+3 ) ∗ C(SO−2

4 )
∗ γ3 ∗ γ2 *(γ1 )(−1) (4.26)

C(Al(SO4 )−2 ) =10(4.92) *C(Al+3 ) ∗ (C(SO−2

4 )
)(2) ∗ γ3 ∗ (γ2 )(2) *(γ1 )(−1) (4.27)

C(AlHSO+2
4 )
=10(2.45) *C(Al+3 ) ∗ C(H+ ) ∗ C(SO−2
4 )
∗ γ3 ∗ γ1 (4.28)

C(AlT) =C(Al+3 )+C(AlSO+4 ) +C(Al(SO4)−2 ) +C(AlHSO+2

4 )
+C(AlH2 PO+2
4 )
(4.29)

 Magnesium

Predominate Magnesium soluble compounds are Mg +2 and MgSO4 . Equilibrium

chemical reaction between Magnesium soluble compounds is given by the chemical
reaction (4.m).

Joseph Kafumbila Page 24

 Mg +2 + SO−2
4 = MgSO4 (4.m)

C(Mg+2 ) is the molarity of Mg +2 and the molarity of MgSO4 (C(MgSO4 ) ) is given by

Equation (4.30). The total molarity of soluble Mg (C(MgT) ) is given by Equation (4.31).

C(MgSO4) =10(2.26) *C(Mg+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.30)

C(MgT) =C(Mg+2 ) +C(MgSO4 ) (4.31)

 Calcium

Predominate Calcium soluble compounds are Ca+2 , and CaSO4 . Equilibrium

chemical reaction between Calcium soluble compounds is given by the chemical reaction
(4.n).

Ca+2 + SO−2
4 = CaSO4 (4.n)

C(Ca+2 ) is the molarity of Ca+2 and the molarity of CaSO4 (C(CaSO4 ) ) is given by
Equation (4.32). The total molarity of soluble Ca (C(CaT) ) is given by Equation (4.33).

C(CaSO4 ) =10(2.36) *C(Ca+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.32)

C(CaT) =C(Ca+2 ) +C(CaSO4) (4.33)

 Iron (II)

Predominate Fe(II) soluble compounds are Fe+2 and FeSO4 . Equilibrium

chemical reaction between Fe(II) soluble compounds is given by the chemical reaction
(4.o).

Fe+2 + SO−2
4 = FeSO4 (4.o)

C(Fe+2 ) is the molarity of Fe+2 and the molarity of FeSO4 (C(FeSO4 ) ) is given by
Equation (4.34). The total molarity of soluble Fe(II) (C(Fe2T) ) is given by Equation
(4.35).

C(FeSO4 ) =K (1.l) *C(Fe+2 ) *C(SO−2

4 )
*(γ2 )(2) (4.34)

C(Fe2T) =C(Fe+2 ) +C(FeSO4 ) (4.35)

Joseph Kafumbila Page 25

  Iron (III)

Predominate Fe(III) soluble compounds are Fe+3, FeSO+ − +2

4 , Fe(SO4 )2 , FeHSO4
and FeH(SO4 )2. Equilibrium chemical reactions between Fe(III) soluble compounds are
given by the chemical reactions (4.p), (4.q), (4.r) and (4.s).

Fe+3 + SO−2 +
4 = FeSO4 (4.p)

Fe+3 +2SO−2 −
4 = Fe(SO4 )2 (4.q)

Fe+3 +H + + SO−2 +2
4 = FeHSO4 (4.r)

Fe+3 +H + + 2SO−2
4 =FeH(SO4 )2 (4.s)

C(Fe+3 ) is the molarity of Fe+3 and the molarities of FeSO+

4 (C(FeSO+
4 )
), Fe(SO4 )−
2
(C(Fe(SO4 )−2 ) ), FeHSO+2
4 (C(FeHSO+2
4 )
) and FeH(SO4 )2 (C(FeH(SO4 )2 ))are given by Equations
(4.36), (4.37), (4.38) and (4.39). The total molarity of soluble Fe (C(Fe3T) ) is given by
Equation (4.40).

C(FeSO+4 ) =10(4.05)*C(Fe+3 ) ∗ C(SO−2

4 )
∗ γ3 ∗ γ2*(γ1 )(−1) (4.36)

C(Fe(SO4 )−2 ) =10(5.38) *C(Fe+3 ) ∗ (C(SO−2

4 )
)(2) ∗ γ3 ∗ (γ2 )(2) *(γ1 )(−1) (4.37)

C(FeHSO+2
4 )
=10(2.48) *C(Fe+3 ) ∗ C(H+) ∗ C(SO−2
4 )
∗ γ3 ∗ γ1 (4.38)

2
C(FeH(SO4 )2 ) =10(8.1) *C(Fe+3 ) ∗ C(H+) ∗ (C(SO−2
4 )
) ∗ γ3 ∗ γ1 ∗ (γ2 )2 (4.39)

C(Fe3T) =C(Fe+3 ) +C(FeSO+4 ) +C(Fe(SO4 )−2 ) +C(FeHSO+2

4 )
+C(FeH(SO4 )2 ) (4.40)

 Fe(II) and Fe(III)

Equilibrium chemical reaction of Fe+3 and Fe+2 is given by the chemical

reaction (4.t).

Fe+3+e− =Fe+2 (4.t)

The molarity of Fe+3 (C(Fe+3 ) ) is given by Equation (4.41).

log(C(Fe+3 ) *γ3 )=log(C(Fe+2 ) *γ2 )+(Eh-0.77)*16.901 (4.41)

Joseph Kafumbila Page 26

 Electrical neutrality

Equation (4.42) gives the electrical charge neutrality of solution.

2*C(SO−2
4 )
+C(HSO−4 ) +2*C(S2 O−2
6 )
+C(H2 PO−4 ) +C(Al(SO4)−2 ) +C(Fe(SO4 )−2 ) =
C(H+ ) +2*C(Cu+2 ) +2*C(Co+2 ) +2*C(Zn+2 )+2*C(Ni+2 ) *2+2*C(Mn+2 ) *2+2*C(Mg+2 ) +2*
C(Ca+2 ) +3*C(Al+3 )+C(AlSO+4 ) +2*C(AlHSO+2
4 )
+2*C(AlH2 PO+2
4 )
+2*C(Fe+2 ) +3*C(Fe+3 ) +
C(FeSO+4 ) +2*C(FeHSO+2
4 )
(4.42)

 Total molarity of sulfur

Equation (4.43) gives the total molarity of sulfur (C(ST) ) in solution.

C(ST) =C(SO−2
4 )
+C(HSO−4 ) +C(H2 SO4) +2*C(S2 O−2
6 )
+C(CuSO4 ) +C(CoSO4 )+C(ZnSO4 )+
C(NiSO4 ) +C(MnSO4 )+C(MgSO4 )+C(CaSO4 )+C(AlSO+4 ) +2*C(Al(SO4 )−2 ) +C(AlHSO+2
4 )
+
C(FeSO4 ) +C(FeSO+4 ) +2*C(Fe(SO4 )−2 ) +C(FeHSO+2
4 )
+2*C(FeH(SO4 )2 ) (4.43)

 Total concentration of soluble compounds

Equation (4.44) gives the total concentration of soluble compounds (g/L)(GT ).

GT =G(H) +G(SO4 )+G(PO4 ) +G(S2 O6 ) +G(Cu) +G(Co) +G(Zn)+G(Ni) +G(Mn)+G(Mg)+G(Al)

+G(Ca) +G(Fe2) +G(Fe3) (4.44)

G(H) =(C(H+ ) +C(HSO−4 ) +2*C(H2 SO4 )+2*C(H2 PO−4 ) +3*C(H3 PO4 ) +2*C(AlH2PO+2
4 )
+
C(AlHSO+2
4 )
+C(FeHSO+2
4 )
+C(FeH(SO4 )2 ))*1.007 (g/L) (4.45)

G(SO4 ) =(C(SO−2
4 )
+C(HSO−4 ) +C(H2 SO4 ) +C(CuSO4 )+C(CoSO4) +C(ZnSO4) +C(NiSO4 ) +
C(MnSO4 )+C(MgSO4 )+C(CaSO4) +C(AlSO+4 ) +2*C(Al(SO4 )−2 ) +C(AlHSO+2
4 )
+C(FeSO4 )+
C(FeSO+4 ) +2*C(Fe(SO4 )−2 ) +C(FeHSO+2
4 )
+2*C(FeH(SO4 )2 ))*96.061 (g/L) (4.46)

G(PO4 ) =(C(H2 PO−4 ) +C(H3 PO4 ) +C(AlH2PO+2

4 )
)*94.966 (g/L) (4.47)

G(S2 O6 ) =C(S2 O6) *160.124 (g/L) (4.48)

G(Cu) =C(CuT) *63.54 (g/L) (4.49)

G(Co) =C(CoT)*58.93 (g/L) (4.50)

G(Zn) =C(ZnT)*65.38 (g/L) (4.51)

Joseph Kafumbila Page 27

G(Ni) =C(NiT) *58.63 (g/L) (4.52)

G(Mn) =C(MnT) *54.94 (g/L) (4.53)

G(Mg) =C(MgT) *24.31 (g/L) (4.54)

G(Al) =C(AlT)*26.98 (g/L) (4.55)

G(Ca) =C(CaT) *40.08 (g/L) (4.56)

G(Fe2) =C(Fe2T) *55.85 (g/L) (4.57)

G(Fe3) =C(Fe3T) *55.85 (g/L) (4.58)

G(P) =(C(H2 PO−4 ) +C(H3 PO4 )+C(AlH2 PO+2

4 )
)*30.97 (g/L) (4.59)

G(S) =C(ST) *32.065 (g/L) (4.60)

G(Ac) =C(Ac)*98.075 (g/L) (4.61)

Joseph Kafumbila Page 28

5. Conventional circuit

5.1. Configuration

5.1.1. Flow diagram

Figure (5.1) gives the flow diagram of Copper conventional circuit on which the
mass balance is done.

Figure 5.1: Flow diagram of conventional circuit

Joseph Kafumbila Page 29

Abbreviations of unit operations:

 LC : Leach circuit.
 PKT: Primary thickener.
 KTn: Thickener of rank “n” in CCD train.
 SX En: Stage of rank “n” in CuSX - extraction train.
 ACT: Aqueous coalescing Tank.
 SX Sn: Stage of rank “n” in CuSX - stripping train.
 EW: .Copper electrowinning.

Abbreviations of lines between unit operations:

 FCake: Pre-leach filtration cake.

 LCA: Leach concentrated acid.
 RE2L: Raffinate of stage 2 of CuSX - extraction train to leach.
 RE2B: Raffinate of stage 2 of CuSX extraction train to water balance
bleed.
 OLC: Outlet leach circuit.
 PTKFC: Flocculants of primary thickener.
 PTKUF: Underflow of primary thickener.
 PTKOF: Overflow of primary thickener.
 TKFCn: Flocculants of thickener of rank “n” in CCD train.
 TKnUF: Underflow of thickener of rank “n” in CCD train.
 TKnOF: Overflow of thickener of rank “n” in CCD train.
 WW: Wash water of CCD train.
 PLS: Pregnant leach solution.
 REn: Raffinate of stage of rank “n” in CuSX - extraction train.
 LOEn: Loaded organic of stage of rank “n” in CuSX - extraction train.
 ALOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
CuSX - extraction train.
 LOAC: Loaded organic from aqueous coalescing tank.
 ALOAC: Aqueous entrainment in loaded organic from aqueous coalescing
tank.
 ACTD: Drain of aqueous coalescing tank.
 SOSn: Stripping organic of stage of rank “n” in CuSX - stripping train.
 SOASn: Aqueous entrainment in stripping organic of stage of rank “n” in
CuSX - stripping train.
 ADSn: Advance electrolyte of stage of rank “n” in CuSX - stripping train.
 RADSn: Recirculated advance electrolyte of stage of rank “n” in CuSX -
stripping train.
 SPE: Spent electrolyte.
 EWO: Oxygen produced in Copper electrowinning circuit.
Joseph Kafumbila Page 30
  EWCC: Copper cathode produced in Copper electrowinning circuit.
 EWS: Sulfur produced in Copper electrowinning circuit.
 EWW: Water for Copper electrowinning circuit.
 EWCA: Concentrated acid for Copper electrowinning circuit.
 OEW: Outlet of Copper electrowinning circuit.
 EWB: Bleed of Copper electrowinning circuit.
 ACS: Acid solution.

5.1.2. Plant description

The cake of pre-leach filtration cake is fed in leach circuit with one part of
raffinate from raffinate pond. Concentrated acid and sulfur dioxide gas are also added in
the leach circuit for pH and redox potential control. Slurry discharged from the leach
circuit is thickened in primary thickener. Underflow of primary thickener is fed to
counter current decantation circuit where leach residue is washed with acidulated
water.

Overflow of primary thickener is called pregnant leach solution and is fed to the
copper solvent extraction circuit. One part of raffinate of solvent extraction step is sent
back to leach and the remaining is sent to cobalt circuit.

The loaded organic from organic CuSX – extraction train is sent to aqueous
coalescing tank to remove a maximum volume of aqueous entrainment solution. Loaded
organic from aqueous coalescing tank is sent to CuSX - stripping train.

Spent electrolyte from copper electrowinning circuit is sent to CuSX - stripping

train. Advance electrolyte from CuSX - stripping train is sent back to Copper
electrowinning circuit. Concentrated acid and water are also added in Copper
electrowinning circuit. Copper cathode, Oxygen gas and sulfur are produced in Copper
electrowinning circuit. Iron bleed solution from Copper electrowinning circuit is sent
back to PLS pond.

5.2. Mass balance

5.2.1. Design criteria

5.2.1.1. Leach circuit

Design criteria of leach circuit mass balance are the following:

 Specific gravity of feed solid: 2.7t/m3.

 Solid percent in pre-leach filtration cake: 78%.

Joseph Kafumbila Page 31

  Solid percent in outlet leach circuit: 30% (maximum for reductive
leaching of Cobalt).
 Leach redox potential (LRP): 350 mV (Ag/AgCl).
 Leach pH: 1.7.
 Leach test (Kafumbila J., 2021):
o Gangue acid consumption (GAC): 43.260 kg/ton.
o SO2 consumption (SO2C): 14.850 kg/ton.
o CO2 production (CO2P): 7.510 kg/ton.
o Leach weight lost (LWL): 32.5 kg/ton.
o Leaching efficiency of sulfide minerals: 0% (assumption).
o Solubility:
 Cu: 14.041 kg/ton.
 P: 0.300 kg/ton.
 Fe: 0.861 kg/ton.
 Al: 0.688 kg/ton.
 Co: 4.500 kg/ton.
 Zn: 0.500 kg/ton.
 Ni: 0.068 kg/ton.
 Mn: 0.788 kg/ton.
 Mg: 1.002 kg/ton.

 Sulfur percentage in solid:

o Percentage of sulfur in the feed:0.1%.
o Sulfur percentage in the leach residue: 1.5%.

 SO2 consumption: Equation (5.1) gives empirical Equation giving

6 (G(S2 O−2
concentration of S2 O−2 6 )
) (g/L) as function of Eh (v) (leach
redox potential) and sum of concentration of Co (G(Co) ), Mn (G(Mn) ) and
Fe(II) (G(Fe(II)) ) in leach solution (Kafumbila J., 2022a). The assumption
is that: SO2 consumption in the plant is obtained from sulfur mass
balance on leach circuit.
o Percent of sulfur in SO2 gas: 50.052%.

G(S2 O−2
6 )
=19.380+2.471*[G(Co)+G(Mn)+G(Fe(II)) ]-49.112*Eh (5.1)

 Acid consumption is obtained from gangue acid consumption from leach

test. In the case of conventional circuit Equation (5.2) gives concentrated
acid consumption.
o Percent of acid in concentrated acid: 98%
o Specific gravity of concentrated acid: 1.80.

Joseph Kafumbila Page 32

 OLC L
CAC=Gac *FOLC +FFS *(GAC+SolCu ∗ 1.543)- Gac
RE2L L
*FRE2L (5.2)

𝑂𝐿𝐶
Where “𝐺𝑎𝑐 ” is free acid concentration in outlet leach solution (g/L),
“𝐹𝑂𝐿𝐶 ” is the liquid flow rate of outlet leach solution, “𝐹𝐹𝑆 ” is solid flow
𝐿

rate of feed (t/hr), “GAC” is gangue acid consumption (kg/t), “𝑆𝑜𝑙𝐶𝑢 ” is

𝑅𝐸2𝐿
the solubility of copper, “𝐺𝑎𝑐 ” is free acid concentration in the SX
𝐿
raffinate (g/L), “𝐹𝑅𝐸2𝐿 ” is the liquid flow rate of raffinate pumped to leach
and “CAC” is pure acid consumed to leach (kg/hr).

 Chemical reaction (5.a) gives gypsum precipitation reaction. Equation

(5.3) gives the precipitation condition of reaction (5.a).

Ca+2 + SO−2
4 + 2H2 O =CaSO4 . 2H2 O (5.a)

4.60=-log(a(Ca(+2)) )-log(a(SO−2
4 )
)-2*log(aw ) (5.3)

Where “𝑎(𝐶𝑎(+2)) ”, “𝑎(𝑆𝑂4−2 ) ” and “𝑎𝑤 ” are the activities of calcium ion,
sulfate anion and water.

 Chemical reaction (5.b) gives Copiapite precipitation reaction. Equation

(5.4) gives precipitation condition of chemical reaction (5.b). In this
simulation is that the iron dissolution stops when the concentration of
Iron in leach solution reaches the saturation concentration.

Fe+2+4Fe+3 +6SO−2
4 + 22H2 O = Fe5 (SO4 )6 (OH)2 . 20H2 O + 2H
+
(5.b)

33.737=-2*pH-log(a(Fe(+2)) )-4*log(a(Fe(+3)) )-6*log(a(SO−2

4 )
)-22*log(aw ) (5.4)

Where “𝑎(𝐹𝑒 (+2)) ”, “𝑎(𝐹𝑒 (+3))”, “𝑎(𝑆𝑂4−2 ) ” and “𝑎𝑤 ” are the activities of Fe(II)
ion, Fe(III) ion, sulfate anion and water.

5.2.1.2. Primary thickener

Design criteria of primary thickener mass balance are the following:

 Flocculants dosage: 40 g/ton.

 Flocculants concentration: 0.25%.
 Solid percent in underflow of primary thickener: 54%.
 Chemical reaction (5.a) gives gypsum precipitation reaction. Equation
(5.3) gives the precipitation condition of reaction (5.a).

Joseph Kafumbila Page 33

5.2.1.3. CCD circuit

Design criteria of CCD circuit mass balance are the following:

 Solid percent in thickener underflow: 54%.

 Flocculants concentration: 0.25%.
 Flocculants dosage for the first thickener: 60% of flocculants dosage of
primary thickener.
 Flocculants dosage for other thickeners: 40% of flocculants dosage of
primary thickener.
 Mixing efficiency: 100%
 Wash efficiency: concentration of Co in the liquid of the last thickener in
the CCD train must be between 0.08 to 0.1g/L.
 pH of wash solution: 2.5.
 Chemical reaction (5.a) gives gypsum precipitation reaction. Equation
(5.3) gives the precipitation condition of reaction (5.a).

5.2.1.4. CuSX – extraction train

Design criteria of CuSX - extraction circuit mass balance are the following:

 Type of extractant: Lix984N.

 Saturation ratio (LO/ML): ranges from 70 to 80% the ratio Cu/Fe in E1
loaded organic must be greater than 1000.
 O/A ratio (Loaded organic of stage of rank “2” on extraction train onto
overflow of primary thickener): 1.25.
 Number of stage: 2.
 Volume percent of extractant in organic phase: depends on saturation
ratio.
 Mixing efficiency for Copper:
o Stage E1: 95%.
o Stage E2: 97%.
 Aqueous entrainment in organic:
o Stage E1: 1000ppm.
o Stage E2: 1000ppm.
 Equilibrium copper concentration: Equation (5.5) gives equilibrium
condition of chemical reaction (5.c) (Kafumbila J., 2022b).

Cu+2 +2HR=CuR 2 +2H + (5.c)

Joseph Kafumbila Page 34

 Ce(CuR2 ) ∗ (Ce + ∗γ(H+ ) )2
(H )
=(-109.99 * v/v%(−1.699) ) ∗ Cue(or)+ 46.386 * v/v%(−0.618) (5.5)
Ce(Cu+2 ) ∗γ(Cu+2 ) ∗ (Ce(HR) )2

 Equilibrium Fe(III) concentration: Data of Lix984 (Kafumbila J., 2022b)

on extraction train. Equation (5.6) gives equilibrium condition of
chemical reaction (5.d).

Fe+3+3HR=FeR 3 +3H + (5.d)

[FeR ]∗([H+ ])3

10(−3.431) =[Fe+33]∗([HR])3 (5.6)

 Mixing efficiency for Fe(III) (assuming the same as for Copper):

o Stage E1: 95%.
o Stage E2: 97%.

5.2.1.5. Aqueous coalescing tank

Design criterion of aqueous coalescing tank is:

o Aqueous entrainment in organic: 400 ppm

5.2.1.6. CuSX – stripping train

Design criteria of CuSX - stripping circuit mass balance are the following:

 O/A (internal): 1.25

 Number of stage: 2.
 Concentration of copper in advance electrolyse: 49-50 g/L.
 Spent electrolyte composition:
o Copper concentration: 35 g/L.
o Acid concentration: 180 g/L.
o Fe(II) concentration: 1.0 g/L.
o Fe(III) concentration: 1.0 g/L.
 Mixing efficiency:
o Stage S1: 95%.
o Stage S2: 90%.
o Aqueous entrainment in organic:
o Stage S1: 300ppm.
o Stage S2: 300ppm.
o Equilibrium copper concentration: Equation (5.7) gives equilibrium
condition of chemical reaction (5.e) (Kafumbila J., 2022b).

Joseph Kafumbila Page 35

 CuR 2 +2H + =Cu+2 +2HR (5.e)

Ce(CuR2 ) ∗ (Ce + ∗γ(H+ ) )2

(H )
=(-80.719 * v/v%(−1.508) ) ∗ Cue(or)+ 87.123* v/v%(−0.826) (5.7)
Ce(Cu+2 ) ∗γ(Cu+2 ) ∗ (Ce(HR) )2

 Ferric stripping efficiency: Concentration of Ferric in stripped organic –

1ppm (Hans Hein, 2005).

5.2.1.7. Copper electrowinning

Design criteria of Copper electrowinning circuit mass balance are the following:

 Spent electrolyte and iron bleed composition:

o Copper concentration: 35 g/L.
o Acid concentration: 180 g/L.
o Fe(II) concentration: 1.0 g/L.
o Fe(III) concentration: 1.0 g/L.
 Percent of acid in concentrated acid: 98%
 Specific gravity of concentrated acid: 1.80.
 Chemical reaction (5.f). Equation (5.8) gives the production of oxygen.

2CuSO4 +2H2 O=2Cu° +O2 +2H2 SO4 (5.f)

O2P=0.252CCP (5.8)

Where “O2P” is the quantity of oxygen produced in copper electrowinning

and “CCP” is copper cathode produced in copper electrowinning.

 Dithionate decomposition:

o Half of dithionate is oxidized to sulfate by oxygen on anode

according to the chemical (5.g). Equation (5.9) gives mass of
oxygen gas (CM(O2 ) ) used to oxidize M(S O(−2)) mass of dithionate
2 6

to sulfate. Equation (5.10) gives the mass of sulfate produced

during the oxidation of M(S O(−2)) mass of dithionate
2 6

(−2) (−2)
2S2 O6 +O2 +2H2 O=4SO4 +4H + (5.g)

CM(O2 ) =0.100*M(S (−2) (5.9)

2 O6 )

PM(SO(−2)) =1.200*M(S (−2) (5.10)

4 2 O6 )

Joseph Kafumbila Page 36

 o Half of dithionate is reduce to elementary sulfur on cathode
according to the chemical reaction (5.h). Equation (5.11) gives
mass of oxygen gas produced (PM(O2 ) ) during the production of
elementary sulfur from M(S O(−2)) mass of dithionate. Equation
2 6

(5.12) gives mass of elementary sulfur produced from M(S (−2)

2 O6 )
mass of dithionate

(−2)
S2 O6 +2H + =O2 +2S ° +H2 O (5.h)

PM(O2 ) =0.200*M(S (−2) (5.11)

2 O6 )

PM(S° ) =0.401*M(S (−2) (5.12)

2 O6 )

 Flowrate of concentrated acid: sulfur mass balance on CuEW

5.2.2. Mass balance results

Tables from (A.1) to (A.7) in the appendix (A) give the mass balance of
conventional circuit using the realistic simulation model. The solid feed flow rate and
the number of thickener in CCD train are optimized to have the flowrate of primary
thickener overflow between 1800 and 2200 m3/hr that gives 4 copper solvent
extraction trains according to copper solvent extraction design model (Kafumbila J.
2022b).

Table (5.1) gives the summary of simulation results. Here are some
observations:

 The solid feed flow rate and the number of thickener in the CCD train are
optimized respectively at 800 t/hrs and 6 to have the PLS flow rate at
2166.20 m3/hr.
 80.8% of the inlet sulfate in the leach circuit comes with concentrated
sulfuric acid and 19.2% from SO2 oxidation.
 69.7% of inlet sulfur in the leach circuit comes with concentrated sulfuric
acid and 30.3% from SO2.
 The Iron concentration in the leach solution is not the saturation
concentration (Fe(2): 1.131g/L and Fe(3): 0.062g/L).
 The increase of sulfur grade in the leach residue is due to gypsum
precipitation.

Joseph Kafumbila Page 37

  The Calcium concentration in the leach solution and CCD train solutions
are the saturation concentrations. Therefore there is dissolution of
gypsum from primary thickener to the last thickener of CCD train.
 The concentration of Iron LOE1 (0.0047ppm) is lower than the
concentration of Iron in LOE2 (0.0059ppm). There is rejection of Iron
from organic phase in the E1 due to the increase of copper concentration
in LOE1 (6.80 g/L) comparatively to LOE2 (3.34g/L).
 The ratio Cu/Fe in LOE1 is greater than 1000 at the ratio LO/ML equal to
0.7 at volume percent of Lix984N in organic about 18.4%, at Fe(3)
concentration in PLS about 0.050g/L and at phosphate and dithionate
concentrations respectively about 0.99g/L and 9.04g/L (Kafumbila J.,
2022b).

Table 5.1: Result summary

Description
Solid feed flow rate 800 Ton/hr
Number of thickener in CCD train 6
Acid consumption – Leach circuit 53.22 Kg/t feed
Acid consumption – CuEW circuit 1.86 Kg/t feed
Acid consumption – wash CCD circuit 0.45 Kg/t feed
Total acid consumption 55.53 Kg/t feed
Lost acid (free acid and acid associated with Copper) – CCD TK6 UF 0.38 Kg/t feed
Lost acid (free acid and acid associated with Copper) – RE2B 9.80 Kg/t feed
SO2 consumption – Leach circuit 14.81 Kg/t feed
Flocculants consumption – Primary thickener and CCD train 139.32 g/t feed
PLS flow rate 2172.4 m3/hr
Extractant percent in organic phase 18.38 %
Saturation ratio (LO/ML) 0.700
Cu/Fe in LOE1 1453
Copper production 13.83 Kg/t feed
Ratio Copper in EWB onto Copper production 1.52 %
Lost copper in CCD-TK6 UF 0.08 Kg/t feed
Lost copper in RE2B 0.14 Kg/t feed
Soluble copper recovery 98.46 %
CCD wash ratio 1.39 m3/ton
Cobalt concentration in TK6 UF 0.089 g/L

5.3. Reagent consumption

5.3.1. Design criteria

5.3.1.1. Acid and SO2

Acid and SO2 are produced from sulfur. The percent of conversion of sulfur to
acid and SO2 is 98%. Table (5.2) gives the specific consumption of sulfur. Molar mass of
sulfur, SO2 and acid are respectively 32.065 g/mol, 64.063g/mol and 98.075g/mol.

Joseph Kafumbila Page 38

Equations (5.11) and (5.12) give the specific consumption of sulfur from specific
consumptions of acid and SO2.

32.065
SCS=SCAC* (5.11)
98.075∗SCV

32.065
SCS=SCSO* (5.12)
64.063∗SCV

Where “SCS” is specific consumption of sulfur, “SCAC” is specific consumption of

acid, “SCSO” is specific consumption of SO2 and “𝑆𝐶𝑉” is sulfur conversion.

Table 5.2: Sulfur specific consumption

Specific consumption Unit

Acid consumption 55.54 Kg/t feed
Sulfur to acid 18.83 Kg/t feed
SO2 consumption 14.81 Kg/t feed
Sulfur to SO2 7.57 Kg/t feed
Total sulfur consumption 26.10 Kg/t feed

5.3.1.2. Lix984N and Kerosene

The concentrations of organic phase in raffinate and advance electrolyte are

respectively 50mg/L and 150mg/L. The recoveries of organic phase from raffinate and
advance electrolyte are respectively 30 and 70%. The specific gravity of Lix984N and
Kerosene are respectively 0.94 and 0.81 t/m3.

Equations (5.13) and (5.14) give the lost organic in the raffinate and advance
electrolyte respectively.

30
LOR=F(RE2) *50*(1- )*10(−6) (t/h) (5.13)
100

70
LOA=F(ADS1) *150*(1- )*10(−6) (t/h) (5.14)
100

Where “LOR” is lost organic in the raffinate (t/hr), “LOA” is lost organic in the
advance electrolyte (t/hr), “𝐹(𝑅𝐸2) ” is raffinate flow rate (m3/hr) and “𝐹(𝐴𝐷𝑆1) ” is
advance electrolyte flow rate (m3/hr)

Equations (5.15) give the approximate specific gravity of organic phase.

v v
% %
d(Or) = v
*d(Lix) +(1- v
)* d(Ker) (5.15)
100 100

Joseph Kafumbila Page 39

 Where “𝑑(𝑂𝑟) ” is specific gravity of organic phase, “𝑑(𝐿𝑖𝑥) ” is specific gravity of
𝑣
Lix984N, “𝑑(𝐾𝑒𝑟) ” is specific gravity of Kerosene and “𝑣 %” is Lix984N percent in
organic phase

Equations (5.16) and (5.17) give specific consumption of Lix984N and

Kerosene.

v
(LOR+LOA) v% 1000
SCLix= * *d(Lix) * (kg/tCu) (5.16)
d(Or) 100 EWCC

v
(LOR+LOA) % 1000
SCKer= *(1- v
)*d(Ker) * (kg/tCu) (5.17)
d(Or) 100 EWCC

Where “SCLix” is specific consumption of Lix984N (kg/tCu) and “SCKer” is

specific consumption (kg/tCu)

Table (5.3) gives specific consumptions of Lix984N and Kerosene.

Table 5.3: Specific consumptions of Lix984N and Kerosene

Specific consumption Unit

Lix984N 2.06 Kg/tCu
Kerosene 7.88 Kg/tCu

5.3.1.3. EW-Guar

The specific consumption of Guar is 0.2 kg/tCu.

5.3.2. Results

Table (5.4) gives reagent consumption.

Table 5.4: reagent consumption

Unit
Hours per year 8 322 hrs
Feed 6 657 600 t/y
Copper production 92 055 t/y
Sulfur 173 707 t/y
Flocculants 928 t/y
Lix984N 190 t/y
Kerosene 725 t/y
Guar 18 t/y

Joseph Kafumbila Page 40

5.4. Equipment size

5.4.1. Design criteria

5.4.1.1. Pre-leach Filtration

 The filterability is 800 kg/m2/hr.

5.4.1.2. Leach circuit

 Residence time: 8 hrs

 Free board: 10%.

5.4.1.3. Primary Thickener and CCD

 Flux: 500 kg/m2/hr.

5.4.1.4. Ponds

 Pre-settler ponds retention time: 2hours

 Surge ponds retention time: 14hours

5.4.1.5. Mixer - settler

Figures (5.2), (5.3), (5.4) and (5.5) give respectively Mixer, settler, Feed launder
and discharge launder layouts (Kafumbila J., 2022b).

 TRM (Residence time): 2.8 minutes

 HL2 =2.2m
 HF2 =0.9m
M
 HB4 =1.5m
M
 HB3 =0.1m
 HM =0.8m
M
 HB1 =0.85m
 HL1 =2.15m
 HF1 =0.15m
 LFS =4m
 LLS =2.5m
 LLA1 =5.5m
 HA =0.6m (height of aqueous in settler)
 HO =0.3m (height of organic in settler)

Joseph Kafumbila Page 41

 Figure 5.2: Mixer layout

Figure 5.3: Settler layout

Joseph Kafumbila Page 42

 Figure 5.4: Feed launder

Figure 5.5: Discharge launder

 LOL =0.8m
O
 HOL =0.3m
 Settler specific rate (SSR): 5m3/m2/hr
 Organic specific velocity (OSV): 3cm/s
 WLA2 =DM *0.4
 WLA2 =LLA3
FO +FA
 SS (settler area)= (FO and FA organic and aqueous flowrates in
SSR
Mixer)
FO
 Ws = H ∗ OSV
O
SS
 LIS = W
S

Joseph Kafumbila Page 43

 M 𝜋
 VLT (Mixer total live volume)= 4 *(HL1 +HF1 +HL2 +HF2 )*(DM )(2) (DM
Mixer diameter)
M
 VLT = (F0 + FA )*TRM

5.4.1.6. Aqueous coalescing tank

Figure (5.5) gives layout of aqueous coalescing tank.

Figure 5.5: Layout of aqueous coalescing tank.

AC
 VLT (live volume)=FO *TRAC
 TRAC (residence time)=4minutes
F 4
 O
DAC =(ACF ∗ 𝜋)0.5
 ACF (flux)=25m3/m2/hr
4∗VAC
 HAC =π∗(D LT)2
AC

5.4.1.7. Organic surge tank

 VLOS (live volume)=FO *TROS

 TROS (residence time)=20 minutes
π π
 VLOS =4∗R*(DOS )(3) - 2 *(DOS )(2) *HBOS ((DOS diameter and HBOS free board)
DOS
 =3 (HTOS total height)
HOS
T

Joseph Kafumbila Page 44

5.4.1.8. Organic inventory

AC FO
 VOI (inventory)=(VLT +VLOS +VST
O O
+VFL O
+VDL M
+VLT *(F )in*NMS )*1.2 (NMS
O +FA
number of mixer settler)
O
 VST =(LIS +LFS )*Ws *HO *NMS
O FO
 VFL =HF2 * WLA2 *LLA *(F )𝑖𝑛 *NMS
O +FA
O O
 VDL =Ws *LOL *HOL *NMS

5.4.1.9. Advance electrolyte filter

 Filter specific flow rate: 12 (m3/m2/h) (max 18)

 Minimum number of unit operation: 3
 Filter backwash frequency: 8-12hours
 Back wash cycle: 40-50 minutes
 Back wash specific flow rate: 24 (m3/m2/hr)
 Back wash holding tank volume: (Volume set to contain three
consecutive electrolyte filter backwash cycle)

5.4.1.10. Advance electrolyte surge tank

 VTAE (total volume)=FAE *TRAE *1.1

π
 VTAE = 4 *(DAE )2*HAE
 TRAE =10 minutes
HAE
 = 0.7
DAE

5.4.1.11. Filtered electrolyte surge tank

 VTFE (total volume)=FFE *TRFE *1.1

π
 VTFE = 4 *(DFE )2 *HFE
 TRFE =10 minutes
HFE
 = 0.7
DFE

5.4.1.12. Copper electrowinning

Reference (Kafumbila J., 2017b).

 Specific electrolyte flowrate into the cell: 0.12 m3/h/m2 (total cell
cathode area)
 Design current density: 300 A/m2.

Joseph Kafumbila Page 45

  Maximum operating current density: 380 A/m2.
 Cathode spacing: 95 mm.
 Cathode active surface area: ISA: 2.41 m2.
 Harvest cycle: 7 days.
 Current efficiency: 0.90.

T PR x 106
 Ncat = 1.18576 x A
cat x DCD x η

𝑇
Where “𝑁𝑐𝑎𝑡 ” is the calculated number of cathodes in the tank-house, “PR” is the
copper cathode production rate (t/h), “𝐴𝑐𝑎𝑡 ” cathode active surface area (m2),
“DCD” is the design current density (A/m2) and “η” is the current efficiency
(0.90)

d 3 x NT
 HCr =HC x N cat
= 33 – 50 (Harvest per crane par day)
OHC x NC
cat

𝑇
Where “𝑁𝑐𝑎𝑡 ” is the calculated number of cathodes in tank-house, “HC” is the
harvest cycle (days), “𝑁𝑂𝐻𝐶 ” is the number of overhead crane in the tank-
𝐶
house and “𝑁𝑐𝑎𝑡 ” is the number of cathodes per cell (multiple of 3 and ranged
from 22 - 69). For a known number of overhead cranes “ 𝑁𝑂𝐻𝐶 ”, the number of
𝐶 𝑑
cathodes per cell “𝑁𝑐𝑎𝑡 ” is changed until the value of 𝐻𝐶𝑟 is between 33 and 50.

o Less than 45ktpa – the number of overhead cranes is 1.

o Between 45 and 90 ktpa – the number of overhead cranes is 2.
o Between 90 and 135 ktpa – the number of overhead cranes is 3.

 Design number of cells in tank-house “Ncell ” is even number multiple of

the chosen number of rectifiers “Nrec ” in tank-house and close to the
NT
calculated number of cells in tank-house “Ncat
C ”.
cat

Rec N
 Ncell = Ncell (Number of cells per rectifier)
rec

PR x 106
 OCD = 1.18576 x A (Operating current density)
cat x Ncell x Nccat x η

𝐶
Where “OCD” is operating current density (A/m2), “𝑁𝑐𝑎𝑡 ” is the number of
cathodes in the cell, “PR” is copper cathode production rate (t/h), “𝐴𝑐𝑎𝑡 ” cathode
active surface area (m2), “𝑁𝑐𝑒𝑙𝑙 ” is design number of cells in the tank-house, and
“η” is current efficiency (0.90)

Joseph Kafumbila Page 46

  Weight of cathode after deposition cycle (harvest cycle) can reach 150 kg
(copper deposit + permanent cathode). Overhead crane capacity is 150
kg multiplied by the number of unloaded cathodes. The number of
unloaded cathodes is the number of cathodes per cell divided by 3.

C
 AR =Acat * OCD*Ncat (rectifier amperage in A)

Rec
 VRTC =2.2*Ncell (Total cell voltage per rectifier in V)

 VRB = 0.15*VRTC (lost bus-bar voltage per rectifier in V)

 VR = VRTC +VRB (Voltage per rectifier in V)

 PR =VR *AR (Rectifier operating Power in W)

 PRM = 1.25*PR (rectifier Max Power in W)

Nc xN
 Mc =HC xcat cell
WHS x N SM

Where “𝑀𝑐 ” is the capacity of cathode stripping machine (cathodes/hour),

“WHS” is working hours of cathodes stripping machine per day (19 hours) and
“𝑁𝑆𝑀 ” number of cathode stripping machines.

c
 Fcell = Acat x Ncat x 0.12 (electrolyte flowrate per cell- m3/h)

sca
 Number of scavenger cells “Ncell ” is whole number close to
Advance electrolyte flowrate
Fcell

sca
 Fcir = (Ncell - Ncell ) x Fcell (circulating flow rate - m3/h)

Electrolyte recirculation tank (2 inter-connected tanks)

 VTFE (total volume)=FFE *TRFE *1.1

π
 VTFE = 4 *(DFE )2 *HFE
 TRFE =45 minutes
HFE
 = 0.7
DFE

Joseph Kafumbila Page 47

5.4.2. Equipment sizing

Table (5.5) gives major equipment size. Figure (5.6) shows the layout of the
conventional circuit.

Table 5.5: Major equipment size

Equipment Design Criteria Units Required Size

Pre-leach Filter 800,00 kg/(h-m2) 1 000,0 m2

Acid Leach Tanks 8,00 hours 16 088,0 m3
Primary Thickener and CCD 500,00 kg/(h-m2) 1 548,0 m2
Pre-settler PLS pond 2,00 hours 4 344,7 m3
Surge PLS Pond 14,00 hours 30 413,2 m3
Pre-settler Raffinate pond 2,00 hours 4 338,9 m3
Raffinate Tank 14,00 hours 30 372,5 m3
Copper Mixer-settler Extraction
E1 aqueous flow rate m3/h 2174,96
E1 Organic flow rate m3/h 2707,75
Number of trains 4,00
Size per train
E1 aqueous flow rate per train m3/h 543,74
E1 Organic flow rate per train m3/h 676,94
Train configuration 2E+2S
Residence Time Mixing 2,80 minutes 57,0 m3
Mixer diameter 3,67
Settling Rate 5,00 m3/(h-m2) 244,1 m2
Organic specific velocity 3,00 cm/s
Settler Organic Height 0,30 m
Settler wild - WS 20,89 m
Settler initial length - LIS 11,68 m
Aqueous coalescing tank 4,00 minutes 45,1 m3
Loaded Organic Tank 20,00 minutes 225,6 m3
Organic inventory 1 055,7 m3
First fill (4 trains)
Copper SX Extractant 729,7 ton
Copper SX Diluent 2 791,8 ton
Electrolyte Filter Feed Tank 10,00 minutes 125,8 m3
Electrolyte filter 12,00 m3/(h-m2) 62,9 m2
Electrolyte Filtered Tank 10,00 minutes 125,8 m3
Cu electrowinning
Number of cells 208,0
Number of cathode per cell 69,0
Operating current density 299,7 A/m2
Number of Crane 2,0
Capacity crane 3,5 ton
Number of rectifier 2,0
Rectifier operating amperage 49,8 KA
Rectifier operating voltage 263,1 V
Number stripping machine 2,0
Capacity of stripping machine 54,0 Cath/h
Recirculation flowrate 3392,32 m3
Number of electrolyte circulating tank 2
Electrolyte Circulating Tank vol. per tank 45,00 minutes 1 272,1 m3

Joseph Kafumbila Page 48

 Figure 5.6: Conventional circuit - layout

Joseph Kafumbila Page 49

6. Split circuit – different organic phase

6.1. Configuration

6.1.1. Flow diagram

Figure (6.1) gives the flow diagram of Copper split circuit with different organic
phase on which the mass balance is done.

Figure 6.1: Flow diagram of split circuit with different organic phase

Joseph Kafumbila Page 50

Abbreviations of unit operations:

 LC : Leach circuit.
 PKT: Primary thickener.
 KTn: Thickener of rank “n” in CCD train.
 HGSX En: Stage of rank “n” in high grade CuSX - extraction train.
 HGACT: high grade aqueous coalescing Tank.
 HGSX Sn: Stage of rank “n” in high grade CuSX - stripping train.
 LGSX En: Stage of rank “n” in low grade CuSX - extraction train.
 LGACT: low grade aqueous coalescing tank.
 LGSX S: stage of low grade CuSX – stripping train.
 EW: .Copper electrowinning.

Abbreviations of lines between unit operations:

 FCake: Pre-leach filtration cake.

 LCA: Leach concentrated acid.
 LCS: Leach circuit solution.
 OLC: Outlet leach circuit.
 PTKFC: Flocculants of primary thickener.
 PTKUF: Underflow of primary thickener.
 PTKOF: Overflow of primary thickener.
 TKFCn: Flocculants of thickener of rank “n” in CCD train.
 TKnUF: Underflow of thickener of rank “n” in CCD train.
 TKnOF: Overflow of thickener of rank “n” in CCD train.
 WW: Wash water of CCD train.
 ACS: Acid solution
 HGPLS: High grade pregnant leach solution.
 HGREn: Raffinate of stage of rank “n” in high grade CuSX - extraction
train.
 HGLOEn: Loaded organic of stage of rank “n” in high grade CuSX -
extraction train.
 AHGLOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
high grade CuSX - extraction train.
 HGLOAC: high grade Loaded organic from aqueous coalescing tank.
 AHGLOAC: Aqueous entrainment in high grade loaded organic from
aqueous coalescing tank.
 HGACTD: High grade Drain of aqueous coalescing tank.
 HGSOSn: Stripping organic of stage of rank “n” in high grade CuSX -
stripping train.

Joseph Kafumbila Page 51

  AHGSOSn: Aqueous entrainment in stripping organic of stage of rank “n”
in high grade CuSX - stripping train.
 HGADSn: high grade Advance electrolyte of stage of rank “n” in CuSX -
stripping train.
 RHGADSn: Recirculated high grade Advance electrolyte of stage of rank
“n” in CuSX stripping train.
 HGSPE: high grade Spent electrolyte.
 LGPLS: low grade pregnant leach solution.
 LGREn: Raffinate of stage of rank “n” in low grade CuSX - extraction train.
 LGLOEn: Loaded organic of stage of rank “n” in low grade CuSX -
extraction train.
 ALGLOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
low grade CuSX - extraction train.
 LGLOAC: Low grade Loaded organic from aqueous coalescing tank.
 ALGLOAC: Aqueous entrainment in low grade loaded organic from
aqueous coalescing tank.
 LGACTD: Low grade Drain of aqueous coalescing tank.
 LGSOS: Stripping organic of low grade CuSX - stripping.
 AHGSOS: Aqueous entrainment in stripping organic of low grade CuSX -
stripping.
 LGADS: Low grade Advance electrolyte in CuSX - stripping.
 RLGADS: Recirculated low grade Advance electrolyte in CuSX - stripping.
 LGSPE: high grade Spent electrolyte.
 LGRE2L: Low grade raffinate of stage 2 of CuSX - extraction train to leach
circuit.
 LGRE2B: Low grade raffinate of stage 2 of CuSX - extraction train to
water balance bleed.
 ADS: Advance electrolyte
 EWO: Oxygen produced in Copper electrowinning circuit.
 EWCC: Copper cathode produced in Copper electrowinning circuit.
 EWS: Sulfur produced in Copper electrowinning circuit.
 EWW: Water for Copper electrowinning circuit.
 EWCA: Concentrated acid for Copper electrowinning circuit.
 OEW: Outlet of Copper electrowinning circuit.
 EWB: Bleed of Copper electrowinning circuit.

Joseph Kafumbila Page 52

6.1.2. Plant description

The cake of pre-leach filtration cake is fed in leach circuit with leach circuit
solution. Concentrated acid and sulfur dioxide gas are also added in the leach circuit for
pH and redox potential control. Slurry discharged from the leach circuit is thickened in
primary thickener. Underflow of primary thickener is fed to counter current
decantation circuit where leach residue is washed with acidulated water.

Overflow of primary thickener is called high grade pregnant leach solution and
is fed to the high grade copper CuSX - extraction train. The high grade loaded organic is
sent to high grade aqueous coalescing tank to remove a maximum volume of aqueous
entrainment solution. High grade Loaded organic from high grade aqueous coalescing
tank is sent to high grade CuSX - stripping train. High grade spent electrolyte from
copper electrowinning circuit is sent to high grade CuSX - stripping train. High grade
Advance electrolyte from CuSX – stripping train is sent back to Copper electrowinning
circuit.

Overflow of first thickener in CCD train is called low grade pregnant leach
solution and is fed to the low grade copper CuSX - extraction train. The low grade loaded
organic from organic is sent to low grade aqueous coalescing tank to remove a
maximum volume of aqueous entrainment solution. Low grade Loaded organic from low
grade aqueous coalescing tank is sent to low CuSX - stripping train. Low grade spent
electrolyte from copper electrowinning circuit is sent to low grade CuSX - stripping. Low
grade Advance electrolyte from CuSX - stripping is sent back to Copper electrowinning
circuit.

Concentrated acid and water are also added in Copper electrowinning circuit.
Copper cathode, Oxygen gas and sulfur are produced in Copper electrowinning circuit.
Iron bleed solution from Copper electrowinning circuit is sent back to high grade PLS
pond.

One part of low grade raffinate of CuSX - extraction train is sent back to leach
circuit and the remaining is sent to cobalt circuit.

Joseph Kafumbila Page 53

6.2. Mass balance

6.2.1. Design criteria

6.2.1.1. Leach circuit

Design criteria of leach circuit mass balance are the following:

 Feed flow rate: 800t/h as in conventional circuit.

 Other as in conventional circuit

6.2.1.2. Primary thickener

Design criteria of primary thickener mass balance are the following:

 Solid percent in underflow of primary thickener: 58%.

 Other as in conventional circuit

6.2.1.3. CCD circuit

Design criteria of CCD circuit mass balance are the following:

 As in conventional circuit

6.2.1.4. High grade CuSX – extraction train

Design criteria of high grade solvent extraction circuit mass balance are the
following:

 Type of extractant: Lix984N.

 Saturation ratio (LO/ML): ranges from 70 to 80% the ratio Cu/Fe in
HGE1 loaded organic must be greater than 1000.
 O/A ratio (Loaded organic of stage of rank “2” on extraction train onto
overflow of primary thickener): 1.25.
 Number of stage: 2.
 Volume percent of extractant in organic phase: depends on saturation
ratio.
 Mixing efficiency for Copper:
o Stage E1: 95%.
Joseph Kafumbila Page 54
 o Stage E2: 97%.
 Aqueous entrainment in organic:
o Stage E1: 1000ppm.
o Stage E2: 1000ppm.
 Equilibrium copper concentration: Equation (5.5) gives equilibrium
condition of chemical reaction (5.c) (Kafumbila J., 2022b).

 Equilibrium Fe(III) concentration: Data of Lix984 (Kafumbila J., 2022b)

on extraction train. Equation (5.6) gives equilibrium condition of
chemical reaction (5.d).

 Mixing efficiency for Fe(III) (assuming the same as for Copper):

o Stage E1: 95%.
o Stage E2: 97%.

6.2.1.5. High grade aqueous coalescing tank

Design criterion of aqueous coalescing tank is:

 As in conventional circuit

6.2.1.6. High grade CuSX – stripping train

Design criteria of high grade stripping circuit mass balance are the following:

 O/A (internal): 1.25

 Number of stage: 2.
 Concentration of copper in advance electrolyse: 49-50 g/L.
 Spent electrolyte composition:
o Copper concentration: 35 g/L.
o Acid concentration: 180 g/L.
o Fe(II) concentration: 1.0 g/L.
o Fe(III) concentration: 1.0 g/L.
 Mixing efficiency:
o Stage S1: 95%.
o Stage S2: 90%.
o Aqueous entrainment in organic:
o Stage S1: 300ppm.
o Stage S2: 300ppm.
o Equilibrium copper concentration: Equation (5.7) gives equilibrium
condition of chemical reaction (5.e) (Kafumbila J., 2022b).

Joseph Kafumbila Page 55

  Ferric stripping efficiency: Concentration of Ferric in stripped organic –
1ppm (Hans Hein, 2005).

6.2.1.7. Low grade CuSX – extraction train

Design criteria of low grade solvent extraction circuit mass balance are the
following:

 Type of extractant: Lix984N.

 Saturation ratio (LO/ML): ranges from 70 to 80% the ratio Cu/Fe in
HGE1 loaded organic must be greater than 1000.
 O/A ratio (Loaded organic of stage of rank “2” on extraction train onto
overflow of first thickener in CCD train): 1.25.
 Number of stage: 2.
 Volume percent of extractant in organic phase: depends on saturation
ratio.
 Mixing efficiency for Copper:
o Stage E1: 95%.
o Stage E2: 97%.
 Aqueous entrainment in organic:
o Stage E1: 1000ppm.
o Stage E2: 1000ppm.
 Equilibrium copper concentration: Equation (5.5) gives equilibrium
condition of chemical reaction (5.c) (Kafumbila J., 2022b).

 Equilibrium Fe(III) concentration: Data of Lix984 (Kafumbila J., 2022b)

on extraction train. Equation (5.6) gives equilibrium condition of
chemical reaction (5.d).

 Mixing efficiency for Fe(III) (assuming the same as for Copper):

o Stage E1: 95%.
o Stage E2: 97%.

6.2.1.8. Low grade aqueous coalescing tank

Design criterion of aqueous coalescing tank is:

 As in conventional circuit

6.2.1.9. Low grade CuSX – stripping train

Design criteria of low grade stripping circuit mass balance are the following:

Joseph Kafumbila Page 56

  O/A (internal): 1.25
 Number of stage: 1
 Concentration of copper in advance electrolyse: 49-50 g/L.
 Spent electrolyte composition:
o Copper concentration: 35 g/L.
o Acid concentration: 180 g/L.
o Fe(II) concentration: 1.0 g/L.
o Fe(III) concentration: 1.0 g/L.
 Mixing efficiency: 95%.
 Aqueous entrainment in organic: 300ppm.
 Equilibrium copper concentration: Equation (5.7) gives equilibrium
condition of chemical reaction (5.e) (Kafumbila J., 2022b).

 Ferric stripping efficiency: Concentration of Ferric in stripped organic –

1ppm (Hans Hein, 2005).

6.2.1.10. Copper electrowinning

Design criteria of Copper electrowinning circuit mass balance are the following:

 As in conventional circuit

6.2.2. Mass balance results

Tables from (B.1) to (B.10) in the appendix (B) give the mass balance of split
circuit with different organic phase using the realistic simulation model. The solid feed
flow rate is as for the conventional.

With a high density thickener (UF -58% solid), the flowrate of primary
thickener overflow is 1166 m3/h. The number of thickener in CCD train is optimized to
have the flowrate of first thickener overflow in CCD train between 900 and 1100 m3/h to
have 4 copper solvent extraction trains (2 on High grade and 2 on low grade) with
approximate same flow rate. Table (6.1) gives the summary of simulation results. Here
are some observations:

 The number of thickener in the CCD train is optimized at 6 to have the

TK1OF flow rate in the CCD train at 1080.3 m3/hr.
 84.4% of the inlet sulfate in the leach circuit comes with concentrated
sulfuric acid and 15.6% from SO2 oxidation.
 69.6% of inlet sulfur in the leach circuit comes with concentrated sulfuric
acid and 30.4% with the SO2.

Joseph Kafumbila Page 57

  The Iron concentration in the leach solution is the saturation
concentration (Fe(2): 1.511g/L and Fe(3): 0.084g/L).
 The increase of sulfur grade in the leach residue is due to gypsum
precipitation.
 The Calcium concentration in the leach solution and CCD train solutions
are the saturation concentrations. Therefore there is dissolution of
gypsum from primary thickener to the last thickener of CCD train.
 The concentration of Iron HGLOE1 (0.0086ppm) is lower than the
concentration of Iron in HGLOE2 (0.0098ppm). There is rejection of Iron
from organic phase in the HGE1 due to the increase of copper
concentration in HGLOE1 (8.78 g/L) comparatively to LOE2 (4.43g/L).
 The ratio Cu/Fe in HGLOE1 is 1022 at the ratio LO/ML equal to 0.715 at
volume percent of Lix984N in organic about 22.95%, at Fe(3)
concentration in HGPLS about 0.090g/L and at phosphate and dithionate
concentrations respectively about 1.80g/L and 19.81g/L (Kafumbila J.,
2022b).
 The concentration of Iron LGLOE1 (0.0051ppm) is lower than the
concentration of Iron in LGLOE2 (0.0059ppm). There is rejection of Iron
from organic phase in the LGE1 due to the increase of copper
concentration in LGLOE1 (5.19 g/L) comparatively to LOE2 (3.04g/L).
 The ratio Cu/Fe in LGLOE1 is 1023 at the ratio LO/ML equal to 0.745, at
volume percent of Lix984N in organic about 13.47%, at Fe(3)
concentration in LGPLS about 0.040g/L and at phosphate and dithionate
concentrations respectively about 0.86g/L and 9.47g/L (Kafumbila J.,
2022b).

Joseph Kafumbila Page 58

 Table 6.1: Result summary

Description
Solid feed flow rate 800 Ton/hr
Number of thickener in CCD train 6
Acid consumption – Leach circuit 50.59 Kg/t feed
Acid consumption – CuEW circuit 3.04 Kg/t feed
Acid consumption – wash CCD circuit 0.49 Kg/t feed
Total acid consumption 54.13 Kg/t feed
Lost acid (free acid and acid associated with Copper) – CCD TK6 UF 0.34 Kg/t feed
Lost acid (free acid and acid associated with Copper) – LGRE2B 7.14 Kg/t feed
SO2 consumption – Leach circuit 14.11 Kg/t feed
Flocculants consumption – Primary thickener and CCD train 139.32 g/t feed
HGPLS flow rate 1174.9 m3/hr
Extractant percent in organic phase 22.95 %
Saturation ratio (LO/ML) 0.715
Cu/Fe in LOE1 1022
LGPLS flow rate 1081.1 m3/hr
Extractant percent in organic phase 13.47 %
Saturation ratio (LO/ML) 0.745
Cu/Fe in LOE1 1023
Split value 69.7 %
Copper transferred from high grade PLS 69.9 %
Copper production 13.88 Kg/t feed
Ratio Copper in EWB onto Copper production 2.59 %
Lost copper in CCD-TK6 UF 0.06 Kg/t feed
Lost copper in LGRE2B 0.10 Kg/t feed
Soluble copper recovery 98.85 %
CCD wash ratio 1.53 m3/ton
Cobalt concentration in TK6 UF 0.093 g/L

6.3. Reagent consumption

6.3.1. Design criteria

6.3.1.1. Acid and SO2

Acid and SO2 are produced from sulfur. Table (6.2) gives the specific
consumption of sulfur.

Table 6.2: Sulfur specific consumption

Specific consumption Unit

Acid consumption 54.13 Kg/t feed
Sulfur to acid 18.06 Kg/t feed
SO2 consumption 14.11 Kg/t feed
Sulfur to SO2 7.21 Kg/t feed
Total sulfur consumption 25.27 Kg/t feed

Joseph Kafumbila Page 59

6.3.1.2. Lix984N and Kerosene

The concentrations of organic phase in raffinate and advance electrolyte are

respectively 50mg/L and 150mg/L. The recoveries of organic phase from raffinate and
advance electrolyte are respectively 30 and 70%. The specific gravity of Lix984N and
Kerosene are respectively 0.94 and 0.81 t/m3.

Table (6.3) gives specific consumptions of Lix984N and Kerosene.

Table 6.3: Specific consumptions of Lix984N and Kerosene

Specific consumption Unit

HG - Lix984N 1.51 Kg/tCu
HG - Kerosene 4.36 Kg/tCu
LG - Lix984N 0.66 Kg/tCu
LG - Kerosene 3.67 Kg/tCu
Total - Lix984N 2.17 Kg/tCu
Total - Kerosene 8.03 Kg/tCu

6.3.1.3. EW-Guar

The specific gravity of Guar is 0.2 kg/tCu.

6.3.2. Results

Table (6.4) gives reagent consumptions.

Table 6.4: reagent consumption

Unit
Hours per year 8 322 hrs
Feed 6 657 600 t/y
Copper production 92 431 t/y
Sulfur 168 215 t/y
Flocculants 928 t/y
Lix984N 201 t/y
Kerosene 742 t/y
Guar 18 t/y

Joseph Kafumbila Page 60

6.4. Equipment size

6.4.1. Design criteria

6.4.1.1. Pre-leach Filtration

 As for conventional circuit.

6.4.1.2. Leach circuit

 As for conventional circuit.

6.4.1.3. Primary Thickener and CCD

 As for conventional circuit.

6.4.1.4. Ponds

 As for conventional circuit.

6.4.1.5. Mixer - settler

 As for conventional circuit.

6.4.1.6. Aqueous coalescing tank

 As for conventional circuit.

6.4.1.7. Organic surge tank

 As for conventional circuit.

6.4.1.8. Organic inventory

 As for conventional circuit.

6.4.1.9. Advance electrolyte filter

 As for conventional circuit.

Joseph Kafumbila Page 61

6.4.1.10. Advance electrolyte surge tank

 As for conventional circuit.

6.4.1.11. Filtered electrolyte surge tank

 As for conventional circuit.

6.4.1.12. Copper electrowinning

 As for conventional circuit.

6.4.2. Equipment sizing

Tables (6.5)-A and (6.5)-B give major equipment size. Figure (6.2) gives the
split circuit with different organic phase layout.

Joseph Kafumbila Page 62

 Table 6.5 - A: Major equipment size

Equipment Design Criteria Units Required Size

Pre-leach Filter 800,00 kg/(h-m2) 1 000,0 m2

Acid Leach Tanks 8,00 hours 15 863,6 m3
Primary Thickener and CCD 500,00 kg/(h-m2) 1 548,0 m2
HG Pre-settler PLS pond 2,00 hours 2 349,8 m3
HG Surge PLS Pond 14,00 hours 16 448,3 m3
HG Pre-settler Raffinate pond 2,00 hours 2 345,8 m3
HG Raffinate Tank 14,00 hours 16 420,6 m3
HG Copper Mixer-settler Extraction
HGE1 aqueous flow rate m3/h 1176,24
HGE1 Organic flow rate m3/h 1457,61
HG Number of trains 2,00
HG Size per train
HGE1 aqueous flow rate per train m3/h 588,12
HGE1 Organic flow rate per train m3/h 728,80
Train configuration 2E+2S
Residence Time Mixing 2,80 minutes 61,5 m3
Mixer diameter 3,81
Settling Rate 5,00 m3/(h-m2) 263,4 m2
Organic specific velocity 3,00 cm/s
Settler Organic Height 0,30 m
Settler wild - WS 22,5 m
Settler initial length - LIS 11,7 m
Aqueous coalescing tank 4,00 minutes 48,6 m3
Loaded Organic Tank 20,00 minutes 242,9 m3
Organic inventory 1 134,2 m3
LG Pre-settler PLS pond 2,00 hours 2 162,1 m3
LG Surge PLS Pond 14,00 hours 15 134,8 m3
LG Pre-settler Raffinate pond 2,00 hours 2 159,6 m3
LG Raffinate Tank 14,00 hours 15 117,5 m3
LG Copper Mixer-settler Extraction
LGE1 aqueous flow rate m3/h 1082,36
LGE1 Organic flow rate m3/h 1350,35
LG Number of trains 2,00
LG Size per train
LGE1 aqueous flow rate per train m3/h 541,18
LGE1 Organic flow rate per train m3/h 675,17
Train configuration 2E+S
Residence Time Mixing 2,80 minutes 56,8 m3
Mixer diameter 3,66
Settling Rate 5,00 m3/(h-m2) 243,3 m2
Organic specific velocity 3,00 cm/s
Settler Organic Height 0,30 m
Settler wild - WS 20,8 m
Settler initial length - LIS 11,7 m
Aqueous coalescing tank 4,00 minutes 45,0 m3
Loaded Organic Tank 20,00 minutes 225,1 m3
Organic inventory 870,6 m3

Joseph Kafumbila Page 63

 Table 6.5 - B: Major equipment size

Equipment Design Criteria Units Required Size

First fill (HG and LG circuits)
Copper SX Extractant 709,7 ton
Copper SX Diluent 2 636,1 ton
Electrolyte Filter Feed Tank 10,00 minutes 127,7 m3
Electrolyte filter 12,00 m3/(h-m2) 63,8 m2
Electrolyte Filtered Tank 10,00 minutes 127,7 m3
Cu electrowinning
Number of cells 208,0
Number of cathode per cell 69,0
Operating current density 300,9 A/m2
Number of Crane 2,0
Capacity crane 3,45 ton
Number of rectifier 2,0
Rectifier operating amperage 50,0 KA
Rectifier operating voltage 263,1 V
Number stripping machine 2,0
Capacity of stripping machine 54,0 Cath/h
Recirculation flowrate 3372,36 m3
Number of electrolyte circulating tank 2
Electrolyte Circulating Tank vol. per tank 45,00 minutes 1 264,6 m3

Joseph Kafumbila Page 64

 Figure 6.2: Split circuit with different organic phases - layout

Joseph Kafumbila Page 65

7. Split circuit – same organic phase

7.1. Configuration

7.1.1. Flow diagram

Figure (7.1) gives the flow diagram of Copper split circuit with same organic
phase on which the mass balance is done.

Figure 7.1: Flow diagram of split circuit with same organic phase

Joseph Kafumbila Page 66

Abbreviations of unit operations:

 LC: Leach circuit.

 PKT: Primary thickener.
 KTn: Thickener of rank “n” in CCD train.
 HGSX En: Stage of rank “n” in high grade CuSX - extraction train.
 ACT: high grade aqueous coalescing Tank.
 SX Sn: Stage of rank “n” in high grade CuSX - stripping train.
 LGSX En: Stage of rank “n” in low grade CuSX - extraction train.
 EW: .Copper electrowinning.

Abbreviations of lines between unit operations:

 FCake: Pre-leach filtration cake.

 LCA: Leach concentrated acid.
 LCS: Leach circuit solution.
 OLC: Outlet leach circuit.
 PTKFC: Flocculants of primary thickener.
 PTKUF: Underflow of primary thickener.
 PTKOF: Overflow of primary thickener.
 TKFCn: Flocculants of thickener of rank “n” in CCD train.
 TKnUF: Underflow of thickener of rank “n” in CCD train.
 TKnOF: Overflow of thickener of rank “n” in CCD train.
 WW: Wash water of CCD train.
 ACS: Acid solution
 HGPLS: High grade pregnant leach solution.
 HGREn: Raffinate of stage of rank “n” in high grade CuSX - extraction
train.
 HGLOEn: Loaded organic of stage of rank “n” in high grade CuSX -
extraction train.
 AHGLOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
high grade CuSX - extraction train.
 LOAC: high grade Loaded organic from aqueous coalescing tank.
 ALOAC: Aqueous entrainment in high grade loaded organic from aqueous
coalescing tank.
 ACTD: High grade drain of aqueous coalescing tank.
 SOSn: Stripping organic of stage of rank “n” in high grade CuSX -
stripping train.
 ASOSn: Aqueous entrainment in stripping organic of stage of rank “n” in
CuSX - stripping train.
 ADSn: Advance electrolyte of stage of rank “n” in solvent stripping train.

Joseph Kafumbila Page 67

  RADSn: Recirculated advance electrolyte of stage of rank “n” in CuSX -
stripping train.
 SPE: Spent electrolyte.
 LGPLS: low grade pregnant leach solution.
 LGREn: Raffinate of stage of rank “n” in low grade CuSX - extraction train.
 LGLOEn: Loaded organic of stage of rank “n” in low grade CuSX -
extraction train.
 ALGLOEn: Aqueous entrainment in loaded organic of stage of rank “n” in
low grade CuSX - extraction train.
 LGRE2L: Low grade raffinate of stage 2 of CuSX extraction train to leach
circuit.
 LGRE2B: Low grade raffinate of stage 2 of CuSX - extraction train to
water balance bleed.
 EWO: Oxygen produced in Copper electrowinning circuit.
 EWCC: Copper cathode produced in Copper electrowinning circuit.
 EWS: Sulfur produced in Copper electrowinning circuit.
 EWW: Water for Copper electrowinning circuit.
 EWCA: Concentrated acid for Copper electrowinning circuit.
 OEW: Outlet of Copper electrowinning circuit.
 EWB: Bleed of Copper electrowinning circuit.

7.1.2. Plant description

The cake of pre-leach filtration cake is fed in leach circuit with leach circuit
solution. Concentrated acid and sulfur dioxide gas are also added in the leach circuit for
pH and redox potential control. Slurry discharged from the leach circuit is thickened in
primary thickener. Underflow of primary thickener is fed to counter current
decantation circuit where leach residue is washed with acidulated water.

Overflow of primary thickener is called high grade pregnant leach solution and
is fed to the high grade CuSX - solvent extraction train. The high grade loaded organic
from organic is sent to aqueous coalescing tank to remove a maximum volume of
aqueous entrainment solution. Loaded organic from high grade aqueous coalescing tank
is sent to CuSX - stripping train. Spent electrolyte from copper electrowinning circuit is
sent to CuSX stripping train. Advance electrolyte from CuSX – stripping train is sent back
to Copper electrowinning circuit. Stripping organic is sent to low grade CuSx - extraction
train.

Overflow of first thickener in CCD train is called low grade pregnant leach
solution and is fed to the low grade copper CuSX - extraction train. The low grade loaded
organic is sent to high grade high grade CuSX - extraction train.

Joseph Kafumbila Page 68

 Concentrated acid and water are also added in Copper electrowinning circuit.
Copper cathode, Oxygen gas and sulfur are produced in Copper electrowinning circuit.
Iron bleed solution from Copper electrowinning circuit is sent back to high grade PLS
pond. One part of low grade raffinate of CuSX - extraction train is sent back to leach
circuit and the remaining is sent to cobalt circuit.

7.2. Mass balance

7.2.1. Design criteria

7.2.1.1. Leach circuit

Design criteria of leach circuit mass balance are the following:

 Feed flow rate: 800t/h as in conventional circuit.

 Other as in conventional circuit

7.2.1.2. Primary thickener

Design criteria of primary thickener mass balance are the following:

 Solid percent in underflow of primary thickener: 58%.

 Other as in conventional circuit

7.2.1.3. CCD circuit

Design criteria of CCD circuit mass balance are the following:

 As in conventional circuit

7.2.1.4. High grade CuSX – extraction train

 As in split circuit with different organic phase

7.2.1.5. Aqueous coalescing tank

 As in conventional circuit

Joseph Kafumbila Page 69

7.2.1.6. CuSX – stripping train

 As in conventional circuit

7.2.1.7. Low grade CuSX – extraction train

 As in split circuit with different organic phase

7.2.1.8. Copper electrowinning

 As in conventional circuit

7.2.2. Mass balance results

Tables from (C.1) to (C.8) in the appendix (C) give the mass balance of split
circuit with same organic phase using the realistic simulation model. The solid feed flow
rate is as for the conventional.

With a high density thickener (UF -58% solid), the flowrate of primary
thickener overflow is 1166 m3/h. The number of thickener in CCD train is optimized to
have the flowrate of first thickener overflow in CCD train between 900 and 1100 m3/h to
have 2 copper solvent extraction trains in which HGPLS flow rate is close to LGPLS.
Table (7.1) gives the summary of simulation results. Here are some observations:

 The number of thickener in the CCD train is optimized at 6 to have the

TK1OF flow rate in the CCD train at 1079.7 m3/hr.
 84.6% of the inlet sulfate in the leach circuit comes with concentrated
sulfuric acid and 15.4% from SO2 oxidation.
 69.9% of inlet sulfur in the leach circuit comes with concentrated sulfuric
acid and 30.1% with the SO2.
 The Iron concentration in the leach solution is the saturation
concentration (Fe(2): 1.505g/L and Fe(3): 0.085g/L).
 The increase of sulfur grade in the leach residue is due to gypsum
precipitation.
 The Calcium concentration in the leach solution and CCD train solutions
are the saturation concentrations. Therefore there is dissolution of
gypsum from primary thickener to the last thickener of CCD train.
 The concentration of Iron HGLOE1 (0.0139ppm) is lower than the
concentration of Iron in HGLOE2 (0.0163ppm). There is rejection of Iron
from organic phase in the HGE1 due to the increase of copper
concentration in HGLOE1 (11.78 g/L) comparatively to LOE2 (7.82g/L).

Joseph Kafumbila Page 70

  The ratio Cu/Fe in HGLOE1 is 847 at the ratio LO/ML equal to 0.8 at
volume percent of Lix984N in organic about 27.16%, at Fe(3)
concentration in HGPLS about 0.091g/L and at phosphate and dithionate
concentrations respectively about 1.80g/L and 19.74g/L (Kafumbila J.,
2022b).
 The concentration of Iron LGLOE1 (0.025ppm) is high than the
concentration of Iron in LGLOE2 (0.011ppm). There is not rejection of
Iron from organic phase in the LGE1 due to the increase of copper
concentration in LGLOE1 (6.37 g/L) comparatively to LOE2 (4.00g/L).

Table 7.1: Result summary

Description
Solid feed flow rate 800 Ton/hr
Number of thickener in CCD train 6
Acid consumption – Leach circuit 50.68 Kg/t feed
Acid consumption – CuEW circuit 3.36 Kg/t feed
Acid consumption – wash CCD circuit 0.49 Kg/t feed
Total acid consumption 54.54 Kg/t feed
Lost acid (free acid and acid associated with Copper) – CCD TK6 UF 0.34 Kg/t feed
Lost acid (free acid and acid associated with Copper) – LGRE2B 7.44 Kg/t feed
SO2 consumption – Leach circuit 13.98 Kg/t feed
Flocculants consumption – Primary thickener and CCD train 139.32 g/t feed
HGPLS flow rate 1175.7 m3/hr
Extractant percent in organic phase 27.16 %
Saturation ratio (LO/ML) 0.8
Cu/Fe in LOE1 847
LGPLS flow rate 1079.7 m3/hr
Split value 69.7 %
Copper transferred from high grade PLS 68.6 %
Copper production 13.94 Kg/t feed
Ratio Copper in EWB onto Copper production 2.97 %
Lost copper in CCD-TK6 UF 0.06 Kg/t feed
Lost copper in LGRE2B 0.04 Kg/t feed
Soluble copper recovery 99.31 %
CCD wash ratio 1.53 m3/ton
Cobalt concentration in TK6 UF 0.093 g/L

7.3. Reagent consumption

7.3.1. Design criteria

7.3.1.1. Acid and SO2

Acid and SO2 are produced from sulfur. Table (7.2) gives the specific
consumption of sulfur.

Joseph Kafumbila Page 71

 Table 6.2: Sulfur specific consumption

Specific consumption Unit

Acid consumption 54.54 Kg/t feed
Sulfur to acid 18.20 Kg/t feed
SO2 consumption 13.98 Kg/t feed
Sulfur to SO2 7.14 Kg/t feed
Total sulfur consumption 25.34 Kg/t feed

7.3.1.2. Lix984N and Kerosene

The concentrations of organic phase in raffinate and advance electrolyte are

respectively 50mg/L and 150mg/L. The recoveries of organic phase from raffinate and
advance electrolyte are respectively 30 and 70%. The specific gravity of Lix984N and
Kerosene are respectively 0.94 and 0.81 t/m3.

Table (7.3) gives specific consumptions of Lix984N and Kerosene.

Table 7.3: Specific consumptions of Lix984N and Kerosene

Specific consumption Unit

HG - Lix984N 2.06 Kg/tCu
HG - Kerosene 4.76 Kg/tCu
LG - Lix984N 1.03 Kg/tCu
LG - Kerosene 2.37 Kg/tCu
Total - Lix984N 3.09 Kg/tCu
Total - Kerosene 7.14 Kg/tCu

7.3.1.3. EW-Guar

The specific gravity of Guar is 0.2 kg/tCu.

7.3.2. Results

Table (7.4) gives reagent consumption.

Table 7.4: reagent consumption

Unit
Hours per year 8 322 hrs
Feed 6 657 600 t/y
Copper production 92 836 t/y
Sulfur 168 684 t/y
Flocculants 928 t/y
Lix984N 287 t/y
Kerosene 663 t/y
Guar 19 t/y

Joseph Kafumbila Page 72

7.4. Equipment size

7.4.1. Design criteria

7.4.1.1. Pre-leach Filtration

 As for conventional circuit.

7.4.1.2. Leach circuit

 As for conventional circuit.

7.4.1.3. Primary Thickener and CCD

 As for conventional circuit.

7.4.1.4. Ponds

 As for conventional circuit.

7.4.1.5. Mixer - settler

 As for conventional circuit.

7.4.1.6. Aqueous coalescing tank

 As for conventional circuit.

7.4.1.7. Organic surge tank

 As for conventional circuit.

7.4.1.8. Organic inventory

 As for conventional circuit.

7.4.1.9. Advance electrolyte filter

 As for conventional circuit.

Joseph Kafumbila Page 73

7.4.1.10. Advance electrolyte surge tank

 As for conventional circuit.

7.4.1.11. Filtered electrolyte surge tank

 As for conventional circuit.

7.4.1.12. Copper electrowinning

 As for conventional circuit.

7.4.2. Equipment sizing

Tables (7.5)-A and (7.5)-B give major equipment size. Figure (7.2) gives the
split circuit with same organic phase layout.

Table 7.5 - A: Major equipment size

Equipment Design Criteria Units Required Size

Pre-leach Filter 800,00 kg/(h-m2) 1 000,0 m2

Acid Leach Tanks 8,00 hours 15 858,4 m3
Primary Thickener and CCD 500,00 kg/(h-m2) 1 548,0 m2
HG Pre-settler PLS pond 2,00 hours 2 351,3 m3
HG Surge PLS Pond 14,00 hours 16 459,1 m3
HG Pre-settler Raffinate pond 2,00 hours 2 349,4 m3
HG Raffinate Tank 14,00 hours 16 445,8 m3
Copper Mixer-settler Extraction
HGE1 aqueous flow rate m3/h 1177,01
HGE1 Organic flow rate m3/h 1457,05
Number of trains 2,00
Size per train
HGE1 aqueous flow rate per train m3/h 588,50
HGE1 Organic flow rate per train m3/h 728,53
Train configuration 2E+2E+2S
Residence Time Mixing 2,80 minutes 61,5 m3
Mixer diameter 3,81
Settling Rate 5,00 m3/(h-m2) 263,4 m2
Organic specific velocity 3,00 cm/s
Settler Organic Height 0,30 m
Settler wild - WS 22,5 m
Settler initial length - LIS 11,7 m
Aqueous coalescing tank 4,00 minutes 48,6 m3
Loaded Organic Tank 20,00 minutes 242,8 m3
Organic inventory 1 526,0 m3
LG Pre-settler PLS pond 2,00 hours 2 159,4 m3
LG Surge PLS Pond 14,00 hours 15 115,6 m3
LG Pre-settler Raffinate pond 2,00 hours 2 156,8 m3
LG Raffinate Tank 14,00 hours 15 097,4 m3

Joseph Kafumbila Page 74

 Table 7.5 - B: Major equipment size

Equipment Design Criteria Units Required Size

First fill (HG and LG circuits)
Copper SX Extractant 779,1 ton
Copper SX Diluent 1 800,8 ton
Electrolyte Filter Feed Tank 10,00 minutes 128,5 m3
Electrolyte filter 12,00 m3/(h-m2) 64,3 m2
Electrolyte Filtered Tank 10,00 minutes 128,5 m3
Cu electrowinning
Number of cells 208,0
Number of cathode per cell 69,0
Operating current density 302,2 A/m2
Number of Crane 2,0
Capacity of crane 3,45 ton
Number of rectifier 2,0
Rectifier operating amperage 50,3 KA
Rectifier operating voltage 263,1 V
Number stripping machine 2,0
Capacity of stripping machine 54,0 Cath/h
Recirculation flowrate 3372,36 m3
Number of electrolyte circulating tank 2
Electrolyte Circulating Tank vol. per tank 45,00 minutes 1 264,6 m3

Joseph Kafumbila Page 75

 Figure 7.2: Split circuit with same organic phase - layout

Joseph Kafumbila Page 76

8. References
Nisbett A. et al, Flowsheet considerations for Copper-Cobalt process, SAIMM,
2009.

Miller G. M. et al, Decreasing operating costs and soluble loss in copper

hydrometallurgy with use of innovative solvent extraction circuits, First
extractive metallurgy operations conference, 2005.

Miller G. M., Design of Copper-Cobalt hydrometallurgical circuits, ALTA Nickel –

Cobalt conference, 2009.

Kafumbila J. Utilization efficiency of sulfur dioxide during reductive leaching of

Copper – Cobalt ores, 2020a.
(PDF) Utilization efficiency of sulfur dioxide during reductive leaching of Copper -
Cobalt ores (researchgate.net)

Kafumbila J., Prediction of dithionate and iron saturation concentrations in

solution during reductive leaching of cobalt using sulfur dioxide gas as reducing
agent, 2022a.
(PDF) Prediction of dithionate and iron saturation concentrations in solution
during reductive leaching of cobalt using sulfur dioxide gas as reducing agent
(researchgate.net)

Kafumbila J., Design of Copper solvent extraction circuit: Effect of dithionate on

copper solvent extraction recovery in sulfate media, 2022b.
(PDF) Design of Copper solvent extraction circuit Effect of dithionate on copper
solvent extraction recovery in sulfate media (researchgate.net)

Shaw D. R., The commercialization of the Fenix Iron control System for
purification of copper electrowinning electrolytes, Journal of Minerals, Metals and
Materials Society, 2004.

Charles E. Harvie et al, The prediction of mineral solubilities in natural water: Na-
K-Mg-Ca-H-Cl-SO4-OH-HCO3-CO3-CO2-H2O system to high ionic strengths at
25°C, Geochimica et Cosmochimica Acta, 1984.

H.C. Helgeson, Thermodynamics of hydrothermal systems at elevated

temperatures and pressures, American Journal of Science 267, 1969.

Joseph Kafumbila Page 77

H.C. Helgeson et al, Theoretical prediction of the thermodynamic behavior of
aqueous electrolytes at high pressures and temperatures: IV calculation of
activity coefficients, osmotic coefficients, and apparent molal and standard and
relative partial molal properties to 600°C and 5 KB, American Journal of Science,
1981.

Bjorn Beverskog, et al, Pourbaix diagrams for the system copper – chlorine at 5 –
100°C, SKI Rapport 98:19, 1998.

Kafumbila J., Design of counter current decantation in Copper metallurgy, 2017a.

(PDF) DESIGN OF COUNTER CURRENT DECANTATION IN COPPER METALLURGY
(researchgate.net)

Kafumbila J., Design of agitated leach circuit: reductive leaching of Copper and
Cobalt ores, 2021.
(PDF) Design of agitated leach circuit (researchgate.net)

Hans Hein, Importance of a wash stage in copper solvent extraction,

Hydrocopper, 2005.

Kafumbila J., Copper solvent extraction: Equipment sizing, 2022b.

(PDF) Copper solvent extraction: Major Equipment sizing (researchgate.net)

Kafumbila J., Design of copper electrowinning circuit using conventional cells,

2017b
(PDF) DESIGN OF COPPER ELECTROWINNING CIRCUIT USING CONVENTIONAL
CELLS (researchgate.net)

Joseph Kafumbila Page 78

 Appendix A – conventional circuit

Joseph Kafumbila Page 79

 Table A.1: Mass balance – conventional circuit

1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00

Fcake LCA SO2 RE2L CO2 OLC PTKFC PTKOF
Solid/Gas
mass t/h 800,00 11,851 6,012 774,00 0,031
volume m3/h 296,30 309,60 0,012
SG solid t/m3 2,700 2,500 2,650
S % 0,100 50,052 1,500
CaSO4,2H2O 7,411
Pulp
mass t/h 1025,64 2580,00 12,38
volume m3/h 521,94 2011,00 12,36
SG solid t/m3 1,965 1,283 1,002
%solid 78,00 30,00 0,25
Liquid
mass t/h 225,64 42,57 1505,95 1806,00 12,35 2272,25
volume m3/h 225,64 23,65 1441,11 1701,40 12,35 2166,20
SG liquid t/m3 1,000 1,800 1,045 1,061 1,000 1,049
GT 47,61 65,84 51,951
H g/l 0,274 0,125 0,099
PO4 g/l 0,994 1,274 0,996
SO4 g/l 1727,78 27,669 34,138 27,044
S2O6 g/l 9,042 11,599 9,060
Cu g/l 0,151 6,730 5,257
Co g/l 4,863 6,235 4,870
Zn g/l 0,540 0,693 0,541
Ni g/l 0,073 0,094 0,073
Mn g/l 0,635 0,815 0,636
Mg g/l 1,083 1,388 1,084
Al g/l 0,743 0,953 0,745
Ca g/l 0,614 0,604 0,615
Fe2 g/l 0,884 1,131 0,883
Fe3 g/l 0,046 0,062 0,048
S g/l 576,73 12,857 16,041 12,656
P g/l 0,324 0,416 0,325
AC g/l 1764,00 10,531 2,916 2,498

Joseph Kafumbila Page 80

 Table A.2: Mass balance – conventional circuit

9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,00

PTKUF TK1FC TK1OF TK1UF TK2FC TK2OF TK2UF TK3FC
Solid/Gas
mass t/h 773,99 0,019 773,99 0,012 773,989 0,012
volume m3/h 309,60 0,007 309,59 0,005 309,592 0,005
SG solid t/m3 2,500 2,650 2,500 2,650 2,500 2,650
S % 1,499 1,498 1,498
CaSO4,2H2O 7,406 7,403 7,402
Pulp
mass t/h 1433,32 7,43 1433,31 4,95 1433,31 4,95
volume m3/h 938,15 7,42 950,16 4,95 957,38 4,95
SG solid t/m3 1,528 1,002 1,508 1,002 1,497 1,002
%solid 54,00 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 659,33 7,41 1113,18 659,32 4,94 1105,74 659,32 4,94
volume m3/h 628,56 7,41 1081,52 640,57 4,94 1086,39 647,79 4,94
SG liquid t/m3 1,049 1,000 1,029 1,029 1,000 1,018 1,018 1,000
GT 51,951 30,641 30,641 18,494 18,494
H g/l 0,099 0,058 0,058 0,034 0,034
PO4 g/l 0,996 0,568 0,568 0,324 0,324
SO4 g/l 27,044 16,161 16,161 9,957 9,957
S2O6 g/l 9,060 5,166 5,166 2,946 2,946
Cu g/l 5,257 2,997 2,997 1,710 1,710
Co g/l 4,870 2,776 2,776 1,584 1,584
Zn g/l 0,541 0,308 0,308 0,176 0,176
Ni g/l 0,073 0,042 0,042 0,024 0,024
Mn g/l 0,636 0,363 0,363 0,207 0,207
Mg g/l 1,084 0,618 0,618 0,353 0,353
Al g/l 0,745 0,424 0,424 0,242 0,242
Ca g/l 0,615 0,629 0,629 0,636 0,636
Fe2 g/l 0,883 0,504 0,504 0,287 0,287
Fe3 g/l 0,048 0,028 0,028 0,016 0,016
S g/l 12,656 7,463 7,463 4,503 4,503
P g/l 0,325 0,185 0,185 0,106 0,106
AC g/l 2,498 1,743 1,743 1,213 1,213

Joseph Kafumbila Page 81

 Table A.3: Mass balance – conventional circuit

17,00 18,00 19,00 20,00 21,00 22,00 23,00 24,00

TK3OF TK3UF TK4FC TK4OF TK4UF TK5FC TK5OF TK5UF
Solid/Gas
mass t/h 773,999 0,012 774,010 0,012 774,018
volume m3/h 309,596 0,005 309,600 0,005 309,603
SG solid t/m3 2,500 2,650 2,500 2,650 2,500
S % 1,498 1,498 1,498
CaSO4,2H2O 7,401 7,401 7,401
Pulp
mass t/h 1433,33 4,95 1433,35 4,95 1433,37
volume m3/h 961,72 4,95 964,33 4,95 965,89
SG solid t/m3 1,490 1,002 1,486 1,002 1,484
%solid 54,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 1100,79 659,33 4,94 1095,86 659,34 4,94 1090,92 659,35
volume m3/h 1088,76 652,13 4,94 1088,19 654,73 4,94 1085,86 656,29
SG liquid t/m3 1,011 1,011 1,000 1,007 1,007 1,000 1,005 1,005
GT 11,423 11,423 7,264 7,264 4,798 4,798
H g/l 0,021 0,021 0,013 0,013 0,008 0,008
PO4 g/l 0,182 0,182 0,098 0,098 0,048 0,048
SO4 g/l 6,346 6,346 4,224 4,224 2,969 2,969
S2O6 g/l 1,653 1,653 0,891 0,891 0,438 0,438
Cu g/l 0,959 0,959 0,517 0,517 0,254 0,254
Co g/l 0,889 0,889 0,479 0,479 0,235 0,235
Zn g/l 0,099 0,099 0,053 0,053 0,026 0,026
Ni g/l 0,013 0,013 0,007 0,007 0,004 0,004
Mn g/l 0,116 0,116 0,063 0,063 0,031 0,031
Mg g/l 0,198 0,198 0,107 0,107 0,052 0,052
Al g/l 0,136 0,136 0,073 0,073 0,036 0,036
Ca g/l 0,641 0,641 0,646 0,646 0,652 0,652
Fe2 g/l 0,161 0,161 0,087 0,087 0,043 0,043
Fe3 g/l 0,009 0,009 0,005 0,005 0,002 0,002
S g/l 2,780 2,780 1,767 1,767 1,166 1,166
P g/l 0,059 0,059 0,032 0,032 0,016 0,016
AC g/l 0,846 0,846 0,595 0,595 0,428 0,428

Joseph Kafumbila Page 82

 Table A.4: Mass balance – conventional circuit

25,00 26,00 27,00 28,00 29,00 30,00 31,00 32,00

TK6FC TK6OF TK6UF WW ACS PLS RE1 LOE1
Solid/Gas
mass t/h 0,012 771,00
volume m3/h 0,005 308,30
SG solid t/m3 2,650 2,501
S % 1,430
CaSO4,2H2O 7,036
Pulp
mass t/h 4,95 1427,77
volume m3/h 4,95 962,96
SG solid t/m3 1,002 1,483
%solid 0,25 54,00
Liquid
mass t/h 4,94 1085,99 656,77 1075,44 7,618 2279,86 2270,79
volume m3/h 4,94 1082,49 654,66 1075,25 6,322 2172,37 2171,58 2707,75
SG liquid t/m3 1,000 1,003 1,003 1,000 1,205 1,049 1,046
GT 3,326 3,326 0,182 249,95 52,531 48,370
H g/l 0,005 0,005 0,004 3,393 0,108 0,245
PO4 g/l 0,018 0,018 0,000 0,388 0,994 0,994
SO4 g/l 2,220 2,220 0,182 211,94 27,584 27,595
S2O6 g/l 0,165 0,165 0,000 2,223 9,041 9,044
Cu g/l 0,096 0,096 0,000 26,913 5,320 1,003 6,800
Co g/l 0,089 0,089 0,000 1,897 4,862 4,863
Zn g/l 0,010 0,010 0,000 0,211 0,540 0,540
Ni g/l 0,001 0,001 0,000 0,028 0,073 0,073
Mn g/l 0,012 0,012 0,000 0,248 0,635 0,635
Mg g/l 0,020 0,020 0,000 0,422 1,083 1,083
Al g/l 0,014 0,014 0,000 0,290 0,743 0,744
Ca g/l 0,658 0,658 0,000 0,239 0,614 0,614
Fe2 g/l 0,016 0,016 0,000 0,979 0,884 0,884
Fe3 g/l 0,001 0,001 0,000 0,775 0,050 0,052 0,0047
S g/l 0,807 0,807 0,061 71,637 12,829 12,833
P g/l 0,006 0,006 0,000 0,126 0,324 0,324
AC g/l 0,318 0,318 0,334 139,56 2,834 8,997

Joseph Kafumbila Page 83

 Table A.5: Mass balance – conventional circuit

33,00 34,00 35,00 36,00 37,00 38,00 39,00 40,00

ALOE1 RE2 LOE2 ALOE2 RE2B ACTD LOAC ALOAC
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 2,708 2267,08 2,708 761,129 1,625 1,083
volume m3/h 2,589 2169,47 2707,75 2,591 728,359 1,554 2707,75 1,036
SG liquid t/m3 1,046 1,045 1,045 1,045 1,046 1,046
GT 48,370 47,612 47,612 47,612 48,370 48,370
H g/l 0,245 0,274 0,274 0,274 0,245 0,245
PO4 g/l 0,994 0,994 0,994 0,994 0,994 0,994
SO4 g/l 27,595 27,669 27,669 27,669 27,595 27,595
S2O6 g/l 9,044 9,042 9,042 9,042 9,044 9,044
Cu g/l 1,003 0,151 3,337 0,151 0,151 1,003 6,800 1,003
Co g/l 4,863 4,863 4,863 4,863 4,863 4,863
Zn g/l 0,540 0,540 0,540 0,540 0,540 0,540
Ni g/l 0,073 0,073 0,073 0,073 0,073 0,073
Mn g/l 0,635 0,635 0,635 0,635 0,635 0,635
Mg g/l 1,083 1,083 1,083 1,083 1,083 1,083
Al g/l 0,744 0,743 0,743 0,743 0,744 0,744
Ca g/l 0,614 0,614 0,614 0,614 0,614 0,614
Fe2 g/l 0,884 0,884 0,884 0,884 0,884 0,884
Fe3 g/l 0,052 0,046 0,0059 0,046 0,0462 0,052 0,0047 0,052
S g/l 12,833 12,857 12,857 12,857 12,833 12,833
P g/l 0,324 0,324 0,324 0,324 0,324 0,324
AC g/l 8,997 10,531 10,531 10,531 8,997 8,997

Joseph Kafumbila Page 84

 Table A.6: Mass balance – conventional circuit

41,00 42,00 43,00 44,00 45,00 46,00 47,00 48,00

ADS1 RADS1 SOS1 ASOS1 ADS2 RADS2 SOS2 ASOS2
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 944,77 1769,96 0,812 936,02 1763,72 0,812
volume m3/h 754,82 1414,10 2707,75 0,649 751,14 1415,35 2707,75 0,652
SG liquid t/m3 1,252 1,252 1,252 1,246 1,246 1,246
GT 301,637 324,80 301,637 315,30
H g/l 3,871 3,871 3,871 4,263 4,263 4,263
PO4 g/l 0,188 0,188 0,188 0,188 0,188 0,188
SO4 g/l 267,44 267,443 267,44 268,95 268,946 268,95
S2O6 g/l 0,012 0,012 0,012 0,000 0,000 0,000
Cu g/l 49,664 49,664 3,567 49,664 38,292 38,292 2,644 38,292
Co g/l 0,921 0,921 0,921 0,920 0,920 0,920
Zn g/l 0,102 0,102 0,102 0,102 0,102 0,102
Ni g/l 0,014 0,014 0,014 0,014 0,014 0,014
Mn g/l 0,120 0,120 0,120 0,120 0,120 0,120
Mg g/l 0,205 0,205 0,205 0,205 0,205 0,205
Al g/l 0,141 0,141 0,141 0,141 0,141 0,141
Ca g/l 0,116 0,116 0,116 0,116 0,116 0,116
Fe2 g/l 0,994 0,994 0,994 0,999 0,999 0,999
Fe3 g/l 1,0063 1,006 0,0010 1,006 0,9988 0,999 0,0010 0,999
S g/l 89,277 89,277 89,277 89,774 89,774 89,774
P g/l 0,061 0,061 0,061 0,061 0,061 0,061
AC g/l 143,83 143,826 143,83 171,74 171,737 171,74

Joseph Kafumbila Page 85

 Table A.7: Mass balance – conventional circuit

49,00 50,00 51,00 52,00 53,00 54,00 55,00 56,00

EWCA EWW EWCC EWO EWS OEW SPE EWB
Solid/Gas
mass t/h 11,062 2,788 0,0019
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1,490 7,187 939,60 933,602 5,994
volume m3/h 0,828 7,187 755,02 750,20 4,816
SG liquid t/m3 1,800 1,000 1,244 1,244 1,244
GT 312,46 312,46 312,46
H g/l 4,374 4,374 4,374
PO4 g/l 0,188 0,188 0,188
SO4 g/l 269,28 269,28 269,28
S2O6 g/l 0,000 0,000 0,000
Cu g/l 35,000 35,000 35,000
Co g/l 0,921 0,921 0,921
Zn g/l 0,102 0,102 0,102
Ni g/l 0,014 0,014 0,014
Mn g/l 0,120 0,120 0,120
Mg g/l 0,205 0,205 0,205
Al g/l 0,141 0,141 0,141
Ca g/l 0,116 0,116 0,116
Fe2 g/l 1,000 1,000 1,000
Fe3 g/l 1,0000 1,0000 1,0000
S g/l 576,699 89,885 89,885 89,885
P g/l 0,061 0,061 0,061
AC g/l 1764,000 180,00 180,00 180,00

Joseph Kafumbila Page 86

Appendix B – split circuit with different organic phases

Joseph Kafumbila Page 87

 Table B.1: Mass balance – split circuit with different organic phases

1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00

Fcake LCA SO2 LCS CO2 OLC PTKFC PTKOF
Solid/Gas
mass t/h 800,00 11,290 6,012 774,00 0,031
volume m3/h 296,30 309,60 0,012
SG solid t/m3 2,700 2,500 2,650
S % 0,100 50,052 1,500
CaSO4,2H2O 7,411
Pulp
mass t/h 1025,64 2580,00 12,38
volume m3/h 521,94 1982,94 12,36
SG solid t/m3 1,965 1,301 1,002
%solid 78,00 30,00 0,25
Liquid
mass t/h 225,64 40,47 1508,61 1806,00 12,35 1257,91
volume m3/h 225,64 22,49 1412,15 1673,34 12,35 1166,09
SG liquid t/m3 1,000 1,800 1,068 1,079 1,000 1,079
GT 73,52 86,04 85,429
H g/l 0,352 0,143 0,142
PO4 g/l 1,644 1,827 1,814
SO4 g/l 1727,688 38,005 40,239 39,957
S2O6 g/l 18,069 20,094 19,947
Cu g/l 0,252 6,925 6,875
Co g/l 8,043 8,939 8,873
Zn g/l 0,894 0,993 0,986
Ni g/l 0,121 0,134 0,133
Mn g/l 1,051 1,168 1,159
Mg g/l 1,791 1,990 1,976
Al g/l 1,230 1,367 1,357
Ca g/l 0,629 0,625 0,626
Fe2 g/l 1,365 1,511 1,500
Fe3 g/l 0,073 0,084 0,084
S g/l 576,699 19,922 21,479 21,326
P g/l 0,536 0,596 0,592
AC g/l 1764,000 12,120 2,894 2,880

Joseph Kafumbila Page 88

 Table B.2: Mass balance – split circuit with different organic phases

9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,00

PTKUF TK1FC TK1OF TK1UF TK2FC TK2OF TK2UF TK3FC
Solid/Gas
mass t/h 773,99 0,019 773,97 0,012 773,946 0,012
volume m3/h 309,60 0,007 309,58 0,005 309,573 0,005
SG solid t/m3 2,500 2,650 2,500 2,650 2,500 2,650
S % 1,499 1,498 1,497
CaSO4,2H2O 7,407 7,401 7,397
Pulp
mass t/h 1334,47 7,43 1433,28 4,95 1433,23 4,95
volume m3/h 829,16 7,42 943,70 4,95 954,59 4,95
SG solid t/m3 1,609 1,002 1,519 1,002 1,501 1,002
%solid 58,00 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 560,48 7,41 1123,19 659,31 4,94 1214,56 659,29 4,94
volume m3/h 519,57 7,41 1080,28 634,12 4,94 1188,28 645,02 4,94
SG liquid t/m3 1,079 1,000 1,040 1,040 1,000 1,022 1,022 1,000
GT 85,429 41,879 41,879 23,039 23,039
H g/l 0,142 0,069 0,069 0,038 0,038
PO4 g/l 1,814 0,861 0,861 0,449 0,449
SO4 g/l 39,957 19,930 19,930 11,263 11,263
S2O6 g/l 19,947 9,468 9,468 4,938 4,938
Cu g/l 6,875 3,263 3,263 1,702 1,702
Co g/l 8,873 4,212 4,212 2,197 2,197
Zn g/l 0,986 0,468 0,468 0,244 0,244
Ni g/l 0,133 0,063 0,063 0,033 0,033
Mn g/l 1,159 0,550 0,550 0,287 0,287
Mg g/l 1,976 0,938 0,938 0,489 0,489
Al g/l 1,357 0,644 0,644 0,336 0,336
Ca g/l 0,626 0,662 0,662 0,672 0,672
Fe2 g/l 1,500 0,712 0,712 0,371 0,371
Fe3 g/l 0,084 0,040 0,040 0,021 0,021
S g/l 21,326 10,444 10,444 5,737 5,737
P g/l 0,592 0,281 0,281 0,146 0,146
AC g/l 2,880 1,826 1,826 1,211 1,211

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 Table B.3: Mass balance – split circuit with different organic phases

17,00 18,00 19,00 20,00 21,00 22,00 23,00 24,00

TK3OF TK3UF TK4FC TK4OF TK4UF TK5FC TK5OF TK5UF
Solid/Gas
mass t/h 773,93 0,012 773,92 0,012 773,91
volume m3/h 309,57 0,005 309,56 0,005 309,56
SG solid t/m3 2,500 2,650 2,500 2,650 2,500
S % 1,497 1,496 1,496
CaSO4,2H2O 7,393 7,391 7,388
Pulp
mass t/h 1433,21 4,95 1433,19 4,95 1433,17
volume m3/h 960,60 4,95 963,89 4,95 965,69
SG solid t/m3 1,492 1,002 1,487 1,002 1,484
%solid 54,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 1209,57 659,28 4,94 1204,59 659,27 4,94 1199,61 659,26
volume m3/h 1194,44 651,03 4,94 1195,57 654,33 4,94 1193,94 656,14
SG liquid t/m3 1,013 1,013 1,000 1,008 1,008 1,000 1,005 1,005
GT 13,104 13,104 7,780 7,780 4,894 4,894
H g/l 0,021 0,021 0,013 0,013 0,008 0,008
PO4 g/l 0,232 0,232 0,116 0,116 0,053 0,053
SO4 g/l 6,689 6,689 4,236 4,236 2,905 2,905
S2O6 g/l 2,552 2,552 1,276 1,276 0,585 0,585
Cu g/l 0,880 0,880 0,440 0,440 0,202 0,202
Co g/l 1,135 1,135 0,568 0,568 0,260 0,260
Zn g/l 0,126 0,126 0,063 0,063 0,029 0,029
Ni g/l 0,017 0,017 0,009 0,009 0,004 0,004
Mn g/l 0,148 0,148 0,074 0,074 0,034 0,034
Mg g/l 0,253 0,253 0,126 0,126 0,058 0,058
Al g/l 0,174 0,174 0,087 0,087 0,040 0,040
Ca g/l 0,674 0,674 0,672 0,672 0,669 0,669
Fe2 g/l 0,192 0,192 0,096 0,096 0,044 0,044
Fe3 g/l 0,011 0,011 0,005 0,005 0,002 0,002
S g/l 3,255 3,255 1,925 1,925 1,204 1,204
P g/l 0,076 0,076 0,038 0,038 0,017 0,017
AC g/l 0,808 0,808 0,552 0,552 0,395 0,395

Joseph Kafumbila Page 90

 Table B.4: Mass balance – split circuit with different organic phases

25,00 26,00 27,00 28,00 29,00 30,00 31,00 32,00

TK6FC TK6OF TK6UF WW ACS HGPLS HGRE1 HGLOE1
Solid/Gas
mass t/h 0,012 770,57
volume m3/h 0,005 308,12
SG solid t/m3 2,650 2,501
S % 1,420
CaSO4,2H2O 6,985
Pulp
mass t/h 4,95 1426,98
volume m3/h 4,95 962,42
SG solid t/m3 1,002 1,483
%solid 0,25 54
Liquid
mass t/h 4,94 1194,64 656,41 1183,50 11,109 1269,02 1262,91
volume m3/h 4,94 1190,81 654,31 1183,29 9,020 1174,88 1174,10 1457,61
SG liquid t/m3 1,000 1,003 1,003 1,000 1,232 1,080 1,076
GT 3,313 3,313 0,185 291,264 87,026 81,861
H g/l 0,005 0,005 0,004 4,013 0,172 0,343
PO4 g/l 0,019 0,019 0,000 0,309 1,803 1,804
SO4 g/l 2,175 2,175 0,182 248,513 41,567 41,597
S2O6 g/l 0,208 0,208 0,000 1,787 19,811 19,824
Cu g/l 0,072 0,072 0,000 32,084 7,070 1,676 8,778
Co g/l 0,093 0,093 0,000 1,510 8,818 8,824
Zn g/l 0,010 0,010 0,000 0,168 0,980 0,980
Ni g/l 0,001 0,001 0,000 0,023 0,132 0,132
Mn g/l 0,012 0,012 0,000 0,197 1,152 1,153
Mg g/l 0,021 0,021 0,000 0,336 1,964 1,965
Al g/l 0,014 0,014 0,000 0,231 1,348 1,349
Ca g/l 0,666 0,666 0,000 0,126 0,622 0,623
Fe2 g/l 0,016 0,016 0,000 1,047 1,497 1,498
Fe3 g/l 0,001 0,001 0,000 0,921 0,090 0,092 0,0086
S g/l 0,809 0,809 0,061 83,669 21,809 21,825
P g/l 0,006 0,006 0,000 0,101 0,588 0,588
AC g/l 0,301 0,301 0,334 164,920 3,821 10,858

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 Table B.5: Mass balance – split circuit with different organic phases

33,00 34,00 35,00 36,00 37,00 38,00 39,00 40,00

AHGLOE1 HGRE2 HGLOE2 AHGLOE2 HGACTD HGLOAC AHGLOAC HGADS1
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1,458 1260,29 1,458 0,875 0,583 669,98
volume m3/h 1,355 1172,90 1457,61 1,357 0,813 1457,609 0,542 535,56
SG liquid t/m3 1,076 1,075 1,075 1,076 1,076 1,251
GT 81,861 80,574 80,574 81,861 81,861 323,631
H g/l 0,343 0,389 0,389 0,343 0,343 3,862
PO4 g/l 1,804 1,804 1,804 1,804 1,804 0,161
SO4 g/l 41,597 41,672 41,672 41,597 41,597 266,54
S2O6 g/l 19,824 19,822 19,822 19,824 19,824 0,020
Cu g/l 1,676 0,283 4,430 0,283 1,676 8,778 1,676 49,681
Co g/l 8,824 8,823 8,823 8,824 8,824 0,787
Zn g/l 0,980 0,980 0,980 0,980 0,980 0,087
Ni g/l 0,132 0,132 0,132 0,132 0,132 0,012
Mn g/l 1,153 1,153 1,153 1,153 1,153 0,103
Mg g/l 1,965 1,965 1,965 1,965 1,965 0,175
Al g/l 1,349 1,349 1,349 1,349 1,349 0,120
Ca g/l 0,623 0,623 0,623 0,623 0,623 0,077
Fe2 g/l 1,498 1,498 1,498 1,498 1,498 0,995
Fe3 g/l 0,092 0,081 0,0098 0,0812 0,092 0,009 0,0918 1,0141
S g/l 21,825 21,849 21,849 21,825 21,825 88,978
P g/l 0,588 0,588 0,588 0,588 0,588 0,052
AC g/l 10,858 13,134 13,134 10,858 10,858 143,81

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 Table B.6: Mass balance – split circuit with different organic phases

41,00 42,00 43,00 44,00 45,00 46,00 47,00 48,00

RHGADS1 HGSOS1 AHGSOS1 HGADS2 RHGADS2 HGSOS2 AHGSOS2 LGPLS
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 791,35 0,437 663,72 788,72 0,437 1124,00
volume m3/h 632,59 1457,61 0,350 532,99 633,37 1457,61 0,351 1081,06
SG liquid t/m3 1,251 1,251 1,245 1,245 1,245 1,040
GT 301,637 323,63 313,83 301,637 313,83 41,877
H g/l 3,862 3,862 4,260 4,260 4,260 0,069
PO4 g/l 0,161 0,161 0,160 0,160 0,160 0,861
SO4 g/l 266,537 266,537 267,954 267,954 267,954 19,930
S2O6 g/l 0,020 0,020 0,000 0,000 0,000 9,468
Cu g/l 49,681 4,447 49,681 38,107 38,107 3,298 38,107 3,261
Co g/l 0,787 0,787 0,782 0,782 0,782 4,212
Zn g/l 0,087 0,087 0,087 0,087 0,087 0,468
Ni g/l 0,012 0,012 0,012 0,012 0,012 0,063
Mn g/l 0,103 0,103 0,102 0,102 0,102 0,550
Mg g/l 0,175 0,175 0,174 0,174 0,174 0,938
Al g/l 0,120 0,120 0,120 0,120 0,120 0,644
Ca g/l 0,077 0,077 0,076 0,076 0,076 0,662
Fe2 g/l 0,995 0,995 0,999 0,999 0,999 0,712
Fe3 g/l 1,014 0,0010 1,0141 0,999 0,999 0,0010 0,9988 0,040
S g/l 88,978 88,978 89,442 89,443 89,442 10,444
P g/l 0,052 0,052 0,052 0,052 0,052 0,281
AC g/l 143,806 143,81 172,19 172,185 172,19 1,828

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 Table B.7: Mass balance – split circuit with different organic phases

49,00 50,00 51,00 52,00 53,00 54,00 55,00 56,00

LGRE1 LGLOE1 ALGLOE1 LGRE2 LGLOE2 ALGLOE2 LGRE2LC LGRE2B
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1121,18 1,350 1119,73 1,350 248,32 871,412
volume m3/h 1080,85 1350,35 1,302 1079,82 1350,35 1,302 239,47 840,354
SG liquid t/m3 1,037 1,037 1,037 1,037 1,037 1,037
GT 39,279 39,279 38,890 38,890 38,890 38,890
H g/l 0,155 0,155 0,172 0,172 0,172 0,172
PO4 g/l 0,861 0,861 0,861 0,861 0,861 0,861
SO4 g/l 19,934 19,934 20,009 20,009 20,009 20,009
S2O6 g/l 9,469 9,469 9,467 9,467 9,467 9,467
Cu g/l 0,569 5,190 0,569 0,098 3,035 0,098 0,098 0,098
Co g/l 4,212 4,212 4,212 4,212 4,212 4,212
Zn g/l 0,468 0,468 0,468 0,468 0,468 0,468
Ni g/l 0,063 0,063 0,063 0,063 0,063 0,063
Mn g/l 0,550 0,550 0,550 0,550 0,550 0,550
Mg g/l 0,938 0,938 0,938 0,938 0,938 0,938
Al g/l 0,644 0,644 0,644 0,644 0,644 0,644
Ca g/l 0,662 0,662 0,662 0,662 0,662 0,662
Fe2 g/l 0,712 0,712 0,712 0,712 0,712 0,712
Fe3 g/l 0,0408 0,0051 0,041 0,0350 0,0059 0,0350 0,0350 0,0350
S g/l 10,446 10,446 10,470 10,470 10,470 10,470
P g/l 0,281 0,281 0,281 0,281 0,281 0,281
AC g/l 5,767 5,767 6,646 6,646 6,646 6,646

Joseph Kafumbila Page 94

 Table B.8: Mass balance – split circuit with different organic phases

57,00 58,00 59,00 60,00 61,00 62,00 63,00 64,00

LGACTD LGLOAC ALGLOAC LGADS RLGADS LGSOS ALGSOS ADS
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 0,810 0,540 288,234 1064,18 0,405 958,21
volume m3/h 0,781 1350,35 0,521 230,446 850,82 1350,347 0,324 766,01
SG liquid t/m3 1,037 1,037 1,251 1,251 1,251 1,251
GT 39,279 39,279 323,26 301,637 323,26 323,52
H g/l 0,155 0,155 3,858 3,858 3,858 3,861
PO4 g/l 0,861 0,861 0,161 0,161 0,161 0,161
SO4 g/l 19,934 19,934 266,23 266,228 266,23 266,44
S2O6 g/l 9,469 9,469 0,021 0,021 0,021 0,020
Cu g/l 0,569 5,190 0,569 49,618 49,618 2,645 49,618 49,662
Co g/l 4,212 4,212 0,786 0,786 0,786 0,787
Zn g/l 0,468 0,468 0,087 0,087 0,087 0,087
Ni g/l 0,063 0,063 0,012 0,012 0,012 0,012
Mn g/l 0,550 0,550 0,103 0,103 0,103 0,103
Mg g/l 0,938 0,938 0,175 0,175 0,175 0,175
Al g/l 0,644 0,644 0,120 0,120 0,120 0,120
Ca g/l 0,662 0,662 0,077 0,077 0,077 0,077
Fe2 g/l 0,712 0,712 0,994 0,994 0,994 0,995
Fe3 g/l 0,041 0,0051 0,041 1,0161 1,016 0,0010 1,0161 1,0147
S g/l 10,446 10,446 88,875 88,875 88,875 88,947
P g/l 0,281 0,281 0,052 0,052 0,052 0,052
AC g/l 5,767 5,767 143,65 143,649 143,65 143,76

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 Table B.9: Mass balance – split circuit with different organic phases

65,00 66,00 67,00 68,00 69,00 70,00 71,00 72,00

EWAC EWW EWCC EWO EWS OEW HGSPE LGSPE
Solid/Gas
mass t/h 11,107 2,799 0,0031
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 2,434 10,370 946,874 662,10 284,773
volume m3/h 1,352 10,370 761,344 532,37 228,975
SG liquid t/m3 1,800 1,000 1,244 1,244 1,244
GT 311,15 311,15 311,15
H g/l 4,365 4,365 4,365
PO4 g/l 0,160 0,160 0,160
SO4 g/l 268,27 268,27 268,27
S2O6 g/l 0,000 0,000 0,000
Cu g/l 35,000 35,000 35,000
Co g/l 0,783 0,783 0,783
Zn g/l 0,087 0,087 0,087
Ni g/l 0,012 0,012 0,012
Mn g/l 0,102 0,102 0,102
Mg g/l 0,174 0,174 0,174
Al g/l 0,120 0,120 0,120
Ca g/l 0,077 0,077 0,077
Fe2 g/l 1,000 1,000 1,000
Fe3 g/l 1,000 1,0000 1,0000
S g/l 576,73 89,548 89,548 89,548
P g/l 0,052 0,052 0,052
AC g/l 1764,00 180,00 180,00 180,00

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 Table B.10: Mass balance – split circuit with different organic phases

73,00 74,00 75,00 76,00 77,00 78,00 79,00 80,00

EWB
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 10,235
volume m3/h 8,23
SG liquid t/m3 1,244
GT 311,15
H g/l 4,365
PO4 g/l 0,160
SO4 g/l 268,27
S2O6 g/l 0,000
Cu g/l 35,000
Co g/l 0,783
Zn g/l 0,087
Ni g/l 0,012
Mn g/l 0,102
Mg g/l 0,174
Al g/l 0,120
Ca g/l 0,077
Fe2 g/l 1,000
Fe3 g/l 1,0000
S g/l 89,548
P g/l 0,052
AC g/l 180,00

Joseph Kafumbila Page 97

 Appendix C – split circuit with same organic phase

Joseph Kafumbila Page 98

 Table C.1: Mass balance – split circuit with same organic phase

1,00 2,00 3,00 4,00 5,00 6,00 7,00 8,00

Fcake LCA SO2 LCS CO2 OLC PTKFC PTKOF
Solid/Gas
mass t/h 800,00 11,185 6,01 774,00 0,031
volume m3/h 296,30 309,60 0,012
SG solid t/m3 2,700 2,500 2,650
S % 0,100 50,052 1,500
CaSO4,2H2O 7,411
Pulp
mass t/h 1025,64 2580,00 12,38
volume m3/h 521,94 1982,30 12,36
SG solid t/m3 1,965 1,302 1,002
%solid 78,00 30,00 0,25
Liquid
mass t/h 225,64 40,55 1508,64 1806,00 12,35 1257,91
volume m3/h 225,64 22,53 1411,43 1672,70 12,35 1165,64
SG liquid t/m3 1,000 1,800 1,069 1,080 1,000 1,079
GT 74,16 86,52 85,903
H g/l 0,353 0,143 0,142
PO4 g/l 1,641 1,825 1,811
SO4 g/l 38,450 40,571 40,287
S2O6 g/l 18,019 20,042 19,896
Cu g/l 0,519 7,153 7,101
Co g/l 8,028 8,926 8,861
Zn g/l 0,892 0,992 0,985
Ni g/l 0,120 0,134 0,133
Mn g/l 1,049 1,166 1,158
Mg g/l 1,788 1,988 1,973
Al g/l 1,227 1,365 1,355
Ca g/l 0,627 0,623 0,624
Fe2 g/l 1,360 1,505 1,494
Fe3 g/l 0,089 0,085 0,084
S g/l 576,699 20,051 21,570 21,416
P g/l 0,535 0,595 0,591
AC g/l 1764,000 12,073 2,893 2,880

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 Table C.2: Mass balance – split circuit with same organic phase

9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,00

PTKUF TK1FC TK1OF TK1UF TK2FC TK2OF TK2UF TK3FC
Solid/Gas
mass t/h 773,99 0,019 773,97 0,012 773,95 0,012
volume m3/h 309,60 0,007 309,58 0,005 309,57 0,005
SG solid t/m3 2,500 2,650 2,500 2,650 2,500 2,650
S % 1,499 1,498 1,497
CaSO4,2H2O 7,407 7,401 7,397
Pulp
mass t/h 1334,47 7,43 1433,28 4,95 1433,24 4,95
volume m3/h 828,96 7,42 943,58 4,95 954,52 4,95
SG solid t/m3 1,610 1,002 1,519 1,002 1,502 1,002
%solid 58,00 0,25 54,00 0,25 54,00 0,25
Liquid
mass t/h 560,48 7,41 1122,80 659,31 4,94 1214,18 659,29 4,94
volume m3/h 519,37 7,41 1079,69 633,99 4,94 1187,77 644,95 4,94
SG liquid t/m3 1,079 1,000 1,040 1,040 1,000 1,022 1,022 1,000
GT 85,903 42,107 42,107 23,160 23,160
H g/l 0,142 0,069 0,069 0,038 0,038
PO4 g/l 1,811 0,860 0,860 0,449 0,449
SO4 g/l 40,287 20,087 20,087 11,345 11,345
S2O6 g/l 19,896 9,445 9,445 4,927 4,927
Cu g/l 7,101 3,371 3,371 1,758 1,758
Co g/l 8,861 4,206 4,206 2,194 2,194
Zn g/l 0,985 0,467 0,467 0,244 0,244
Ni g/l 0,133 0,063 0,063 0,033 0,033
Mn g/l 1,158 0,550 0,550 0,287 0,287
Mg g/l 1,973 0,937 0,937 0,489 0,489
Al g/l 1,355 0,643 0,643 0,335 0,335
Ca g/l 0,624 0,660 0,660 0,671 0,671
Fe2 g/l 1,494 0,709 0,709 0,370 0,370
Fe3 g/l 0,084 0,040 0,040 0,021 0,021
S g/l 21,416 10,488 10,488 5,760 5,760
P g/l 0,591 0,280 0,280 0,146 0,146
AC g/l 2,880 1,827 1,827 1,212 1,212

Joseph Kafumbila Page 100

 Table C.3: Mass balance – split circuit with same organic phase

17,00 18,00 19,00 20,00 21,00 22,00 23,00 24,00

TK3OF TK3UF TK4FC TK4OF TK4UF TK5FC TK5OF TK5UF
Solid/Gas
mass t/h 773,94 0,012 773,93 0,012 773,92
volume m3/h 309,57 0,005 309,56 0,005 309,56
SG solid t/m3 2,500 2,650 2,500 2,650 2,500
S % 1,497 1,496 1,496
CaSO4,2H2O 7,394 7,391 7,388
Pulp
mass t/h 1433,21 4,95 1433,20 4,95 1433,18
volume m3/h 960,56 4,95 963,88 4,95 965,69
SG solid t/m3 1,492 1,002 1,487 1,002 1,484
%solid 54,00 0,25 54,00 0,25 54,00
Liquid
mass t/h 1209,18 659,28 4,94 1204,21 659,27 4,94 1199,23 659,26
volume m3/h 1193,99 651,00 4,94 1195,15 654,31 4,94 1193,54 656,13
SG liquid t/m3 1,013 1,013 1,000 1,008 1,008 1,000 1,005 1,005
GT 13,168 13,168 7,812 7,812 4,909 4,909
H g/l 0,021 0,021 0,013 0,013 0,008 0,008
PO4 g/l 0,232 0,232 0,116 0,116 0,053 0,053
SO4 g/l 6,731 6,731 4,257 4,257 2,915 2,915
S2O6 g/l 2,547 2,547 1,274 1,274 0,584 0,584
Cu g/l 0,909 0,909 0,455 0,455 0,209 0,209
Co g/l 1,134 1,134 0,567 0,567 0,260 0,260
Zn g/l 0,126 0,126 0,063 0,063 0,029 0,029
Ni g/l 0,017 0,017 0,009 0,009 0,004 0,004
Mn g/l 0,148 0,148 0,074 0,074 0,034 0,034
Mg g/l 0,253 0,253 0,126 0,126 0,058 0,058
Al g/l 0,173 0,173 0,087 0,087 0,040 0,040
Ca g/l 0,672 0,672 0,671 0,671 0,669 0,669
Fe2 g/l 0,191 0,191 0,096 0,096 0,044 0,044
Fe3 g/l 0,011 0,011 0,005 0,005 0,002 0,002
S g/l 3,267 3,267 1,931 1,931 1,207 1,207
P g/l 0,076 0,076 0,038 0,038 0,017 0,017
AC g/l 0,809 0,809 0,553 0,553 0,395 0,395

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 Table C.4: Mass balance – split circuit with same organic phase

25,00 26,00 27,00 28,00 29,00 30,00 31,00 32,00

TK6FC TK6OF TK6UF WW ACS HGPLS HGRE1 HGLOE1
Solid/Gas
mass t/h 0,012 770,58
volume m3/h 0,005 308,12
SG solid t/m3 2,650 2,501
S % 1,420
CaSO4,2H2O 6,985
Pulp
mass t/h 4,95 1427,00
volume m3/h 4,95 962,43
SG solid t/m3 1,002 1,483
%solid 0,25 54
Liquid
mass t/h 4,94 1194,26 656,42 1183,13 12,652 1270,56 1264,97
volume m3/h 4,94 1190,42 654,31 1182,91 10,272 1175,65 1174,92 1457,05
SG liquid t/m3 1,000 1,003 1,003 1,000 1,232 1,081 1,077
GT 3,318 3,318 0,185 291,368 87,718 83,011
H g/l 0,005 0,005 0,004 4,038 0,176 0,332
PO4 g/l 0,019 0,019 0,000 0,234 1,798 1,799
SO4 g/l 2,179 2,179 0,182 249,119 42,121 42,147
S2O6 g/l 0,208 0,208 0,000 1,561 19,740 19,753
Cu g/l 0,074 0,074 0,000 32,498 7,325 2,410 11,780
Co g/l 0,093 0,093 0,000 1,143 8,795 8,801
Zn g/l 0,010 0,010 0,000 0,127 0,977 0,978
Ni g/l 0,001 0,001 0,000 0,017 0,132 0,132
Mn g/l 0,012 0,012 0,000 0,149 1,149 1,150
Mg g/l 0,021 0,021 0,000 0,254 1,958 1,960
Al g/l 0,014 0,014 0,000 0,175 1,345 1,346
Ca g/l 0,666 0,666 0,000 0,080 0,619 0,620
Fe2 g/l 0,016 0,016 0,000 1,041 1,490 1,491
Fe3 g/l 0,001 0,001 0,000 0,931 0,091 0,094 0,0139
S g/l 0,810 0,810 0,061 83,778 21,966 21,979
P g/l 0,006 0,006 0,000 0,076 0,586 0,587
AC g/l 0,301 0,301 0,334 166,669 3,956 10,272

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 Table C.5: Mass balance – split circuit with same organic phase

33,00 34,00 35,00 36,00 37,00 38,00 39,00 40,00

AHGLOE1 HGRE2 HGLOE2 AHGLOE2 ACTD LOAC ALOAC ADS1
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1,457 1262,93 1,457 0,874 0,583 963,52
volume m3/h 1,353 1174,70 1457,05 1,355 0,812 1457,05 0,541 771,11
SG liquid t/m3 1,077 1,075 1,075 1,077 1,077 1,250
GT 83,011 81,255 81,255 321,112
H g/l 0,332 0,388 0,388 0,332 0,332 3,845
PO4 g/l 1,799 1,798 1,798 1,799 1,799 0,100
SO4 g/l 42,147 42,130 42,130 42,147 42,147 264,617
S2O6 g/l 19,753 19,745 19,745 19,753 19,753 0,014
Cu g/l 2,410 0,617 7,815 0,617 2,410 11,780 2,410 49,693
Co g/l 8,801 8,797 8,797 8,801 8,801 0,488
Zn g/l 0,978 0,977 0,977 0,978 0,978 0,054
Ni g/l 0,132 0,132 0,132 0,132 0,132 0,007
Mn g/l 1,150 1,150 1,150 1,150 1,150 0,064
Mg g/l 1,960 1,959 1,959 1,960 1,960 0,109
Al g/l 1,346 1,345 1,345 1,346 1,346 0,075
Ca g/l 0,620 0,620 0,620 0,620 0,620 0,034
Fe2 g/l 1,491 1,490 1,490 1,491 1,491 0,995
Fe3 g/l 0,094 0,105 0,0163 0,105 0,094 0,0139 0,094 1,0182
S g/l 21,979 21,971 21,971 21,979 21,979 88,334
P g/l 0,587 0,586 0,586 0,587 0,587 0,033
AC g/l 10,272 12,995 12,995 10,272 10,272 143,774

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 Table C.6: Mass balance – split circuit with same organic phase

41,00 42,00 43,00 44,00 45,00 46,00 47,00 48,00

RADS1 SOS1 ASOS1 ADS2 RADS2 SOS2 ASOS2 LGPLS
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 496,99 0,437 954,27 495,76 0,437 1122,80
volume m3/h 397,74 1457,05 0,350 767,39 398,67 1457,05 0,352 1079,69
SG liquid t/m3 1,250 1,250 1,244 1,244 1,244 1,040
GT 304,810 321,112 310,860 304,810 310,860 42,107
H g/l 3,845 3,845 4,255 4,255 4,255 0,069
PO4 g/l 0,100 0,100 0,099 0,099 0,099 0,860
SO4 g/l 264,617 264,617 265,990 265,989 265,990 20,087
S2O6 g/l 0,014 0,014 0,000 0,000 0,000 9,445
Cu g/l 49,693 5,322 49,693 37,694 37,694 3,888 37,694 3,371
Co g/l 0,488 0,488 0,484 0,484 0,484 4,206
Zn g/l 0,054 0,054 0,054 0,054 0,054 0,467
Ni g/l 0,007 0,007 0,007 0,007 0,007 0,063
Mn g/l 0,064 0,064 0,063 0,063 0,063 0,550
Mg g/l 0,109 0,109 0,108 0,108 0,108 0,937
Al g/l 0,075 0,075 0,074 0,074 0,074 0,643
Ca g/l 0,034 0,034 0,034 0,034 0,034 0,660
Fe2 g/l 0,995 0,995 0,999 0,999 0,999 0,709
Fe3 g/l 1,018 0,0010 1,018 0,9990 0,999 0,0010 0,999 0,0399
S g/l 88,334 88,334 88,787 88,787 88,787 10,488
P g/l 0,033 0,033 0,032 0,032 0,032 0,280
AC g/l 143,774 143,774 173,208 173,208 173,208 1,827

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 Table C.7: Mass balance – split circuit with same organic phase

49,00 50,00 51,00 52,00 53,00 54,00 55,00 56,00

LGRE1 LGLOE1 ALGLOE1 LGRE2 LGLOE2 ALGLOE2 LGRE2LC LGRE2B
Solid/Gas
mass t/h
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 1119,46 1,457 1118,28 1,457 245,709 872,575
volume m3/h 1079,45 1457,05 1,405 1078,39 1457,05 1,405 236,943 841,444
SG liquid t/m3 1,037 1,037 1,037 1,037 1,037 1,037
GT 38,999 38,999 38,931 38,931 38,931 38,931
H g/l 0,172 0,172 0,179 0,179 0,179 0,179
PO4 g/l 0,860 0,860 0,860 0,860 0,860 0,860
SO4 g/l 20,092 20,092 20,172 20,172 20,172 20,172
S2O6 g/l 9,447 9,447 9,444 9,444 9,444 9,444
Cu g/l 0,170 6,369 0,170 0,034 3,998 0,034 0,034 0,034
Co g/l 4,207 4,207 4,206 4,206 4,206 4,206
Zn g/l 0,467 0,467 0,467 0,467 0,467 0,467
Ni g/l 0,063 0,063 0,063 0,063 0,063 0,063
Mn g/l 0,550 0,550 0,550 0,550 0,550 0,550
Mg g/l 0,937 0,937 0,937 0,937 0,937 0,937
Al g/l 0,643 0,643 0,643 0,643 0,643 0,643
Ca g/l 0,660 0,660 0,660 0,660 0,660 0,660
Fe2 g/l 0,709 0,709 0,709 0,709 0,709 0,709
Fe3 g/l 0,0208 0,025 0,0208 0,0075 0,0110 0,0075 0,0075 0,008
S g/l 10,490 10,490 10,516 10,516 10,516 10,516
P g/l 0,280 0,280 0,280 0,280 0,280 0,280
AC g/l 6,662 6,662 7,018 7,018 7,018 7,018

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 Table C.8: Mass balance – split circuit with same organic phase

57,00 58,00 59,00 60,00 61,00 62,00 63,00 64,00

EWAC EWW EWCC EWO EWS OEW SPE EWB
Solid/Gas
mass t/h 11,155 2,8112 0,0021
volume m3/h
SG solid t/m3
S %
CaSO4,2H2O
Pulp
mass t/h
volume m3/h
SG solid t/m3
%solid
Liquid
mass t/h 2,691 11,78 964,020 952,242 11,778
volume m3/h 1,495 11,78 776,101 766,62 9,482
SG liquid t/m3 1,800 1,000 1,242 1,242 1,242
GT 308,530 308,530 308,530
H g/l 4,346 4,346 4,346
PO4 g/l 0,099 0,099 0,099
SO4 g/l 266,260 266,260 266,260
S2O6 g/l 0,000 0,000 0,000
Cu g/l 35,000 35,000 35,000
Co g/l 0,484 0,484 0,484
Zn g/l 0,054 0,054 0,054
Ni g/l 0,007 0,007 0,007
Mn g/l 0,063 0,063 0,063
Mg g/l 0,108 0,108 0,108
Al g/l 0,074 0,074 0,074
Ca g/l 0,034 0,034 0,034
Fe2 g/l 1,000 1,000 1,000
Fe3 g/l 1,0000 1,0000 1,0000
S g/l 576,729 88,877 88,877 88,877
P g/l 0,032 0,032 0,032
AC g/l 1764,000 180,000 180,000 180,000

Joseph Kafumbila Page 106