FERROUNION PROJECT

SCOOPING STUDY

CALCULATION MEMORY
TAILINGS DISPOSAL

DOCUMENT N° 201702-PD-004

REV BY REVIEWED ISSUED FOR DATE CHECKED

A H Parra Manrique Machaca Richard -
B H Parra -
0
 INDEX

1.0.0. SECONDARY AREA ........................................................................................................... 3

1.1.0. OBJECTIVES ...................................................................................................................... 3
1.2.0. GENERAL INFORMATION ................................................................................................. 3
1.3.0. SOLID FEED ....................................................................................................................... 3
1.4.0. CHARACTERIZATION OF RELAYS .................................................................................. 3
1.5.0. EQUIPMENT DESIGN CRITERIA ...................................................................................... 4
1.6.0. FLOCCULATION SYSTEM ................................................................................................. 8
1.7.0. NOMINAL MASS BALANCE AND DESIGN ..................................................................... 11

TABLE INDEX

Table 1. Total production .............................................................................................. 3

Table 2. Characterization of tails .................................................................................. 3
Table 3. Feeding plant thickening ................................................................................. 4
Table 4. Tailings distributor........................................................................................... 4
Table 5. High efficiency thickeners ............................................................................... 5
Table 6. Characteristics of thickener discharge ............................................................ 6
Table 7. Discharge transfer pumps ............................................................................... 6
Table 8. Storage tank of thickened tailings ................................................................... 6
Table 9. Thickening overflow characteristics ................................................................ 7
Table 10. Overflow water storage tank ......................................................................... 7
Table 11. Water pump for dilution and recirculation ...................................................... 8
Table 12. Thickened tailings delivery pump .................................................................. 8
Table 13. Water pump recovered ................................................................................. 8
Table 15. Type of flocculant.......................................................................................... 9
Table 16. Concentration of flocculant ........................................................................... 9
Table 16. Intake flocculant ............................................................................................ 9
Table 17. Preparation of flocculant ............................................................................... 9
Table 18. Flocculant mixing tank ................................................................................ 10
Table 19. Flocculant storage tank ............................................................................... 10
Table 20. Flocculants transfer pumps ......................................................................... 11
Table 21. Flocculant dosing pump .............................................................................. 11
Table 22. Nominal balance ......................................................................................... 12
Table 23. Design balance ........................................................................................... 12
1.0.0. SECONDARY AREA

1.1.0. OBJECTIVES

 Size the equipment required for the thickening plant, which should be adequate to treat
the flows that occur during the tailings disposal process in the secondary zone stage.

1.2.0. GENERAL INFORMATION

The numerical data estimated and calculated; Regarding flows and dimensions in each team,
they will be of both nominal value and design value, the latter being greater at all times. The
calculations described will only be based on nominal values. The design values are found in the
same way.

1.3.0. SOLID FEED

Table 1. Total production

Total production units Nominal Design

Availability % 95 95
Total tailings (dry) t/year 33933607 35388056
Production in thickening plant units Nominal Design
Total tailings (dry) t/day 88320 92106
Total tailings (dry) t/hour 3680 3838

Production of dry tailings in thickening plant per year:

Days per year = 365

Hours per day = 24

3838  24  365
Total tailings dry, t/year = = 33,933,607 TPH
95%

1.4.0. CHARACTERIZATION OF RELAYS

Table 2. Characterization of tails

Characterization units Nominal Design

Specific gravity of solids - 3.073 3.073
pH - 9 - 10.5 9 - 10.5
 Table 3. Feeding plant thickening

Feeding plant thickening units Nominal Design

Percentage of feed solids % 35 35
3
Total pulp flow m /h 8032 8376
Specific gravity of pulp - 1.309 1.309
Flow of water in the pulp m3/h 6834 7127
Dilution perecntage % 8 8

3838
Pulp tonnage = 100  = 10,966 m3/h
35

Water flow in tailings at the entrance = 10966  3838 = 7,127 m3/h

3838  100  35 
Tailings pulp flow at the entrance =  3838    = 8,376m /h
3
3.073  35 

10966
Specific gravity of pulp = = 1,309
8376

1.5.0. EQUIPMENT DESIGN CRITERIA

Table 4. Tailings distributor

Tailings distributor units Nominal Design

3
Incoming flow to the tank m /h 8061 8406
Residence time min 2.5 2.5
3
Tank volume required m 336 350
Total height m 8 8
Diameter m 8 8
3
Tank effective m 402 402

8406
Tank volume required = = 350 m3
 60 
 
 2.5 

Tank volume effective = 402 m3

 Table 5. High efficiency thickeners

High efficiency thickeners units Nominal Design

2
Feeding rate t/m /h 0.7 0.7
2
Unitary area m /t/d 0.06 0.06
2
Thickening area required m 5299 5526
Diameter by thickener m 50 50
2
Sedimentation area by thickener m 1963 1963
2
Total sedimentation area m 5890 5890
Operating number unidad 3 3
Wall height m 8.2 8.2
Technology type HRT

The area of a thickener must be such as to provide adequate residence time for the percent
solids requirements in the discharge. The area of a thickener varies inversely with the rate of
sedimentation.

The sedimentation rate is a fundamental characteristic of each pulp, which must be determined
experimentally under certain flocculation conditions. The sedimentation rate is a parameter
easily obtainable by means of laboratory tests, which consist of determining the decrease in the
boundary of the clarified liquid and the suspension, over time.

The main criterion for the design of thickeners is to determine the relationship between; the
sedimentation speed and the dimensions of the tank to be used. The calculation of the unit area
in thickeners can be determined by three methods (Coe & Clevenger, Talmage & Fitch, Solids
Settling Flux, Fynch), and based on the Sedimentation Curve.

The dimensioning of the thickeners is based on a feed rate of 0.7 t/m2/h, equivalent to a unit
area of 0.06 m2/tpd, which is determined in the laboratory from a representative sample.

Thickening area required = 0.06 m t d  92106 t d = 5,526 m2

2

According to the possibilities of the McLanahan supplier, thickeners HRT-E-50 for the thickening
plant will be adapted.
2
 50 
Sedimentation area by thickener =     = 1,963 m
2

 2 

Depending on the area of thickening required, 3 thickeners HRT-E-50 must be available to

cover the entire tailings production without any problem. The thickeners have a diameter of 50
m each and with 8.2 m height according to their design.

Total sedimentation area = 1963  3 = 5,890 m2

 Table 6. Characteristics of thickener discharge

Characteristics of thickener discharge units Nominal Design

Percentage of solids by weight % 66 66
3
Thickness discharge flow m /h 1081 1127
Specific gravity of discharge - 1.72 1.72
3
Total discharge flow m /h 3242 3381

3838
Discharge pulp tonnage = 100  = 5,815 m3/h
66

5815
Total discharge flow = = 3,381 m3/h
1.72

3381
Discharge flow of each thickener = = 1,127 m3/h
3

Table 7. Discharge transfer pumps

Discharge transfer pumps Unidades Nominal Design

Units per thickener op/stdby 1/0 1/0
3
Pulp flow per pump m /h 1081 1127
Specific gravity of pulp - 1.72 1.72
Type of pump type Centrifuge

Table 8. Storage tank of thickened tailings

Storage tank of thickened tailings units Nominal Design

Number unidad 1 1
Agitation system - SI SI
Covered - NO NO
3
Flow of entry to each tank m /h 3242 3381
Residence time min 15 15
3
Tank volume required m 810 845
Total height m 10.5 10.5
Diameter m 10.5 10.5
3
Tank volume effective m 909 909
Construction material - Carbon steel

Incoming flow to each tank = Total discharge flow from thickeners area = 3,381 m3/h
 3381
Tank volume required = = 845 m3
 60 
 
 15 

Tank volume effective = 909 m3

Table 9. Thickening overflow characteristics

Thickening overflow characteristics units Nominal Design

3
Water flow by thickener m /h 1965.45 2104.85
3
Total water flow m /h 5896.35 6314.55
Solids in suspension (maximum) ppm 20 20

Total water flow = Water recovered + Re-circulated water (dilution and preparation of flocculant)
= 6,315 m3/h

6315
Water flow by thickener = = 2,105 m3/h
3

Table 10. Overflow water storage tank

Overflow water storage tank units Nominal Design

Number unidad 1 1
Agitation system - NO NO
Covered - NO NO
3
Flow of entry to each tank m /h 5896.35 6314.55
Residence time min 20 20
3
Tank volume required m 1965.45 2104.85
Total height m 14 14
Diameter m 14 14
3
Tank volume effective m 2155.13 2155.13
Construction material - Carbon steel

Incoming flow to the tank = Total water flow of the thickeners overflow = 6315 m3/h

6315
Tank volume required = = 2,105 m3/h
 60 
 
 20 

Tank volume effective = 2,155 m3

 Table 11. Water pump for dilution and recirculation

Water pump for dilution and recirculation units Nominal Design

Number op/stby 1 1
3
Flow m /h 944.50 1147.70
Specific gravity of water - 1 1
Type of pump type Centrifuge

Table 12. Thickened tailings delivery pump

Thickened tailings delivery pump units Nominal Design

Number op/stby 3/3 3/3
3
Total flow m /h 3242 3381
Specific gravity of pulp - 1.72 1.72
Type of pump type Centrifuge

The destination of the thickened tailings delivery pump will finally be the thickened tailings field.

Total flow = Total discharge flow of thickeners area = 3,381 m3/h

Table 13. Water pump recovered

Water pump recovered units Nominal Design

Number op/stby 3/3 3/3
3
Total flow m /h 4939 5150
Specific gravity of pulp - 1.00 1.00
Type of pump type Centrifuge

 100  35   100  66 
Total flow = 3838     3838    = 5,151 m /h
3

 35   66 

1.6.0. FLOCCULATION SYSTEM

The theoretical prediction of which synthetic flocculant is most suitable for a particular
suspension is impossible, the selection of flocculants is an empirical process.

The selection criterion of the optimal flocculant is based on the determination of the
sedimentation speed of different polymers on a representative sample of the material to be
sedimented. That flocculant that exhibits the highest velocity is considered optimal.
 Table 15. Type of flocculant

Type of flocculant Praestol 2530

Molecular weight High
Ionic charge Medium

Table 16. Concentration of flocculant

Type of flocculant Units Nominal Design

Mother concentration g/l 2.5 2.5
Diluted concentration g/l 0.1 0.1

Table 16. Intake flocculant

units Nominal Design

g/t 10 10
Intake
kg/d 883 921
kg/h 37 38

10 g t  92106 t d
Intake = = 921 kg/d
1000

Table 17. Preparation of flocculant

Preparation of flocculant Units Nominal Design

Concentration of mother flocculant %S 0.25% 0.25%
Concentration of diluted flocculant %S 0.01% 0.01%

2.5
Concentration of flocculant mother =  100 = 0.25%
2.5  1000

0.1
Concentration of diluted flocculant=  100 = 0.01%
0.1  1000
 Table 18. Flocculant mixing tank

Flocculant mixing tank Units Nominal Design

Number op/stby 1/0 1/0
Agitation system - YES YES
Covered - NO NO
3
Flow of entry to each tank m /h 13.31 16.65
Residence time min 120 120
3
Tank volume required m 27 33
Total height m 3.5 3.5
Diameter m 3.5 3.5
3
Tank volume effective m 34 34
Construction material - Carbon steel

Flow of the flocculants mixture = 16.65 m3/h

16.65
Tank volume required = = 33 m3
 60 
 
 120 

Tank volume effective = 34 m3

Table 19. Flocculant storage tank

Flocculant storage tank units Nominal Design

Number op/stby 1/0 1/0
Agitation system - NO NO
Covered - NO NO
3
Flow of entry to each tank m /h 13.31 16.65
Residence time min 240 240
3
Tank volume required m 53 67
Total height m 4.5 4.5
Diameter m 4.5 4.5
3
Tank volume effective m 72 72
Construction material - Carbon steel

Incoming flow = 16.65 m3/h

16.67
Tank volume required = = 67 m3
 60 
 
 240 

Tank volume effective = 72 m3

 Table 20. Flocculants transfer pumps

Flocculant transfer pumps units Nominal Design

Number op/stby 2/2 2/2
3
Total flow m /h 13.31 16.65
Type - Peristaltics

Table 21. Flocculant dosing pump

Flocculant dosing pumps Units Nominal Design

Number op/stby 3/3 3/3
3
Total flow m /h 319.27 388.12
Type - Peristaltics

Total flow = dosing pump + dilution water in line = 388 m3/h

1.7.0. NOMINAL MASS BALANCE AND DESIGN

NOMINAL DATA: DESIGN DATA:

Relave seco t/h 3680 Dry tail t/h 3838

Gravedad especifica solido 3.073 Specific solid gravity 3.073
Espesadores 3 Thickeners 3

FEED FEED
%S input 35 %S input 35
Tail pulp input t/h 10514.33 Tail pulp input t/h 10964.99
Specific gravity of pulp input 1.309 Specific gravity of pulp input 1.309

OVERFLOW OVERFLOW
%S output 66 %S output 66
Tail pulp output t/h 5575.78 Tail pulp output t/h 5814.77
Specific gravity of pulp output 1.72 Specific gravity of pulp output 1.72
NOMINAL BALANCE

Table 22. Nominal balance

Espesamiento Mezcla de floculante Distribucion de floculante Agua

FLUJO unidad relave alimento descarga rebose agente agua de mezcla solucion recirc. rebose dilucion en linea distribucionbomba dosificadora recuperada
solidos m3/h 1227 409 409 0 0.013 0 0.013 0 0 0.004 0.004 0
solucion m3/h 6834 2278 632 1965 0 13.30 13.30 944.50 314.83 319.27 4.433 4938.55
pulpa m3/h 8061 2687 1041 1965 0 0 13.313 944.50 314.83 319.27 4.438 4938.55

DESIGN BALANCE

Table 23. Design balance

Thickening Flocculant mixture Flocculant distribution Recovered

FLOW unit tail feed discharge overflow agent mixing water solution recirc. overflow online dilution distribution dosing pump water
solid m3/h 1279 426 426 0 0.017 0 0.017 0 0 0.006 0.006 0
solution m3/h 7127 2376 659 2105 0 16.63 16.63 1147.70 382.57 388.11 5.543 5150.22
pulp m3/h 8406 2802 1085 2105 0 0 16.647 1147.70 382.57 388.12 5.549 5150.22