APSC 150 Term 2

Case Studies in Engineering

Case Study 3 Tutorials 3.1 and 3.2
Recovery of Metals from Britannia Mine Acid Rock Drainage
Can Copper and Zinc be economically recovered from the Britannia Mine ARD?
Part 1: Copper and Zinc Recovery
Assumptions:
Use the average mine discharge rate given in the lecture for the Geothermal Energy Project.
The average Copper content of the discharge is about 18 mg/L.
The average Zinc content of the discharge is about 20 mg/L.
Use the LME copper price quoted on February 1, 2013
Use the LME zinc price quoted on February 1, 2013
Assume cost of transportation and smelting/refining charges will be 10% of the total metal
recovered value.
1. How much copper and zinc discharges from the mine each year?
2. What is the total value of these contained metals?
EPCOR's High Density Lime Sludge Water Treatment Plant yields ~17 tonnes of wet sludge per
day from the filters. The %solids by weight of the sludge is 37% (it is literally like toothpaste).
3. What is the calculated copper and zinc content of this sludge, assuming 99.99% recovery of
both metals to the sludge?
Assume a Sulphate Reducing Bacteria process could be installed to recover Cu and Zn ahead
of the existing lime treatment plant. It will recover 99.99% of each metal.
The capital cost to install this plant is estimated to be $135 per m3/day of effluent.
The annual operating costs are estimated as
Reagents
Energy
Labour
Spares
Maintenance

=
=
=
=
=

$0.048/m3
$ 75,000
$125,000
$100,000
$100,000

4. Calculate the simple payback period for this investment and operation?

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Part 2. Increasing Project Value
Examine the option of producing something of value from the "new" sludge that will be
produced. An opportunity exists to blend the sludge (now devoid of Cu and Zn) with pumice
material mined at Mt. Meager (north of Pemberton) which is shipped to Squamish where it is
crushed and stored for sale. Testwork has shown that a sludge:pumice ratio of 20:80 is
technically feasible to manufacture cladding material for buildings. The cladding material will be
in the form of thin (2-inch width) veneer bricks to become attractive facades on and in buildings
and homes. Different colours and textures can be created to yield a variety of products for the
market place. High levels of Cu and Zn in the sludge preclude it being used as cladding
material, but once these are removed, the material is suitable. The average wholesale value of
this cladding is $400/tonne.
Two processes can be used:
(a) A low-temperature processes with 4% by weight organic resin and hardener added to
provide strength to the material;
(b) A high-temperature firing process to create a hard ceramic.
Assume the dry sludge weight will be 80% of current weight after the copper and zinc
hydroxides are no longer present.
The cost to build the low-temperature plant is estimated at $300/tonne of annual feed material
while the high-temperature plant is estimated to cost $325/tonne of annual feed material.
Annual operating costs also depend on the process selected:
Low Temperature
Pumice
Resin
Energy
Labour
Spares
Maintenance
High Temperature
Pumice
Energy
Labour
Spares
Maintenance

=
=
=
=
=
=

=
=
=
=
=

$
$
$
$
$
$

$
$
$
$
$

100/t of pumice F.O.B. Squamish

800/t of resin
300,000
750,000
300,000
400,000

100/t of pumice F.O.B. Squamish

500,000
750,000
250,000
400,000

5. Which process is the better one to select from a strictly-economic viewpoint?

6. The cost to truck sludge up to Jane Basin is about $40/tonne. Since there is no longer any
need to dispose of sludge, this cost is eliminated and can be charged as a cost recovery by
the cladding plant. Calculate the simple payback period for the best of these two plants
combined with the SRB plant to recover copper and zinc from the sludge?
7. Would you recommend this investment? Why or why not?
8. What additional information would you wish to gather before proceeding with this investment?