Estudio económico de la construcción de una planta piloto para recuperar polvos de cobre de fundición con valores reales de plantas mineras.
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Date
2025
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Universidad de Concepción
Abstract
Este estudio evalúa la viabilidad técnica, económica y ambiental de implementar una planta piloto para la recuperación de cobre y la posibilidad de tratamiento para la obtención de metales secundarios desde polvos de fundición, un residuo peligroso generado en procesos pirometalúrgicos de cobre en Chile. Estos polvos contienen altas concentraciones de cobre (10–18 %), así como elementos tóxicos como arsénico, plomo y zinc, lo que los hace difíciles de manejar y costosos de disponer. Actualmente, estos residuos son tratados mayoritariamente mediante procesos de estabilización química sin valorización económica significativa.
La planta piloto propuesta utiliza una tecnología hidrometalúrgica de operación discontinua, basada en lixiviación ácida y reducción selectiva con hidrógeno verde, lo que permite recuperar cobre metálico de alta pureza (>99,99 %) sin necesidad de electrólisis ni solventes orgánicos. Además, el proceso permite recuperar parcialmente subproductos como arsénico, plomo y antimonio, lo que contribuye a reducir el volumen de residuos peligrosos y genera ingresos adicionales.
Se evaluaron dos escenarios de implementación: replicación de la planta piloto en cada fundición del país y construcción de una planta centralizada nacional. Se utilizaron datos reales de generación de polvos y composición química provenientes de fundiciones como Chuquicamata, Caletones, Altonorte, Paipote y Potrerillos. El análisis económico considera inversión inicial (CAPEX), costos operacionales (OPEX), ingresos por valorización metálica, flujo de caja a 15 años, VAN, TIR y Payback.
Los resultados muestran que la planta piloto es técnica y económicamente viable bajo condiciones reales. En su versión modular, alcanza una TIR de 11,6 % y un VAN positivo. A escala centralizada, el proyecto supera ampliamente al modelo actual de tratamiento, con un VAN superior a 330 millones USD, lo que lo posiciona como una alternativa rentable, replicable y sostenible.
This study assesses the technical, economic, and environmental feasibility of implementing a pilot plant for copper recovery and the potential treatment for the extraction of secondary metals from smelter dust, a hazardous by-product generated in pyrometallurgical copper processing plants in Chile. These dusts contain high concentrations of copper (10–18%) along with toxic elements such as arsenic, lead, and zinc, making them difficult and costly to manage. Currently, most of these residues are stabilized chemically without achieving significant metal valorization. The proposed pilot plant employs a two-stage hydrometallurgical process, combining acid leaching and selective reduction using green hydrogen. This enables the production of high-purity metallic copper (>99.99%) without the need for electrolysis or organic solvents. Additionally, the process allows partial recovery of valuable by-products such as arsenic, lead, and antimony, reducing hazardous waste volume and generating supplementary revenue. Two implementation scenarios are evaluated: (1) the replication of the pilot plant at each smelter and (2) the development of a centralized national facility. The study incorporates real operational data from major Chilean smelters, including Chuquicamata, Caletones, Altonorte, Paipote, and Potrerillos. The economic evaluation includes capital expenditure (CAPEX), operational expenditure (OPEX), projected revenues from metal recovery, a 15-year cash flow, and financial indicators such as Net Present Value (NPV), Internal Rate of Return (IRR), and Payback period. Results demonstrate that the proposed pilot plant is technically and economically feasible under real-world conditions. In the modular configuration, it achieves an IRR of 11.6% with a positive NPV. At the industrial scale, the centralized plant model significantly outperforms the current treatment methods, reaching an NPV of over 330 million USD, positioning it as a profitable, scalable, and sustainable alternative for smelter dust management.
This study assesses the technical, economic, and environmental feasibility of implementing a pilot plant for copper recovery and the potential treatment for the extraction of secondary metals from smelter dust, a hazardous by-product generated in pyrometallurgical copper processing plants in Chile. These dusts contain high concentrations of copper (10–18%) along with toxic elements such as arsenic, lead, and zinc, making them difficult and costly to manage. Currently, most of these residues are stabilized chemically without achieving significant metal valorization. The proposed pilot plant employs a two-stage hydrometallurgical process, combining acid leaching and selective reduction using green hydrogen. This enables the production of high-purity metallic copper (>99.99%) without the need for electrolysis or organic solvents. Additionally, the process allows partial recovery of valuable by-products such as arsenic, lead, and antimony, reducing hazardous waste volume and generating supplementary revenue. Two implementation scenarios are evaluated: (1) the replication of the pilot plant at each smelter and (2) the development of a centralized national facility. The study incorporates real operational data from major Chilean smelters, including Chuquicamata, Caletones, Altonorte, Paipote, and Potrerillos. The economic evaluation includes capital expenditure (CAPEX), operational expenditure (OPEX), projected revenues from metal recovery, a 15-year cash flow, and financial indicators such as Net Present Value (NPV), Internal Rate of Return (IRR), and Payback period. Results demonstrate that the proposed pilot plant is technically and economically feasible under real-world conditions. In the modular configuration, it achieves an IRR of 11.6% with a positive NPV. At the industrial scale, the centralized plant model significantly outperforms the current treatment methods, reaching an NPV of over 330 million USD, positioning it as a profitable, scalable, and sustainable alternative for smelter dust management.
Description
Tesis presentada para optar al título de Ingeniero/a Civil Químico/a.
Keywords
Minería, Cobre, Metales secundarios, Hidrometalurgia