Backfilling - K-UTEC AG Salt Technologies
Backfilling - K-UTEC AG Salt Technologies
Backfilling - K-UTEC AG Salt Technologies
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Possibilities for a Discharge Reduced<br />
<strong>Salt</strong> and Potash Production<br />
Experience from worldwide engineering activities of K-<strong>UTEC</strong> <strong>AG</strong><br />
Dr. Heiner Marx<br />
Stephan Kaps | Dr. Heinz Scherzberg | Dr. Bernd Schultheis<br />
Dipl.-Phys. Jürgen Bach | Dr. Axel Stäubert<br />
Exchange Conference on Potash<br />
June 2013 | Geermu, China
Content<br />
1. European Legislation<br />
2. Types of Crude Potash <strong>Salt</strong>s<br />
3. Processing and Residues<br />
4. Residue Utilization Options<br />
• Recovery of Saleable <strong>Salt</strong>s<br />
• <strong>Backfilling</strong><br />
5. Project Examples<br />
6. Conclusion<br />
2
According to the actual European Legislation ….<br />
European Legislation<br />
… mineral deposits generally have to be used sustainably.<br />
… aqueous systems have to achieve a good status until 2015.<br />
3
Types of Crude Potash <strong>Salt</strong>s<br />
… in Europe<br />
-Chemical Composition<br />
4
Processing and Residues<br />
Exploitation<br />
-Actual Situation<br />
Crude <strong>Salt</strong> / Raw Brine<br />
Processing<br />
Products<br />
Solid Wastes<br />
Liquid Wastes<br />
small<br />
mounts<br />
Stockpiling <strong>Backfilling</strong> River Deep<br />
Underground<br />
Percolating Brine
Residue Utilization Options<br />
Recovery of saleable salts<br />
<strong>Backfilling</strong> (water reduced and/or solidified by additives)<br />
Stockpiling according to the state of the art<br />
6
Recovery of Saleable <strong>Salt</strong>s<br />
-Treatment of the Liquid Wastes Resulting from Processing<br />
Crude <strong>Salt</strong> Liquid Wastes Products<br />
SALT TYPE (ORE) PROCESS RECOVERED SALTS<br />
Sylvinite: Evaporation, Cooling NaCl, KCl<br />
Anhydritic Hard <strong>Salt</strong>: Glaserite-Process, Cooling K 2 SO 4<br />
Kieseritic Hard <strong>Salt</strong>: Schoenite-Process; K 2 SO 4<br />
poss. separate MgCl 2 -Treatment<br />
Carnallitite: Carnallite-Process; KCl<br />
separate MgCl 2 -Treatment<br />
7
Recovery of Saleable <strong>Salt</strong>s<br />
-Options for MgCl 2 -Solution (End Bittern)<br />
End Bittern<br />
(approx. 450 g/l MgCl 2 )<br />
O P T I O N 1 O P T I O N 2 O P T I O N 3 O P T I O N 4<br />
MgCl 2·6H 2 O<br />
MgO + HCl Mg(OH) 2 + CaCl 2 / NaCl MgCl 2 -Brine<br />
8
<strong>Backfilling</strong><br />
-History and Effects<br />
Since 1908, hydraulic stowing for backfilling has been applied<br />
in the German Potash industry.<br />
Protection of the surface<br />
Optimized utilization of the resources<br />
Recycling of waste materials<br />
9
<strong>Backfilling</strong><br />
-<strong>Backfilling</strong> in Combination with Pillar Re-mining | Mine Bleicherode<br />
<strong>Backfilling</strong> and Pillar Re-mining (MER 80 … 90 %)<br />
Conventional Mining (MER 40 … 50 %)<br />
1000 m<br />
10
storage and mixing<br />
plant<br />
sludge<br />
plant<br />
brine tank<br />
<strong>Backfilling</strong><br />
P<br />
P<br />
P<br />
P<br />
Solid and Liquid Waste Materials<br />
from the Processing Plant<br />
Solid and Liquid Industrial<br />
Waste Materials<br />
sandstone<br />
salt horizon<br />
Hydraulic <strong>Backfilling</strong><br />
mine opening ,<br />
backfilling required<br />
P<br />
brine drainage system<br />
11
Project Examples<br />
Realized Projects<br />
Iberpotash | Spain:<br />
Production of common salt (NaCl) based on flotation tailings<br />
Salinen Austria | Austria: SOP and NaCl production from purges of salt winning plant<br />
Thangone | Lao:<br />
Purge free MOP production based on Carnallite solution mining<br />
Concepts<br />
GSES | Germany:<br />
Rossleben | Germany:<br />
Concept for a new Potash production in Sondershausen<br />
Concept for a new Potash production in Rossleben<br />
K+S | Germany:<br />
Proposal to avoid the discharge of waste brines<br />
12
Solution Mining<br />
Project Examples<br />
Salinen Austria | Austria<br />
Process<br />
since 1978<br />
Purification<br />
Slugde<br />
<strong>Backfilling</strong><br />
Evaporation<br />
NaCl<br />
Disposal Brine<br />
Discharge<br />
into River<br />
Modification<br />
since 2006<br />
Future<br />
SOP Plant<br />
Reduced Effluent<br />
NaCl<br />
Bromine Plant<br />
No Effluent<br />
K 2 SO 4<br />
NaBr
Project Examples<br />
Thangone | Lao<br />
Processing<br />
Carnallite<br />
Brine<br />
Disposal Brine<br />
KCl<br />
NaCl<br />
120,000 t/a<br />
40,000 t/a<br />
Evaporation<br />
ca. 310,000 m³/a<br />
Volume<br />
<strong>Backfilling</strong> Slurry<br />
ca. 330,000 m³/a<br />
Produced Cavity<br />
14
Project Examples<br />
Concept GSES | Germany<br />
Objective:<br />
Production of KCl<br />
MASS<br />
VOLUME<br />
Ore: Carnallitite with 10 % Hard <strong>Salt</strong> 1,000,000 t/a 525,000 m³/a<br />
Products: Kieserite 135,000 t/a<br />
Anhydrite<br />
16,000 t/a<br />
KCl<br />
137,000 t/a<br />
NaCl (98 %)<br />
350,000 t/a<br />
MgCl 2 -Solution (ca. 450 g/l MgCl 2 )<br />
399,000 t/a<br />
MgCl 2 -Solution for <strong>Backfilling</strong> 198,000 t/a 138,000 m³/a<br />
d ~ 1.44 t/qm
Project Examples<br />
Concept K+S | Germany<br />
River<br />
Deep<br />
Underground<br />
Brine from<br />
Potash Plant<br />
Brine from<br />
Tailings Disposal<br />
Brine from<br />
Kieserite Plant<br />
Actual Situation<br />
Cooling<br />
Proposed<br />
Process<br />
Mixed Brines<br />
MgCl Evaporation<br />
2<br />
NaCl<br />
Refining<br />
NaCl<br />
SOP Plant<br />
Additives<br />
K 2 SO 4<br />
<strong>Backfilling</strong><br />
Na 2 SO 4<br />
16
Conclusion<br />
Avoiding of discharge of waste brines is possible.<br />
Minimizing of valuables loss is possible.<br />
Sustainable use of the desposit by backfilling is possible.<br />
Each crude salt and each process need their<br />
specific way in order to find out the right answer.<br />
17
Potash<br />
Fertilization<br />
No Potash<br />
Fertilization<br />
THANK YOU!<br />
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