Dynamic modelling of copper solvent extraction mixer–settler units

Abstract

The copper Leaching, Solvent Extraction and Electrowinning circuit (LX–SX–EW) is one of the most effective processes for extracting copper from low grade ores. This work focuses on the liquid–liquid extraction SX sub-process, since many difficult to handle operational problems within LX–SX–EW circuits are related to SX malfunction. Controlling these problems better can reduce operational costs and increase recovery and copper production. Realistic dynamic simulation is a standard tool nowadays to design and assess more effective control strategies. In this work we present a general dynamic model for SX mixer–settlers, and applied it to two different units, one located in an extraction stage and the other in a stripping stage of a copper plant. The model includes a non-trivial settler hydrodynamics represented by a set of nonlinear differential equations for both mixer and settler units. The mixer is modelled as a continuous stirred tank reactor and the settler as a hydrodynamic circuit combining series and parallel connections of continuous stirred tank and plug flow reactors. The model was calibrated with industrial plant data, resulting in realistic simulations of outlet copper concentrations. Using the proposed model, we obtained better fitting than that achieved with simpler settler models that include only a time delay. The model fitting parameters provide sufficient flexibility to accurately reproduce the dynamics of different units in industrial plants.