Hydrometalurgicals Model and Simulation Key Points Compilation Practical Issues for In Site Implementation I Introduction Key Points

Vision. The Model and Simulation Area or experts have to support and assist its stakeholders and internal customers through the entire process. For example the area must support the metallurgical testwork and scale-up during heap leach design, construction and start-up. In other words, we we have to put our analytical skills and software tools to give support to innovation, improvement, and optimization for the projects. A comprehensive set of mathematical models is a MUST. The optimization of a static heap bioleach operation is not trivial and is impossible to accomplish on the basis of operator experience alone. Thats also true in almost all the others metallurgical processes. There should be a set of models for the different phases and objectives of the specific task. As an overall classification we have to work with: (1) process control oriented low complexity models and (2) complex multi-physics high end models. The challenge. Engineering problems encountered in the field of metallurgy involve some of the most complex physical and chemical phenomena, Multiphysical in nature. As a rule of thumb, in order to model complex processes is strongly recommended to identify the main sub-processes and the rate controlled sub-process for different situations in time and/or space. The real complexity of this lies in the fact that different sub-processes can be rate controlling at different locations in the heap at different times. See II. Software Tools and Model Packages . The multi-physical nature issue is very important because problems involving a single physical domain can be solved fairly easy with many commercially available software tools. Because of that we need a selected set of software tools and models packages. As far as I know, in spite of the later efforts and developments, main companies models are not truly based on Multi-Physical domains. Of course they are high complex models. As far as I know, they are no enough complete to master the total subject and also not enough simple to use as a low complexity easy to scale up- process control and optimization oriented model. In my opinion the CFDs standard packages based models are by far, easiest to scale up than the phenomenological models. The reason is almost obvious because the first ones are based on a powerful an user friendly standard package. See III.

CFDs based models. In the case of piles, we have to fed the Models, as a black box. In spite of the strength and usefulness of it, the Limitations are all related to the solid phase, specially in Static Heap Piles. The reason is almost obvious, the package is mainly a CFD (Computational Flow Dynamics) and lacks a strong CSD package (computational solid dynamics). Scale-up and Process Control Oriented and Skilled Team. Any model is only as good as the data that is fed, the assumptions that are made in its formulation and clear objectives of each model, simulation and validation task. Process Control Oriented and Skilled Modeling Team is a need for scale-up and recoveryoriented project. A fact well known in the area of model identification and control is that very often a relative simple model suffices as the basis for successful control design for complexes processes, as long as essential dynamic aspects of the process are captured by the model. Local based Modelers should help a lot in the process of the specific piles models as well as the analysis of individual and interim data and as an essential component in the Iterative Process, support of the progression of metallurgical testwork and scale-up and interaction with international modelers. II Multi-physical. A typical mistake is to overestimate or underestimate a specific sub-process just because thats true for a certain case. In the literature (Dixon, Petersen, Casas, etc) and in my own experience, we could find examples similar to the one below for each sub-processes: (1) Solution flow and the effect of preferential flow that may act as a bypass, in addition to the hydraulic permeability and sealing areas, (2) Gas Flow and air permeability. Also the already mentioned with respect to Oxygen and CO2 dissolved in the aqueous phase, (3) Diffusive transport of dissolved constituents. In this sense the geometry of stagnant solution zones relative to flow channels is of importance, as is the distribution of particle sizes. (4) microbial dynamics. (5) other chemical reactions associated including abiotic and because the medium is sulfated and ferric, we well know what can happen with precipitation of jarosite, etc.. (6) galvanic coupling mainly by the presence of pyrite. (7) Grain Topology. The mineral leach kinetics is strongly related to the total mineral surface available to leaching, that has to do with the distribution of grains of different size and accesibility within the ore. (8) Ore geo-technical effects on copper heap leach kinetics. It seems that we have forgotten the differential element techniques and software packages. An example, heap temperatures tend to be low near the surface, but higher in the center. Consequently, the kinetics of mineral dissolution, which are often a strong function of temperature, may limit the rate of leaching near the surface, but are rapid in the center. Conversely, the rate of gas absorption is determined by the solubility of oxygen in the aqueous phase, which decreases with increasing temperature, and hence it may be this process that is rate limiting in the center of the heap. Furthermore, this dynamic may shift as the heap heats up at the beginning or cools down near the end of its cycle.

III Software Tools Needed. A Multi-physical software package as PHYSICA, COMSOL or ANSYS. A couple of CFD and CSD interoperative packages. For example, for CFD ( Computational Fluid Dynamics) PHOENICS, CFX, FLUENT and STAR-CD. In the case of CSD (computational solid dynamics) could be FLEXPDE (an excelent time and space adaptive finite element package), NASTRAN, or ABAQUS. The Classicals. MathLab, Mathematica, SIMNON and Visual WOrks.

IV Process Control Oriented and Skilled Team. All members of the Team Skills: Ability to work in multidisciplinary teams. Love for job, eager to give and receive knowledge. Strong and Up to date Scientific base in Maths, Physics, Chemical, Biology and Metalurgy. Full command of written and spoken English. Deep knowledge in the area of process engineering and numerical methods applied to engineering problems. Advanced use of Modeling and Simulation software: At least MatLab, Mathematica, one CFD package and one CSD package. Experience in innovative analytical Instrumentation and Process Control Systems