High Accuracy Modeling of Copper Mine Pipeline System Using AFT Fathom
AFT Fathom™ Case Study
Southern Peru Copper | Acid Leaching System | Mining & Metals
“AFT Fathom reduced the amount of time needed for the
analysis and provided a clean description of the pressure and flow results.”
– Arturo Saenz, Mechanical Design Engineer
PROBLEM
- Acid leaching involves use of sulfuric acid solution to extract copper from ore
- Extraction was to be improved by evaluating alternate system configurations and improved pump efficiency
ANALYSIS
- AFT Fathom model was created and calibrated, analyzing the system’s pumping stations over 7 km (4.65 mi)
- Results matched field data to within 1% across 14 different tests
SOLUTION
- Calibrated model saved time during analysis and provided clear pressure and flow results
- Testing of design alternatives was streamlined using baseline model
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Problem Explained
The Toquepala copper mine operation includes an acid leaching system for copper extraction where ore is sprayed with a sulfuric acid solution. This acid and copper-rich solution, called Pond Liquid Solution (PLS) is collected in ponds and then pumped back to the leaching plant. Beginning in 2007, Southern Peru Copper undertook a project to improve the extraction of the PLS fluid, evaluate alternate system configurations and improve pumping efficiency.
Referred to as the Área 823 Sistema de Bombeo de PLS, the pumping system utilizes three pumping stations in series over the pipeline measuring 7-km (4.65 mi). Each pumping station is equipped with three pumps, two normally operating, rated at 1,100 m3/hr (11,341 gpm). The design head is varied according to the pumping station location along the pipeline to achieve high pumping efficiency and ranges from 360-760 meters (1,181-2,493 feet). Pumps are equipped with variable-speed drives for efficient capacity control.
Solutions & Benefits
System testing was conducted under a variety of operating scenarios to verify the design. Arturo Saenz, the mechanical design engineer at Southern Peru Copper’s Central Project Office, compared the measured flow over 14 tests to that predicted by their AFT Fathom model and found they agreed within 1%.
Asked about the advantages obtained from modeling the system with AFT Fathom, Arturo commented that it reduced the time required for design analysis, provided clear results, and confirmed a good design approach that saved money.
Toquepala Copper Mine electrical wiring frame and
excavations for pipelines and bank boxes
AFT Fathom water distribution system model output