Topic-1: Statistical Quality Control

ARD (Acid Rock Drainage) Neutralization as Column Wash Water

Arif Susanto
Environmental, Health & Safety Department, Concentrating Division, PT Freeport Indonesia
Lecturer:
Dr. Mursyid Hasan Basri, ST, MT.
Background
Water is main resources for concentrate milling process in all it flow generation. The existing
column wash water contains high solid that often plug the wash water pan holes that reduces their
effectiveness and availability. ARD (Acid Rock Drainage) water is one of water resources from
Underground Mine and come from Kucing Liar. Through preliminary pH measurement, that ARD water
that sent to mill is not acidic anymore and can be classified as clean water.
Sampling campaign was conducted to prove that ARD water that is currently sent to the ARD
neutralization tanks can be used in mill process as wash water in the column floatation and classified as
clean water. Currently ARD water goes through two main pipes to tank 2TK-242 then sequentially being
neutralized by lime in three mixing tanks (2TK-244, 2TK-245 and 2TK-246) and discharge to tail box
TT-301, where it is mixed with tailing from C3 concentrator as illustrated on flowsheet in Exhibit-2.
Initial visual observation on ARD water was conducted routinely and found that water quality is
clean with low suspended solid and low dissolve solid (clear water). To prove, frequent sampling on ARD
water was conducted and the samples sent to be analyzed in the laboratory. Simple random sampling
method is used to get representative sample for reliable data in Exhibit-1. The samples were analyzed by
some parameters to confirm the good quality based on visual observation on the field. Some parameters
analyzed are: pH.
Objective and Problem
The objectives of ARD neutralization utilization is to improve the confidence in using ARD
water as column wash water and that it will not give negative effect to column flotation performance. To
increase the effectiveness and productivity of the cleaner circuits. As wash water effectiveness is
increased and the ability to maintain concentrate grade is improved by minimizing insoluble contents,
cleaner recovery may also be improved by maintaining higher cleaner mass yield.
The ARD water in 2TK242, its pH is monitored at the tank and its flow is monitored by a
flowmeter at the line discharge to the mill. The water flow to three neutralization tanks (2TK244, 2TK245
and 2TK246). In these three tanks the pH is monitored and some amount of lime will be induced to the
water if the pH reading still lower than 9.0. Every tank has its discharge line if the volume of ARD water
is exceeding 173,000 gallon. The ARD water that will be used for the SAG column wash water will end
up in the flotation process, where pH is maintained above 10.8 as part of creating the optimum flotation
condition.
Conclusion
From mean and range control chart as seen below, while 2TK246 subscribed as subgroup define
to 2TK244 and 2TK245, the lime additional for each tank not reach standard quality as needed to
classifying ARD reach pH level goal. The pH of ARD water samples results consistently not in maximum
neutral range with average 7.67 (based on average from last tank 2TK246), and from its condition lime
induce to the water is needed to reach pH in average level goal. ARD water specification is still refer to
regulation where are pH level in range 6.5-9.0 (LSL and USL) to classfied not as waste water.
Concentrating Division can improve productivity that is currently utilized for to clean-up sanded material
in column wash water pan, ensure column have enough and consistent wash water to make sure stable
%solid, and more effectively remove gangue material in concentrate.

X-Bar Control Chart should meet the following requirements:

Above +3 sigma and below -3 sigma
2 out of last 3 above +2 sigma and 2 of last 3 below -2 sigma
4 out of last 5 above +1 sigma and 4 out of last 5 below -1 sigma
8 point above center line and 8 point below center line
6 in a row trending up and 6 in a row trending down
14 in row alternating
And for the Range Control Charge should meet the following requirement:
Above +3 sigma and below -3 sigma
2 out of last 3 above +2 sigma and 2 of last 3 below -2 sigma
4 out of last 5 above +1 sigma and 4 out of last 5 below -1 sigma

 8 point above center line and 8 point below center line

Level point 7.6 used to determine Langelier Index. It is used to determine the water quality in term of
scaling and corrosion potential. The Langerier Index calculation is given in following figure:

and LSI interpretation is given in figure below:

ARD water can be classified as under saturated water that have tendency to remove existing calcium
carbonate in the wash water pan. ARD water also has tendency to form scaling but has a slightly potential
to occur corrosion in wash water pan. Following table shows the Langerier Index of ARD water.
pH Saturation
LSI

Mean
7.70
-044

Stdev
0.06
0.24

Median
7.69
-047

Min
7.61
0.83

Max
7.83
0.07

Recommendation
Check level sensor in each tank and ensure in induce lime at 2TK244 reach pH level 7.6 for the goal
to utilize ARD water as column wash water.
Check level sensor on 2TK-246 to monitor the ARD water and lime availability.

Exhibit-1
pH ARD water monitoring result
Day
Day-1

Day-2

Day-3

Day-4

Day-5

Day-6

Sampler
(4hourly)

2TK-244

2TK-245

2TK-246

7,03

7,57

8,00

7,02

7,57

8,01

Day

Neutralization Tank

Day-7

Sampler
(4-hourly)

Neutralization Tank
2TK-244

2TK-245

2TK-246

6,49

6,75

7,60

6,49

6,62

7,52

7,04

7,57

8,01

6,47

6,66

7,51

6,97

7,60

8,02

6,47

6,49

7,50

6,96

7,62

8,02

6,51

6,58

7,49

6,72

8,03

8,02

6,52

6,66

7,50

6,68

8,28

8,01

6,54

6,66

7,51

6,73

8,92

9,27

6,55

6,65

7,51

6,76

9,78

10,00

6,54

6,58

7,51

6,93

8,47

9,39

6,54

6,55

7,85

6,95

8,32

8,85

6,66

6,98

8,03

6,90

8,17

8,33

6,72

7,18

7,52

6,88

8,23

8,37

6,74

7,02

6,86

6,90

8,48

8,63

6,51

7,05

7,30

Day-8

Day-9

6,99

8,50

8,71

6,48

7,16

7,59

6,90

8,36

8,96

6,48

7,04

7,49

6,96

8,19

9,14

6,48

7,00

7,50

7,03

7,98

9,13

6,48

6,97

7,51

Day10

7,14

8,15

8,94

6,54

6,84

7,51

7,18

8,17

8,47

6,55

6,86

7,50

6,99

7,86

8,48

6,51

6,83

7,50

7,02

7,59

8,06

6,65

6,85

7,49

6,75

7,59

8,03

6,69

6,83

7,48

6,71

7,60

8,05

6,67

6,71

7,37

6,64

7,59

8,06

6,66

6,69

7,32

6,63

7,58

8,04

6,59

6,69

6,99

Day-11

6,62

7,58

8,04

6,59

6,73

6,89

6,66

7,59

8,04

6,50

7,13

7,27

6,70

7,57

8,04

6,46

7,30

7,64

6,58

7,57

8,04

6,46

7,76

8,01

Day12

6,58

7,57

8,05

6,44

7,88

7,99

6,59

7,57

8,05

6,82

7,79

7,88

6,54

7,58

8,04

7,12

7,60

7,77

6,52

7,58

8,04

6,77

6,98

7,55

6,53

7,59

8,04

6,60

6,99

7,48

6,58

7,74

8,04

6,67

7,14

7,35

Exhibit-2
Flowsheet current ARD water treatment

Flowsheet of existing wash water on SAG mill