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By J. G. Jenkins

Magma Copper Co.'s San Manuel solvent extraction/electrowinning (SX-EW) facility has operated since May 1986. The original facility had a design capacity of 22.6 kt/a (25,000 stpy) of electrowon copper cathode produced by processing pregnant leach solution from an open pit-heap leach operation. In 1988, the plant was expanded to 45.3 kt/ a (50,000 stpy) to incorporate processing in-situ leach solutions. This pager focuses primarily on the heap leaching area with regard to exploration, testing, feasibility, permitting, design and construction, and operating practices. Research using surfactant leaching aids to enhance copper recovery is also discussed.

Jan 1, 1995

By C. Salcedo, J. Vallance, J. Sáez, M. Robles, J. Spangenberg, S. Rosas, L. Fontboté

The Tambomachay ore deposit (13°28'36.78"S, 71°57'35.98"W, about 6 km north of the town of Cuzco, Peru) consists of Cu hosted in arkosic red beds of the Kayra Formation (Lower Eocene). Bornite, chalcopyrite, chalcocite, covelite, digenite, malachite, and chrysocolla occur disseminated in thin layers and in veinlets. The occurrence of the copper ores in a part of the red bed sequence containing green reducing layers, the presence of organic matter in interstices between the hypogene sulfides, and the sulfur composition of the copper sulfides (δ34S values between -16.9 and -12.4‰ vs VCDT) pointing to bacterial sulfate reduction, are strong arguments to propose that mineralization was caused by copper-bearing oxidizing saline basinal fluids that precipitate copper sulfides when they meet reduced sulfur in an organic matter-rich horizon. Faults parallel to the regional Tambomachay Fault could have acted as feeders for oxidizing basinal copper-bearing fluids. Fluid migration was probably driven by tectonically-induced topography gradient. INTRODUCTION A number of red bed Cu occurrences are known in the Cuzco region in the early Eocene – early Oligocene San Jerónimo Group (Gregory, 1916; Carlotto et al., 1996, 2011; Loza et al., 2004). In the past, copper ores were extracted in several small-scale mines in the surroundings of Cuzco, including Tambomachay, Tipón, and Zurite in the Cusco province and Ushpa, Guilda, Giovanna, and Langui in the Sicuani Province. The abandoned Tambomachay Mine (13°28'36.78"S, 71°57'35.98"W), about 6 km to the north of the town of Cuzco (Romero et al., 2015; Salcedo et al., 2017, Fig. 1) was chosen as the main site for the present research aimed to better study the genesis of these copper occurrences. Results deriving from fieldwork, microscopic characterization of ore and host rock, and sulfur isotope determination suggest that the key factor for the genesis of the copper ores is that copper transported by oxidizing basinal fluids is trapped by reduced sulfur of bacteriogenic origin located in a part of the red bed sequence that shows intercalatins of green reduced horizons.

Jan 1, 2019

By Archie W. Fletcher, R. J. Wesely, Nathaniel Arbiter, A. D. Zunkel

In contrast to pyrometallurgy's six thousand year history in the production of metals, that of hydrometallurgy is of relatively recent origin. The earliest reference to it at all was in the 16th century, with the first applications to copper in the 17th and 18th. In the 19th century, increased demands for pure metal resulted in development of electrolytic refining, and early in this century electrowinning. The rapid growth in wpper production in the present century, paricularly in the United States and Chile, stimulated the development of new technology for leaching, and for the recovery of copper from leach solutions. Solvent extraction has become a major factor during the past quarter century by permitting novel leaching technology which produces dilute or complex solutions. In addition, solvents other than sulphuric acid, and chemical methods for precipitating copper metal are now of increasing interest. These are trends which should grow in importance in the future with the need to process lower grade and more complex materials. The evolution of copper hydrometallurgy is reviewed briefly and key factors in recent major developments are presented with details of specific operations and with trends for the future indicated. The relative importance of copper hydrometallurgy is compared to that of pyrometallurgy in the light of probable changes in ore supplies and character.

Jan 1, 1993

By Nathaniel Arbiter

In contrast to pyrometallurgy's 6000year history in metals production, hydrometallurgy is of relatively recent origin. The earliest reference to it was in the 16th century, with the first applications to copper in the 17th and 18th centuries. In the 19th century, increased demands for pure metal resulted in the development of electrolytic refining, and early in this century electrowinning. The rapid growth in copper production in the 20th century, particularly in the United States and Chile, stimulated the development of new technology for leaching and for the recovery of copper from leach solutions. In the past 25 years, solvent extraction has become a major factor by permitting novel leaching technology that produces dilute or complex solutions. In addition, solvents other than sulfuric acid, and chemical methods for precipitating copper metal are now of increasing interest. These are trends that should grow in importance with the need to process lower grade and more complex materials. The evolution of copper hydrometallurgy is reviewed. Key factors in recent major developments are presented with details of specific operations and with trends for the future indicated. The relative importance of copper hydrometallurgy is compared with that of pyrometallurgy in the light of probable changes in ore supplies and character.

Jan 1, 1994

By William R. Yernberg

SME’s Arizona Conference was held at the Doubletree Hotel at Reid Park in Tucson on Dec. 4 and 5, 2005. The annual conference is organized by the Arizona Conference Board of Directors, which represents SME sections in Arizona and adjacent areas. The conference provides an opportunity for individuals and corporations associated with mining in the region to get together once each year to discuss the status of the industry. Important topics discussed among the attendees included the price of copper, community relations and education.

Jan 1, 2006

By E. E. Malouf

For centuries small amounts of copper have been recovered from acid mine-drainage waters. In recent years, the expansion of copper-bearing waste dump leaching for copper recovery has established a technological basis that is rapidly converting the art of copper leaching' into a science. Leaching of copper, whether from copper-bearing ore or waste, follows well established chemical reactions. These reactions are commonly in an acid circuit, but where leaching of copper is to be made in rock that is a high acid consumer, ammonia and ammonia carbonate, as well as cyanide leach solutions, can be used effectively. Current hydrometallurgical processes are being applied at an ever increasing rate to recover the trace amounts of copper in copper mine waste by in-place leaching. Currently approximately 300, 000 tons of copper are produced annually in this manner where as recently as ten years ago, only one-eighth of this amount of precipitate copper was produced.. Where copper occurs as an oxide in higher concentrations as to be classified as an ore rather than waste, then the hydro-metallurgical processes are applied as percolation or agitation leaching in vats, pachuca tanks, or prepared heaps. This approach gives better control over the recovery of the leach solutions, particularly in the processes where ammonia or cyanide leaching agents are to be used.

Jan 1, 1972

By R. Scheffel, R. Washnock, G. Zarate

"The second survey of global copper leaching operations has been completed, the data published in 1998 has been updated. A survey questionnaire was sent to 40 identified copper leach operations around the world including those leach properties still in operation that responded to the 1998 survey. This paper lists the results of 26 operations that responded to the survey. Selected information from the survey is represented in graphical form. INTRODUCTION Copper leaching was first performed by truck dumping huge monolithic stockpiles of ore and flooding the surface with leach solution or lixiviant with little understanding to the parameters that support optimum recovery of the metal. Heap leaching has evolved into a controlled process whereby a complex low grade ore is stacked in shallow lifts (under 10 m in most cases). The ore is usually crushed and agglomerated, conveyor stacked on an engineered containment system (leach pad) and irrigated in a controlled manner. The lixiviant chemistry is designed to extract the optimum amount of metal from the ore. At first glance, heap leaching appears to be simple in nature. In fact, it is a very complex process. A plethora of technologies such as material handling, environmental control, analytical techniques, solution chemistry, hydrology and many others contribute to the design and operation of a heap leach. Heap leaching requires an inter-disciplinary approach between geologists, mining engineers and metallurgists. Many operational factors affect heap leaching. The process must address climatic factors, flexible operation, quality control before and after leaching, physical characteristics of the ore, geology, mineralogy, reagent consumption, solution application rate and methods (wobblers or emitters), particle size, and favorable conditions for bacterial growth and survival. Predicting, troubleshooting, and optimization of leach recovery is a significant challenge when considering the number of variables involved and their interactions The survey updates many of these key operating parameters to the current state of the art. It should provide the reader an excellent benchmarking summary of these factors on a site-by-site basis."

Jan 1, 2016

By J. Alvarez, S. Helle, U. Kelm, M. Pincheira

The principal geological and mineralogical characteristics of Chilean porphyry copper deposits are described. Elevated contents of fine grained ore and gangue material may cause copper losses and pose problems or render useless the flotation process. Examples of chalcopyrite and bornite size distributions are given. The state of the art of mineralogical and mineral chemical characterization in Chile is evaluated permitting analyses to lm and nm level by lacking the regular use of direct surface analysis.

Jan 1, 1998

By ?. ?ivkovic

The silicate slag and copper matte that are the byproducts of smelting copper in a reverberatory furnace contain SiO2, FeO, Fe3O4, CaO and Al2O3, and Cu, Fe and S, respectively. These components influence the oxide (Cuox), sulfide (Cusul) and total (Cutotal) copper content lost in the waste slag. This paper uses multiple linear regression analysis (MLRA) to determine the degree of influence. The results of calculations obtained using MLRA were compared to actual measured results and found to have a large degree of correspondence, with the coefficient of determination R2 = 0.975. These results indicate that slag composition and copper content in the matte influence the copper losses in the waste slag with a probability of above 97%. It was determined that, of the total copper content of the slag, 74% is in sulfide and 26% in oxide form, and that this ratio is not dependent on the slag or matte composition.

Jan 1, 2010

By A. E. Isaacson

The Bureau of Mines is studying the effect of supercritical water, at 4000 C and 3,500 psi and subcritical water at lower temperatures and pressures. on mixtures of minerals and metals to determine the possible applications of water at high temperature and pressure for processing these materials. This research was conducted using a flow-through bench-scale system. Copper-bearing minerals studied were chalcocite, chalcopyrite, covellite, and cuprite. In general, mixtures of copper minerals and pyrite reacted to form bornite. Intermediate phases formed were chalcopyrite and digenite. Similar reactions occurred between pyrite and metallic copper. A mixture of chalcopyrite and pyrite was inert in supercritical water. The reaction between cuprite and metallic zinc yielded metallic copper. The cuprite was reduced by hydrogen generated by the reaction between metallic zinc and water. None of the reactions occurred exclusively in supercritical water, but also occurred in water at high temperature and pressure below the critical point. Experimental results did show that a dual-reaction process, consisting of solid-state diffusion and fluid transport, was occurring.

Jan 1, 1989

ME?s Arizona Conference was held at the Hilton El Conquistador resort in Tucson on Dec. 2 and 3, 2007. The annual conference is organized by the Arizona Conference Board of Directors, which represents SME sections in Arizona and adjacent areas. The conference provides an opportunity for individuals and corporations associated with mining in the region to get together once each year to discuss the status of the industry. The 2007 meeting featured a keynote address, a distinguished lecturer and more than 25 technical papers that were presented in seven sessions. The sessions included environmental, geology, safety, metallurgy, mining, new projects and a special session on Mexico. Topics covered included mine closure, sustainable mining, exploration methods, health and safety issues, mining equipment and drilling. Much of the discussion at the conference concerned major new developments in the region?s copper mining industry. For example, Freeport-McMoRan?s new Safford Mine and BHP Billiton?s Pinto Valley restart were the topics of technical presentations. There was also much discussion among the attendees on the current and future price of copper, community relations, education issues and recruitment concerns. At the time of the conference, the price of copper hovered around $3.30/lb, up considerably from the 61 cents/lb in late 2001, when the industry was being challenged by world market conditions and a weakened domestic economy. Since then, strong demand from China helped push copper prices to record levels that at one time reached as high as $4/lb. The general consensus among the attendees is that the current price of around $3.30/lb will continue through 2008. Most attendees also expect increased corporate investments in the industry to continue. Copper mining in Arizona has been a major industry since the 1800s. In 2007, Arizona was the leading copper-producing state in the United States and produced more than $5 billion worth of copper. The copper mining industry in Arizona also produces byproduct gold, silver and molybdenum. Arizona is the second largest molybdenum producer in the United States.

Jan 1, 2008

By G. Hoffmeyer, I. Ream

"Several copper projects exclusively utilizing in-situ recovery methods are currently under development in Arizona. Favorable conditions for In-Situ Copper Recovery (ISCR) include a saturated orebody, fracture hosted mineralization, hydraulic conductivity sufficient to effectively inject and recover solutions using wells, and a relatively flat background hydraulic gradient. Safe operation of an ISCR project requires that the operator have the ability to induce and maintain localized hydraulic gradients, thereby controlling the movement of injected and recovered solutions. Benefits of ISCR include reduced initial capital, and a greatly reduced environmental footprint. THE ISCR METHOD EXPLAINED The method chosen to extract a mineral from a deposit is driven by characteristics such as its size, grade and depth of burial. Large lower grade deposits that require significant excavation to access using surface methods are potential candidates for in-situ recovery. ISCR may also be ideal for smaller deposits due to the lower initial capital. However, regardless of the size of the deposit, certain hydrogeologic conditions must be present for ISCR to be successful. In-situ recovery methods do not require excavations of rock from the surface or underground, resulting in a dramatic reduction in surface disturbance when compared to conventional mining. With the ISCR method, what is visible above ground is the processing plant, well heads, piping, process solution impoundments and evaporation ponds. There are no waste rock piles, tailings impoundments, leach pads, or impacts associated with blasting and hauling. Other benefits include reduced initial capital, reduced dust and noise, and lower water use. Early testing of the in-situ copper recovery method by Occidental on the Van Dyke deposit east of Phoenix and by Kennecott at Safford Arizona in the 1970s produced encouraging results, but the permitting regime for a large-scale operation was not yet in place. Additional testing and commercial application of in-situ copper recovery techniques have expanded since the 1980s, most commonly in conjunction with open pit or underground mining operations. For example, several operations in Arizona (San Manuel, Miami East and Tohono) have used in-situ techniques to extract additional copper following conventional mining from parts of the deposits adjacent to open pits or underground workings. Where the rock has been broken up by conventional methods, the method is called “in-place” leaching. The US government has also been involved in assessing in-situ techniques. For example, joint research was conducted by the US Bureau of Mines and industry on the Santa Cruz deposit in Arizona; and both federal and state agencies have been involved to establish the comprehensive permitting regime that exists today. Currently there are several projects in Arizona being evaluated as stand-alone ISCR operations."

Jan 1, 2016

By S. Acar, M. Botz

Introduction In 2007, Newmont Mining Corporation will begin construction of a milling and cyanidation leaching circuit for the Yanacocha site in Peru. Ore to be processed in the circuit contains a relatively high level of cyanide-soluble copper, and as a result, leach solutions are expected to contain elevated levels of copper and WAD cyanide. As the means of controlling copper levels in leach solution, a circuit will be installed to precipitate copper sulfide from barren solution using sodium hydrosulfide. In addition, a circuit will be installed to recover cyanide from barren solution, with recovered cyanide to be returned to the leaching circuit and treated solution to be utilized as make-up in existing heap leaching facilities. As needed to support design of the copper precipitation and cyanide recovery circuits, pilot testing was conducted in 2005 to determine preferred operating conditions and evaluate the performance of the processes. This paper presents results from the pilot testing where 99% copper reduction was achieved and 95% to 98% cyanide recovery was achieved.

Jan 1, 2007

By Simon D. Strauss

This article is part of a presentation Strauss made Dec. 3, 1988 at the sixth annual American Mining Hall of Fame (AMHofF) banquet in Tucson, AZ. At the banquet, the Mining Club of the Southwest honored Strauss by naming him the 1988 recipient to the AMHofF. (Industry newswatch, page 6). Introduction In the last two decades, there have been two previous periods of sharply rising copper prices. One was in 1973-74; the other in 1979-80. In both cases, a short period of high copper prices was followed by steep and prolonged periods of low prices. In the language of the market analyst, the high prices were called spikes. Is it likely, then, that three or four years from now the present price of copper will show up as a spike in the charts? There are substantial differences between the current position and the markets of 1973-74 and 1979-80. In 1973-74, US copper prices were subject to government-imposed price ceilings of $0.60 per lb through early December, 1973. These were increased to $0.68 per lb through May, 1974. Meanwhile, mines outside the United States were free of restraint. Rising demand in London pushed the price above $1 per lb in the third quarter of 1973. In early April 1974, it reached a peak of $1.50 a lb. In May of that year, the US ceilings were removed and the domestic price began to rise. What were the causes of this price strength? While ceilings held the domestic price below the world market, domestic consumers acquired all the tonnage offered by US mines. Meanwhile, in the world market, buyers feared prolonged shortages. The Club of Rome had warned that world economic growth would be limited by impending depletion of mineral resources. There was al so concern about a copper cartel that might increase copper prices even more. In early 1974, at a special United Nations session, developing-country spokesmen warned the industrialized world to expect high commodity prices. Also adding to the concerns of copper buyers was the fear that when US wage contracts expired in mid-1974, protracted strikes might ensue. The combined effect of this atmosphere was that consumers accumulated large amounts of copper, far above their normal carry. By midsummer, the position changed radically. While some strikes did occur in the United States, they proved short-lived. The most significant development was a massive economic recession. The energy crisis was causing enormous dislocations in the world economy. Construction activities were sharply reduced and automobile sales plummeted. Public confidence was shaken. Copper sales fell precipitately as consumers decided to draw down their swollen inventories. The price came down too. In April 1974, the London price- as noted-was $1.50 per lb. By the end of the year, it was down to $0.57 per lb. In 1973-74, the copper price rise was fed by fears of shortages, cartels, and strikes. In 1979-80, the market rose on the strength of good demand plus political and military instability. The price rise was also fed by inflationary trends, exemplified by speculation in precious metals. Prior to this second spike in copper prices, the market had been depressed despite economic recovery. Despite reduced US output, copper production in the rest of the world was increasing. Though consumption was rising, surplus stocks reached unprecedented levels. At the end of 1977, the aggregate of stocks at the refineries and in the exchange warehouses was 1.5 Mt (1.67 million st). That was more than three months' shipments at then rates of consumption. In 1978, the statistical position improved. Shipments of refined copper that year were 8% greater than in 1977. The result was reduced visible stocks but -just as was to be the case in 1984-86 - the price remained depressed. In 1979, an even sharper drop in visible stocks occurred as shipments rose by another 4%. This time, though, the price responded. In December 1978, the price in current dollars had been less than $0.70 per lb. By the end of 1979, it was above $1 per lb. And in the first quarter of 1980, it averaged more than $1.20 per lb. Military and political developments were a factor. The hostage crisis in Iran was followed by the Soviet invasion of Afghanistan. To many, it appeared that war might result if the Soviets pushed on into Pakistan. At the same time, speculation drove gold and silver prices to incredible levels. As silver prices rose above $40 per oz), copper above $1 per lb did not seem unreasonable. Then, in March 1980, the precious metals price boom collapsed. Copper prices also retreated, though not as much. In February 1980, the copperprice averaged $1.32 per lb. By December, it had dropped to $0.85 per lb. In 1981 and 1982, the decline continued. The present copper situation Why is the current situation different from these two previous episodes of high prices? First of all, today's inventories are far lower than they were in either 1974 or 1980, when the price declines began. The stocks at refineries and in exchange warehouses are substantially less than they were then. More significantly, consumers today have very limited holdings compared with stocks they carried in 1974 and 1980. Even if faced with a downturn in their own business, copper consumers will not be able to stay out of the market. To the extent they have any business at all, they will have to buy copper. And on the supply side, there is also a significant difference. The year 1988 has been unusual. US production is up sharply, responding to higher prices. But production is little changed in the rest of the Free World. Indeed, several of the major producing countries have mined less copper this year than in 1987 despite the prices increases. Peru has had labor problems that have cut its output. Zambia and Zaire suffer from shortages of expatriate technicians, not to mention spare parts. They also suffer from the failure to maintain equipment or perform adequate development. In Chile, the two largest mines, Chuquicamata and El Teniente, have not met their production targets. Chuquicamata is struggling with high arsenic content in its ore. And, in late 1987, severe rockbursts hampered operations at El Teniente. In addition, depletion of some mines in Australia and South Africa has offset rising output at other properties. Indeed, when final mine output figures for 1988 become available, it may well be

Jan 1, 1989

By William R. Yernberg

SME’s Arizona Conference was held at the Doubletree Hotel at Reid Park in Tucson on Dec. 5and 6, 2004. The annual conference is organized by the Arizona Conference Board of Directors, which represents SME sections in Arizona and adjacent areas. The conference provides an opportunity for individuals and corporations associated with mining in the region to get together each year to discuss the status of the industry. The meeting featured a keynote address and more than30 technical papers. Two years ago, the U.S. copper industry was facing on a run for two years now,” and “both precious metal and base metal prices are going up.” The increases in metal prices were attributed to development in China and other Asian countries. “With a population of 1.6 billion, China has recently created 80 million jobs,” said Silver.

Jan 1, 2005

By F. Milton Lewis

In 1977 a paper was presented which reviewed the cost trends in producing copper by conventional processes for five years, 1972 through 1976. In this paper these costs have been updated to include the years 1977 and 1978.

Jan 1, 1979

By F. Milton Lewis

In this paper an attempt has been made to review the cost trends in producing copper by conventional milling. smelting and hydro-metallurgical means during the last five years. The primary objectives of this cost analysis are to provide a base for future projections as well as to indicate which cost items are more volatile in their influence on overall cost of producing copper.

Jan 1, 1977

By Leons Kovisars

Two-thirds of the world copper produced in 1979 incurred cash costs between $0.35 and $0.89 per lb, averaging $0.62 per lb. North American costs are higher at $0.48, $0.88, and $0.68 per lb, respectively. Variable cash costs are $0.20, $0.58, and $0.39 per lb for the world; $0.29, $0.63, and $0.46 per lb for North America. Cash costs are relevant for comparing existing operations and evaluating market pricing during periods of excess supply. Analysis of full costs of production (cash costs plus income taxes, profit, and non-cash items) becomes relevant in evaluating the incentive price required to develop new production plants. In mid-1979 this cost (incentive price) was about $1.10 per lb; it is expected to approach $2.00 per lb by 1985.

Jan 1, 1979

By V. M. Torres

Arapiraca ore deposit has a mixed chalcopyritelbornite mineralogy, with a copper head grade of 0.7%. The reserve size does no allow profitable exploration by grinding/flotation. The technical feasibility of exploring the reserve by heap leaching was studied. Preliminary agitation tests indicated 85% copper recovery. To simulate heap leaching, column tests were performed. The tests included different ore types and acid addition levels. Operating at pH range 1.6-1.8, 67% copper extraction was achieved. Also, it was found an empirical correlation between the operation pH range, copper extraction and acid consumption.

Jan 1, 1996

By J. A. Hartlage

Four years ago, Ashland Chemical Company introduced a new copper solvent extraction reagent for hydrometallurgical utilization. The reagent, an alkylated 8-hydroxyquinoline, is called Kelex 100 ®(1). Since the time of introduction, the reagent has been investigated by several workers for its solvent extraction utility in the separation and purification of transition metals (2-7). In the following text, those factors which are essential to the optimum performance of Kelex 100 on concentrated copper solutions will be discussed. To date, the reagent has been found useful in active concentrations of from 1 to 20% Kelex 100. In order to achieve the best performance for Kelex 100, it has been found that a phase modifier is essential. Various alcohols and phenols have been evaluated in order to improve phase performance and stripping characteristics of the solvent system. Modifiers and diluents are especially important when solvent activities between 3 and 20% Kelex 100 are employed. A 15% Kelex 100 solvent, for example, containing 15% nonyl phenol in Escaid 100 (Exxon) can be utilized to remove greater than 33 grams per liter of copper from an aqueous feed without interstage neutralization, and in the same process scheme the reagent can be stripped to less than 1 gram per liter barren organic producing a pregnant electrolyte containing greater than 40 grams per liter copper and less than 120 grams per liter sulphuric acid. The unusually efficient stripping of Kelex is accomplished by protenation of the extractive molecule during the stripping process.

Jan 1, 1974