Improved dynamic modeling and simulation of an industrial copper solvent extraction process

Existing dynamic models of the mixer-settler SX process assume that the mixing stage can be modeled as a single mixer, whereas in recently developed technology, there are two mixing chambers (a pump-mixer and a mixer). Moreover, existing dynamic models assume that the hydrodynamics of the aqueous and organic phases in the settler were the same, whereas they are not similar. In this study, the existing dynamic models are extended to more accurately represent the mixing and settling behavior. Firstly, the parameters of the pump-mixer model were estimated using CFD simulation for each mixer-settler unit. Then, the dynamic simulation was performed to test the simulator with practical parameters over a period of 30 days of industrial operating data. Compared to existing dynamic models, better fitting was obtained due to the continual updating of parameters, the use of multiple mixer unit models (pump-mixer and mixer) as well as allowance for different hydrodynamics of organic and aqueous phases in the settler.