Metallurgical Model Presentation
Maximizing metallurgical yields at minimal environmental cost
ProcessingTechnologies,MetalRecoveries&EconomicFeasibilityofDeepSeaMining
Monday,September3–Wednesday,September5
MinistryofEnvironment,Warsaw,Poland
SimonBoel,GSRNV.
1. Base thought
• Mining–transport–processingshouldhavelowerimpactthanland-basedalternatives• Leadingtoanenvironmentalimpactoptimisation–E.gTheuseofanenvironmentalcostcurve
Nickelminescarbonemissionperkgnickel
2. Applied on nodule processing
• CO2impact(energyuse)• Toxicityreagents• Wasteproduced• Efficiencyofprocess/irrevocablelossofmetals
3. Choice of metallurgical route
1. Cuprion+EMM–processdescription2. Overviewenergy&reagentiaimpact3. Waste
3.1. Cuprion + EMM – Winning of Ni-Cu-Co
• Selectivemetalrecovery• Notoxicreagentia• Lowpressure(patm)• Lowtemperature(40°C)
Optimalenergyuse
3.1. Cuprion + EMM – Winning of Ni-Cu-Co Selectivepickingofmetalsfrompoly-metallicinflow
3.1. Cuprion + EMM – Winning of Ni-Cu-Co
• Physicalbreakdown• Chemicalbreakdown
MnO2(s)+CO(g)→MnCO3(aq)
Ni,Cu,Co:liberatedfromcrystalstructureOthertraceelements
• Recoveryoftracemetals(SX/EW)Organicacid:selectivebindingofNiandCuStripping:H2SO4/recoveryRR2Cuorg+H2SO4→2R-Horg+CuSO4(aq)EW→Nimetal&CumetalCu2++2e-→CuRemaining:Mn,Co,traceelements
3.1. Cuprion + EMM – Winning of Ni-Cu-Co
• RecoveryofCoCo2++impurities(aq)+H2S→CoS(s)↓CoS+H2SO4→CoSO4(aq)
EW→CometalRemaining:MnCO3(majorfraction!)&traceelements
3.1. Cuprion + EMM – EMM substitution
• MassbalanceBulkofinflow:wastestockpile/low-gradeproduct(MnCO3:6-7USD/DMTU)
NeedforfurtherprocessingofMnCO3
• EMM:highvalue,knownprocess• EW→ElectrolyticManganeseMetal(EMM)• At3Mtpanodules:729000tEMM• AnnualEMMmarket:1400000tEMM
MnCO3 MnCO3 MnCO3
Ni Ni Ni 370kgCu Cu Cu Co MnCO3
Co Co Co
12.35 kgNimetal 9.9 kgCumetal 1.68 kgCometal
aquoussolution
Cuprionroute
→aquoussolution
↓H2S→H2SO4→EW
↓
→
↓
aquoussolution
→aquoussolution
↓SX/EW↓
CuCo
→
↓SX/EW
MnO2-structure
elementslockedinstructure
→
1000kgnodules
MnO2breaksdown→dissolvedMnCO3
elementsfreeinsolution
CO,NH3
↓
Marketingstrategyrequired
3.1. Cuprion + EMM – Processing of MnCO3
• Substitutiontheory• SellingEMMintootherMnmarkets• TherebyavoidingdisruptionofMnprices
3.2. Overview energy & reagents impact
• Energyuse
ReferenceNickelelectrowinning 3,000 4,000 40 50 1-2-10Copperelectrowinning 2,000 3,000 20 30 1-2Cobaltelectrowinning 3,000 4,500 5 8 3-4-10EMMelectrowinning 1-5-10Auxiliaryprocesses 40 80 1-2Total 145 208
xx
ElectricityconsumptionCuprion+EMMProcesskWh/tonnemetal
10,000
kWh/tonnenodules
40
3.2. Overview energy & reagents impact
• ImpactofenergyuseCoal Oil&Gas Renewable Nuclear Overall(kgCO2/kWh) Reference
CO2emissionsgeneration(kgCO2/kWh) 1.1 0.35 0.025 0.115 - 6
GenerationdistributionCanada 10% 10% 65% 15% 0.17 7GenerationdistributionMexico 10% 70% 20% 0% 0.35 8GenerationdistribtutionChina 65% 5% 25% 5% 0.71 9
ProcessinginCanada 25 36ProcessinginMexico 51 73ProcessinginChina 103 148
1kgCO2emitted=driving10kmbycar
ElectricityimpactCuprion+EMMProcesskgCO2/tonnenodules
Impactofelectricitygeneration
Coal Oil&Gas Renewable Nuclear Overall(kgCO2/kWh) ReferenceCO2emissionsgeneration(kgCO2/kWh) 1.1 0.35 0.025 0.115 - 6
GenerationdistributionCanada 10% 10% 65% 15% 0.17 7GenerationdistributionMexico 10% 70% 20% 0% 0.35 8GenerationdistribtutionChina 65% 5% 25% 5% 0.71 9
ProcessinginCanada 25 36ProcessinginMexico 51 73ProcessinginChina 103 148
1kgCO2emitted=driving10kmbycar
ElectricityimpactCuprion+EMMProcesskgCO2/tonnenodules
Impactofelectricitygeneration
Coal Oil&Gas Renewable Nuclear Overall(kgCO2/kWh) ReferenceCO2emissionsgeneration(kgCO2/kWh) 1.1 0.35 0.025 0.115 - 6
GenerationdistributionCanada 10% 10% 65% 15% 0.17 7GenerationdistributionMexico 10% 70% 20% 0% 0.35 8GenerationdistribtutionChina 65% 5% 25% 5% 0.71 9
ProcessinginCanada 25 36ProcessinginMexico 51 73ProcessinginChina 103 148
1kgCO2emitted=driving10kmbycar
ElectricityimpactCuprion+EMMProcesskgCO2/tonnenodules
Impactofelectricitygeneration
Coal Oil&Gas Renewable Nuclear Overall(kgCO2/kWh) ReferenceCO2emissionsgeneration(kgCO2/kWh) 1.1 0.35 0.025 0.115 - 6
GenerationdistributionCanada 10% 10% 65% 15% 0.17 7GenerationdistributionMexico 10% 70% 20% 0% 0.35 8GenerationdistribtutionChina 65% 5% 25% 5% 0.71 9
ProcessinginCanada 25 36ProcessinginMexico 51 73ProcessinginChina 103 148
1kgCO2emitted=driving10kmbycar
ElectricityimpactCuprion+EMMProcesskgCO2/tonnenodules
Impactofelectricitygeneration
3.2. Overview energy & reagents impact
• Impactofenergyuse
Relativelyeasyoptimisationbyrelocation
3.2. Overview energy & reagents impact
• Consumptionofmainreagents
ReferenceNH3 90 100 2-5CaO 12 13 2H2SO4 240 550 2-5-11CO stoichiometrySteam 1-2Cross-checkedwithatmosphericsulphuricacidleachingoflimoniticlateriteore
148500
MainreagentiaconsumptionCuprion+EMMProcesskg/tonnenodules
3.2. Overview energy & reagents impact
• Impactofreagentsconsumption
ReferenceNH3 12-13-14CaO 13-14H2SO4 13-14CO stoichiometrySteam
NH3 189 210CaO 14 14H2SO4 34 77COSteamTotal 774 839
1.57
233
ImpactofmainreagentiaconsumptionCuprion+EMMProcess
0.61
305
kgCO2/tonnenodules
kgCO2/kgreagens
0.141.22.1
ImpactofmainreagentiaCuprion+EMMProcess
ReferenceNH3 12-13-14CaO 13-14H2SO4 13-14CO stoichiometrySteam
NH3 189 210CaO 14 14H2SO4 34 77COSteamTotal 774 839
1.57
233
ImpactofmainreagentiaconsumptionCuprion+EMMProcess
0.61
305
kgCO2/tonnenodules
kgCO2/kgreagens
0.141.22.1
ImpactofmainreagentiaCuprion+EMMProcess
3.2. Overview energy & reagents impact
• Impactofreagentsconsumption
Intrinsicto
process–
optimizatio
nmuchha
rder
3.2. Overview energy & reagents impact
• Impactoftransport
sailingdistance gCO2/(tonnexkm) kgCO2/tonnenodules ReferenceVancouver,CA 4100 5 21 16Manzanillo,MX 2400 5 12 16Shanghai,CN 11400 5 57 16
Impactoftransportbybulkcarrier
3.2. Overview energy & reagents impact
• Overallimpact• Maindriver:chemicalreagents–definedbylawsofnature• Secondarydriver:electricity–CO2optimizationbychoiceoflocation• Transport:smallimpact–longerroutesjustifiedbygreenerelectricity• Conservativefigures
kgCO2/tonnenodulesDestination:Canada 21 25 36 774 839 799 875 820 895Destination:Mexico 12 51 73 774 839 825 912 837 924Destination:China 57 103 148 774 839 877 987 934 1044
Transportimpact
Impactofchain"MiningshiptoMetal"
Processingimpact MiningshiptoMetal
kgCO2/tonnenodules kgCO2/tonnenoduleskgCO2/tonnenodulesMainreagentiaimpactElectricityimpact
Cuprion+EMM
kgCO2/tonnenodules
3.2. Overview energy & reagents impact
• Discussion/outstandingissues• Consumptionofminorreagents• Consumptionsteam:Dames&Moore(1977):1600kg/tonnenodules–CO2!
3.3. Waste
• Majormetalsrecovered• Verylittleamounts• Closedloopprocess• PossibilityofMorecovery
• Efficientprocess• Veryhighrecoveryrateofmetals
4. Alternative routes (Blue Nodules)
• EUHorizon2020programme• RWTHAachen:pyrometallurgicalroute• Underexamination• www.blue-nodules.eu
Questions?
Thank you
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