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“ARD REMEDIATION WITH SLAG: AN APPLICATION
TO BERKELEY PITLAKE WATER”
Courtney A. Young
Dept Head and Lewis S. Prater Professor
Metallurgical & Materials Engineering
Montana Tech
Butte MT 59701
Denver, CO April 3-5, 2012 Monitoring and Treatment Session 8
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Dick Berg, State Geologist, MBMG
Montana Tech, Butte MT
Larry Twidwell, Professor Emeritus, M&ME
Montana Tech, Butte MT
Krag Filius, Project Engineer
MSE Technology, Butte MT
Eric Streich, Process Engineer
Holcim Cement, Trident MT
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• Berkeley Pitlake
• Previous Research
• Silicate Slags
• Objectives
• Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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• Berkeley Pitlake
• Previous Research
• Silicate Slags
• Objectives
• Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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Continental Pit
– Treatment Plant
– Horseshoe Bend Water
– MR Concentrator
Butte – Viewing Stand
Interstate 15/90 –
Walkerville –
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1880 - Butte was an early copper-mining town:
- Referred to as “The Richest Hill on Earth”
- One of the world’s largest sulfide ore deposits
1920 - ACC controlled most mines
1955 - ACC began phasing out underground mining
1977 - ARCO purchased all operations
1982 - Operations halted and pumps turned off
1983 - Water first appeared in the pit
- Listed as a Superfund site
- Part of the largest mining Superfund site
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Berkeley Pitlake Water: - encompasses ~700 acres - is ~1,000 feet deep - contains ~40 billion gallons - fills at 2.6 million gallons per day - will reach “critical level” in 2023
SO4 (7500 ppm) Fe (1000 ppm) Zn (650 ppm) Al (300 ppm) Mn (250 ppm) Cu (200 ppm) Cd (2.5 ppm) As (0.5 ppm)
Berkeley Pitlake Water: - is acidic near pH 2.5 - contains metals at high concentrations (99% Water):
1984
Concentrations change with
position, depth and time
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– Horseshoe Bend Water
– Continental Pit –
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1995 - HSBW also diverted to pond (3M GPD)
- MR starts operating Continental Pit to the east
- ARCO and MR named responsible parties
2000 - MR halts operations including diversion
2003 - HSBW Treatment Plant is commissioned
- two-stage lime precipitation process
- diversion of treated water begins
- sludges are disposed into the BPL
2004 - MR reopens and begins full operations
2005 - MR pumps BPL water to Cu-cementation
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Horseshoe Bend Water Treatment Plant
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Horseshoe Bend Water Treatment Plant
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Berkeley Pitlake
• Previous Research
• Silicate Slags
• Objectives
• Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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Participate in a “series” of 5 studies to summarize available information Generate new information to formulate conceptual environmental models for the Berkeley Pitlake from all of its features Provide data for the development of advanced treatment technologies
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0.24 18.2 < 0.02 < 0.05 3.72 < 0.11 < 0.04 Stage 4 - NaOH
186.2 49.4 < 0.02 < 0.05 4.2 < 0.11 0.22 Stage 3 - Na2S
203.2 482.6 1.7 0.09 4.9 < 0.11 0.27 Stage 2 - Na2S
213.2 495.6 1.84 138.8 4.5 < 0.11 0.23 Stage 1B - KMnO4
222.7 529.7 1.9 146.3 198.5 < 0.11 8.43 Stage 1A - H2O2/UV
243.5 566.3 2.3 151.2 214.2 5.9 1019.8 Initial BPL Water
Al Zn Cd Cu Mn As Fe
0.2 5 0.005 1.3 0.05 0.05 0.3 Drinking Standard
Stage 1A: H2O2 = 2OH
; Fe2+ + OH
= Fe3+ + OH-; Fe3+ + 3OH
- = Fe(OH)3
Stage 1B: 3Mn2+ + 2MnO4
- + 2H2O = 5MnO2 + 4H+
Stage 2: Cu2+ + S2- = CuS
Stage 3: Cd2+ + S2- = CdS; Zn2+ + S2- = ZnS
Stage 4: Al3+ + 3OH- = Al(OH)3
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G a s
G l a s s F r i t
U V S o u r c e
M a g n e t i c S t i r r e r
E l e c t r o d e
M a g n e t
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Fe/Mn/As Precipitation
Cu Precipitation
Zn/Cd Precipitation
Al Precipitation
SO Remediation
Berkeley PitlakeWater
2 2
H S
H S
NaOH
UV/H O /NaOH
2
2
Vacuum
Na, K, Mg, Ca Solution
To Softening and Discharge
?
• Selective metal recovery is possible • A 7-stage process has been envisioned and shown to work (in batch mode) • Fe, As, Cu and Cd met DWS • Al almost met DWS • Mn and Zn did not meet DWS • KMnO4 addition needs to be precise • Zn may have precipitated amorphously • SO4 removal was not done but options are Freeze Crystallization Reverse Osmosis Gypsum Precipitation SRB Bioreduction Chemoreduction Photoreduction Reductive Precipitation • Softening to remove Na, K, Mg and Ca
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0 5 1 0 1 5 2 0 2 5 3 0 3 5
D e p t h ( m )
2 . 2 0
2 . 2 5
2 . 3 0
2 . 3 5
2 . 4 0
2 . 4 5
2 . 5 0
p H
0 . 0
0 . 5
1 . 0
1 . 5
2 . 0
2 . 5
3 . 0
3 . 5
4 . 0
4 . 5
D i s s o
l v e d
O x y
g e n
( m g / l )
3 0 0
3 5 0
4 0 0
4 5 0
5 0 0
5 5 0
6 0 0
6 5 0
E ( m
V )
6
8
1 0
1 2
1 4
1 6
1 8
2 0
2 2
2 4
T e m
p e r a t u r e ( C )
p H
H
E H
D O
T e m p
B e r k e l e y P i t l a k e S e p t . 5 , 1 9 9 1
o
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-1.0
-0.5
0
0.5
1.0
1.5
0 2 4 6 8
pH
Fe(SO 4 ) +
Fe(
SO
4 ) 2
-
Fe 2+
FeSO 4 ( aq )
Fe
Fe 8 O 8 (OH) 6 SO 4 . 5H 2 O
(HSO 4 - ) (SO
4 2- )
(HS - ) {H 2 S( aq )}
E H
(V
olt
s)
*
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Profiles indicated chemoclines/thermoclines existed and were successfully reproduced in lab
They have been explained by, but can not be totally attributed to
HSBW being less dense than BPLW so, when it enters the pitlake, it floats on top rather than mixes in, and
Biological activity which should increase DO as well as pH
Experiments showed that the interaction of sunlight (UV radiation) and air with BPL water plays a significant role
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(Deep Water, Pore Water and Sediment)
Collect Core Sample Split & Section the Core Siphon/Filter Off
Deep/Pore Water
Analyze the Water
& Solid Contents
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(Deep Water, Pore Water and Sediment)
zzz
zzzzzzz
wwwwwwwwvvv
Ferric Iron Solubility in Pore WaterSchwertzmannite
Fe8O8(OH)6SO4
0.001
0.01
0.1
1
10
100
Fe
3,p
pm
0 1 2 3 4 5
pH
x x x x x x
z z z z z z z z z
z w w
w w w w w w v
v v
Potassium Solubility Jarosite
A KFe 3 (SO 4 ) 2 (OH) 6 B KAl 2 AlSi 3 O 10 (OH) 2
A A + B
A A + B
0.001
0.1
10
1000
0 1 2 3 4 5
pH
Surface Water (pH ~ 2.5)
Deep Water (pH ~ 3.3)
Concentrations are controlled by the solubility of identified minerals and precipitates!
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(Deep Water, Pore Water and Sediment)
Muscovite [KAl3Si3O10(OH)2] controls Al3+ concentration
Quartz (SiO2) controls Si4+ concentration
Schwertmannite [Fe8O8(OH)6SO4] precipitate controls the Fe3+ concentration
Jarosite [KFe3(SO4)2(OH)6] precipitate controls K+ concentration
Cu2+, Fe2+, Zn2+ and Cd2+ concentrations could not be associated with a mineral or precipitate are therefore considered to be unsaturated
However, Cu2+, Fe2+, Zn2+ and Cd2+ concentrations were found to increase with depth giving the appearance that supergene deposition is occurring
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Mineralogy is essentially the same except fine native rock (granite) and gypsum precipitate are more abundant:
Native:
Granite (38%)
Quartz (33%)
Muscovite (4%)
Precipitate:
K-jarosite (22%)
Gypsum (3%)
Muscovite coated with Jarosite
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Chemical controls should be about the same as at depth
0 1 2 3 4 5 6 7
p H
0
1
2
3
4
5
6
p S
i O 2
A m o r p h o u s S i O 2
A - K a o l i n i t e B - M u s c o v i t e C - K F e l d s p a r D - O r t o c l a s e E - A l b i t e F - A n o r t h i t e G - A n n i t e
A B C D E F G
Deep Water ~p H 3 . 3
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Silicate (and oxide) slags should do the same thing!
6 7 8 9 1 0 1 1 1 2 1 3
p H
0
1
2
3
4
5
6
p S
i O 2
A m o r p h o u s S i O 2
H - F a y a l i t e I - P s u e d o w o l l a s t o n i t e J - A c k e r m a n i t e K - R a n k i n i t e
H I J K
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Berkeley Pitlake
Previous Research
• Silicate Slags
• Objectives
• Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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Source of Silicate (and lime)
Act as pH-Buffers (replace lime)
Available in Montana (inactive)
Anaconda (ARCO) - Fayalite, Fe2SiO4
East Helena (ASARCO) - Olivine-type, CaFeSiO4
Rocker (Rhone) - Pseudowallastonite, CaSiO3
Slag Ca (%) Fe (%) Si (%)
Rhone 30.3 0.4 19.0
ASARCO 14.0 27.6 12.7
Anaconda 2.6 30.9 15.8
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Rocker/Rhone Poulenc
Pseudowollastonite (CaSiO3)
Anaconda/ACC
Fayalite (Fe2SiO4)
East Helena/ASARCO
Olivine-type (FeCaSiO4)
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Other Global Sources
Columbus (Stillwater)
Salt Lake City (Kennecott)
Trail, BC (Teck Cominco)
Dual Ecosystem Enhancement
Remove Slag Piles
Remediate Berkeley Pitlake
In-Situ or Ex-Situ
Provide Entertainment
Golf Courses
Parks & Walkways
Sports Complexes
Attract Businesses
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Berkeley Pitlake
Previous Research
Silicate Slags
• Objectives
• Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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Dry Grinding
Wet Grinding
Slag Ball Mill Cyclone Pneumatic Spray BPL
Slag Ball Mill Cyclone Mixer & Pump BPL
BPL Water Pump
Slag Ball Mill Hydrocyclone BPL
BPL Water Pump
Conceptual Flowsheet Designs
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Berkeley Pitlake
Previous Research
Silicate Slags
Objectives
• Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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Characterize Montana Slags
Bond Work Index
SEM/EDX/MLA Analysis
Remediation Potential
Model Effects
Parameters
Slag Type (Fe/Si Ratio)
Particle Size (100-400 Mesh)
Slag Amount (200-800 g/L)
Experimental Design (StatEase)
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Berkeley Pitlake
Previous Research
Silicate Slags
Objectives
Procedures
• Results & Discussions
• Conclusions
• Acknowledgements
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Date
Slag
Target Size
Mesh (mm)
F80
(mm)
P80
(mm)
Avg
Gbp
Bond
Work
Index
1/29/05 ACC 48 (0.295) 2.825 0.205 0.95 20.52
2/17/05 ACC 100 (0.147) 2.603 0.117 0.94 20.44
2/20/05 ACC 200 (0.074) 2.603 0.058 0.53 24.86
1/29/05 ASARCO 48 (0.295) 2.652 0.230 1.76 16.26
2/12/05 ASARCO 100 (0.147) 2.555 0.113 1.24 15.93
1/30/05 ASARCO 200 (0.074) 2.603 0.053 0.50 24.68
2/26/05 RP 48 (0.295) 1.414 0.251 2.79 14.18
3/4/05 RP 100 (0.147) 1.414 0.121 1.53 15.48
3/4/05 RP 200 (0.074) 1.414 0.063 0.76 20.66
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(150 um Asarco Slag Before)
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(150 um Asarco Slag After)
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Size = 53 um; Amount = 100 g/L
12 hours
(Bottle Roll Tests)
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0
1
2
3
4
5
6
7
8
9
0 50 100 150 200 250 300 350 400
Concentration (grams/liter)
pH
ARCO ASARCO Rhodia
Size = 53 um; Time = 12 hrs
(Bottle Roll Tests)
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Amount = 100 g/L; Time = 12 hrs
(Bottle Roll Tests)
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Run Slag Type
(Fe/Si Ratio)
Particle Size
(μm)
Slag Amount
(g/L)
1 0 = Rhodia -37 = 400 mesh 500
2 2 = ARCO -37 500
3 0 -147 = 100 mesh 500
4 2 -147 500
5 0 -74 = 200 mesh 200
6 2 -74 200
7 0 -74 800
8 2 -74 800
9 1 = ASARCO -37 200
10 1 -147 200
11 1 -37 800
12 1 -147 800
13 1 -74 500
14 1 -74 500
15 1 -74 500
(Box-Behnken Matrix)
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pH Al As Cd Cu Fe Mn SO42- Zn
Test
Run
BPL Concentrations (mg/L)
2.5 289 0.15 2.1 168 793 276 2723 621
Final Responses (mg/L)
1 9.08 0.043 0.0025 0.002 0.19 0.29 4.42 829 0.24
2 5 6.32 0.09 2.1 2.26 95 276 1980 621
3 7.77 0.20 0.001 0.034 0.063 0.069 57.8 1075 2.02
4 5.19 11.6 0.09 1.69 34.2 772 276 2210 621
5 7.68 0.20 0.0008 0.055 0.136 0.096 83.7 619 3.84
6 4.55 37.8 0.15 2.1 168 793 268 2450 621
7 8.42 0.041 0.001 0.002 0.179 0.014 5.13 879 0.11
8 5.52 0.37 0.039 1.13 0.566 271 276 1720 531
9 5.62 1.39 0.0049 1.03 0.39 6.99 266 1680 601
10 4.74 26.1 0.021 1.57 18.05 595 265 2045 621
11 6.89 0.20 0.0014 0.059 0.095 0.069 181 1270 24.1
12 6.16 0.444 0.0023 0.38 0.141 2.37 248 1395 212
13 6.02 0.62 0.0023 0.44 0.174 4.77 250 1410 278
14 6.08 0.53 0.0023 0.42 0.139 3.76 248 1410 254
15 6.08 0.51 0.0022 0.45 0.277 3.67 252 1450 257
Drinking Water Standards (mg/L)
6.5 - 8.5 0.05 0.01 0.005 1.3 0.3 0.05 250 5
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pH = 8.31 – 3.49A – 0.0012B + 0.0018C + 0.006AB + 0.7A2
Log [H] = -8.31 + 3.49A + 0.0012B – 0.0018C – 0.006AB – 0.7A2
Log [Al] = 2.05 + 1.44A + 0.0063B – 0.0011C – 0.0011AC
[As]0.5 = 0.39 + 0.48A + 0.0015C – 0.006AC + 3.35A2
[Cd]0.5 = 16.77 + 20.36A – 0.027*C
Log [Cu] = 2.29 + 0.17A + 0.0074B – 0.0019C + 0.0083AB – 0.0023AC – 0.00002BC + 0.59A2 + 0.0000038C2
Log [Fe] = 2.1 + 1.95A + 0.0099B – 0.0025C
[Mn] = 738886 + 26555A + 252B – 127C + 63.5AC – 86310A2
[Zn]0.5 = 315.4 + 420A – 0.49C
A = Fe/Si Ratio (0-2); B = Size (um); C = Amount (g/L)
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Size = 37 μm Size = 147 μm
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Design-Expert® Software
pH 10.05
4.57
X1 = A: Fe/Si Ratio X2 = C: Amount, g/L
Actual Factor B: Size, um = 37
0.0 0.5 1.0 1.5 2.0
200
350
500
650
800 pH
A: Fe/Si Ratio
C: A
mo
un
t, g
/L
5.5 6.0 7.0
7.5
9.0
5.0
6.5 8.0
8.5
9.5
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Size = 92 μm
0 0.5
1 1.5
2
200 350
500 650
800
0
650
1300
1950
2600
Fe
(p
pm
)
Fe/Si Ratio
Amount (g/L)
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Design-Expert® Software
Original Scale
Log10(Fe, ug/L)
974000
13.7
X1 = A: Fe/Si Ratio
X2 = C: Amount, g/L
Actual Factor
B: Size, um = 37
0.0 0.5 1.0 1.5 2.0
200
350
500
650
800
Fe, ug/L
A: Fe/Si Ratio
C: A
mount, g/L
300 1000100 10000
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0
0.5
1 1.5
2
200 350
500 650
800
0.0
42.5
85.0
127.5
170.0
As (ppb)
Conc (g/L)
0
0.5
1
1.5
2
200 350
500 650
800
0
650
1300
1950
2600
Fe (ppm)
Fe/Si Ratio Conc (g/L)
Fe/Si Ratio
0 0.5
1 1.5
2 200
350
500
650
800
0
300
600
900
1200
Zn (ppm)
Fe/Si Ratio Conc (g/L)
0 0.5
1 1.5
2
200
350
500
650
800
0
700
1400
2100
2800
Cd (ppb)
Fe/Si Ratio Conc (g/L)
a) b)
c) d)
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Berkeley Pitlake
Previous Research
Silicate Slags
Objectives
Procedures
Results & Discussions
• Conclusions
• Acknowledgements
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Slags can be an effective for remediating ARD
Their use could or will: replace lime (pseudowollastonite slag) diminish lime consumption (fayalite/olivine) lead to remediation of two ecosystems
Depending on the slag type and particle size: effluent pH from 5-9 can result effluent concentrations can meet DWS
Al and Cu concentration profiles are similar to Fe
Likewise, Al and Cu redissolution at high pH is minimal similar to Fe
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Berkeley Pitlake
Previous Research
Silicate Slags
Objectives
Procedures
Results & Discussions
Conclusions
• Acknowledgements
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This research was previously funded by the MWTP via an Interagency Agreement (IAG) between the U.S. EPA and the U.S. DoE, IAG No. DW89935117-01-0.
Thanks are also extended to the Department of Metallurgical & Materials Engineering at Montana Tech for bearing the costs for some analyses and the MBMG for helping collect samples: James Madison and Ted Duaime.
Sincere appreciation is given to the workforce who have worked on these projects over the years. MS students included Ray Ziolkowski, Tom McMillan, Yu Chuan Tai, Eric Streich and Krag Filius. BS students include Sonny Adams, Jennifer Gambill and Brian Ross.
We are always on the lookout for funding Series VI to !
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Berkeley Pitlake
Previous Research
Silicate Slags
Objectives
Procedures
Results & Discussions
Conclusions
Acknowledgements
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U.S. EPA Hardrock Mining Conference (Advancing Solutions for a New Legacy)
Denver CO April 3-5, 2012
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?