Solvent extractionSolvent extraction (SX) is a fundamental process in hydrometallurgyHydrometallurgy that recovers valuable metalsMetal from aqueous solutions. Mintek-Measurement and Control Division (MAC) has conducted audits on SX plants and found that most of the SX plants are operating inefficiently due to a lack of advanced process controlAdvanced Process Control and instrumentation. In response, a prototype instrument has been developed and advanced process controlAdvanced Process Control strategies have been proposed. To initiate testing of the proposed control strategies, the development of a simulator was deemed necessary. Testing the proposed strategies using a simulator is more cost-effective than using the actual plant or pilot plant. Conducting online or plant tests for control strategies can be very expensive, highlighting the need for reliable simulation modelsModel. These modelsModel will aid in troubleshooting plant performancePerformance issues and will be valuable for future plant auditing and troubleshooting, in addition to testing control strategies. To achieve this, a computational simulationComputational Simulation of solvent extractionSolvent extraction was developed using both Python and MATLAB Simulink. For this part of the study, the focus was on the copper extractionCopper extraction circuit from a plant in Southern Africa. This SX plant runs with a feed flow rateFlow rate range of between 500 and 700 m3/h of pregnant leach solutionPregnant Leach Solution (PLS). The organic feed flow ratesFlow rate range from 1.3 to 1.5 times the PLSPregnant Leach Solution (PLS) feed. A distribution coefficientDistribution coefficient (KD) was randomly selected from 10–50 to modelModel the transfer of copperCopper ions from the aqueous phase to the organic phase during equilibration. The simulation then incorporates a strippingStripping step where the organic phase, enriched with copperCopper, is mixed with a strippingStripping solution. An assumed strippingStripping efficiencyEfficiency of 80% is applied to transfer copperCopper ions back to the aqueous phase. Python-based simulator was developed following a fundamental analysisAnalysis of the chemical reactions inherent to the solvent extractionSolvent extraction process. The simulation tracks copperCopper ion concentrations in both the aqueous and organic phases over 50 discrete time steps using mass balance equations. The proposed method is validated using real-time data from industrial copperCopper SX circuits.

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Computational Simulation of Copper Solvent Extraction: Modelling and Analysis of the SX Control

  • Khuthadzo Mudzanani,
  • Samuel Ramatsoma,
  • Terence Phadi

摘要

Solvent extractionSolvent extraction (SX) is a fundamental process in hydrometallurgyHydrometallurgy that recovers valuable metalsMetal from aqueous solutions. Mintek-Measurement and Control Division (MAC) has conducted audits on SX plants and found that most of the SX plants are operating inefficiently due to a lack of advanced process controlAdvanced Process Control and instrumentation. In response, a prototype instrument has been developed and advanced process controlAdvanced Process Control strategies have been proposed. To initiate testing of the proposed control strategies, the development of a simulator was deemed necessary. Testing the proposed strategies using a simulator is more cost-effective than using the actual plant or pilot plant. Conducting online or plant tests for control strategies can be very expensive, highlighting the need for reliable simulation modelsModel. These modelsModel will aid in troubleshooting plant performancePerformance issues and will be valuable for future plant auditing and troubleshooting, in addition to testing control strategies. To achieve this, a computational simulationComputational Simulation of solvent extractionSolvent extraction was developed using both Python and MATLAB Simulink. For this part of the study, the focus was on the copper extractionCopper extraction circuit from a plant in Southern Africa. This SX plant runs with a feed flow rateFlow rate range of between 500 and 700 m3/h of pregnant leach solutionPregnant Leach Solution (PLS). The organic feed flow ratesFlow rate range from 1.3 to 1.5 times the PLSPregnant Leach Solution (PLS) feed. A distribution coefficientDistribution coefficient (KD) was randomly selected from 10–50 to modelModel the transfer of copperCopper ions from the aqueous phase to the organic phase during equilibration. The simulation then incorporates a strippingStripping step where the organic phase, enriched with copperCopper, is mixed with a strippingStripping solution. An assumed strippingStripping efficiencyEfficiency of 80% is applied to transfer copperCopper ions back to the aqueous phase. Python-based simulator was developed following a fundamental analysisAnalysis of the chemical reactions inherent to the solvent extractionSolvent extraction process. The simulation tracks copperCopper ion concentrations in both the aqueous and organic phases over 50 discrete time steps using mass balance equations. The proposed method is validated using real-time data from industrial copperCopper SX circuits.