Main projects
- 1. Main completed projects with the current employer HudBay Minerals Name The estimated economic gain for the company, $ Notes Quebracho reagent optimization project >$285 000 per year (permanent gain) The project allowed a significant reduction in the total consumption of one of the key reagents. The optimization of the assay schedule for the Zinc Plant >$150 000 per year (permanent gain) The target was reached in two stages of optimization. HAL belt filtration >$600 000 per year (permanent gain) The modification of the filtration mode brought about an increase in the spare capacity of the filter, reduced the economic losses associated with Zn losses with washing SR&D research rebate on the Cu- saving trial >$500 000 per year (one time gain) Planning a test trial for Cu saving project in a manner eligible for claiming SR&D tax rebate for the company High Ni feed treatment mode and SR&D research rebate on the trial >$1000 000 per year (one time gain) Development of modifications of the process to make it possible to continue the zinc plant operation at much higher Ni peak
- 2. values in the incoming concentrate. Making the corresponding trials eligible for SR&D tax rebate program. Lignosol reagent reduction project >$450 000 per year (permanent gain) The project allowed a significant reduction in the total consumption of one of the key reagents. Copper & Zinc Recovery Project in the Gypsum/Iron precipitation circuit ~$450 000 one time gain on SR&D for 2015 Successful application for SR&D program of Canadian Revenue Agency for this project allowed the company to save a substantial amount of money. Cobalt & nickel purification improvement project Lack of quantification methods to estimate the economic equivalent with acceptable accuracy A dramatic reduction in the frequency of production disruption (hence shutdown time and losses) because of the purification problems. Sulfate balance monitoring and optimization project Lack of quantification methods to estimate the economic equivalent with acceptable accuracy A dramatic reduction in the production problems associated with the over-
- 3. generation or deficit of sulfate in the plant circuit Engineering of the most optimal parameters for the ‘idle’ cellhouse regime during prolonged plant shutdowns Lack of quantification methods to estimate the economic equivalent with acceptable accuracy The result is a dramatic reduction in the losses of production time and labor. During planned and unplanned shutdowns the cellhouse “idle” mode was engineered to reduce cathodes problems and risks of fire. Process crisis- management in dealing with 2013 Mn crisis at the Zinc Plant Possible direct and indirect economic damage for the company, that was prevented, could have run into $1000 000s (loss of clientele, compensations, loss of a great number of anodes etc). The exact prediction is hard to make. Mn crisis of 2013 was caused by an almost total depletion of Mn in the solutions. The proper estimations of the scale, consequences, urgency of and recipe for the solution of the problem were developed and promoted on my part. Process crisis- management in stopping 2016 Cu contamination crisis at the Zinc Plant Possible direct and indirect economic damage for the company, that was prevented, could have run into 1000 000s (loss of clientele, compensations, etc). The exact quantitative prediction is difficult to make. A long period of contamination of the produced metal with Cu which I was asked and challenged to
- 4. resolve. Successful diagnostics, cause establishment, the crisis action list was developed on my part, that included urgent short term mitigation measures, mid- term prevention measures, and long term ultimate prophylactic modifications. Modification of the purification-related process streams to drastically decrease the risks & frequency of Co removal disruption in 2012. From 100 000 s to 1000 000s per year possible savings in comparison to years of operation before Oct 2012. Frequent and long disruptions on the Co removal purification stage caused significant reductions in the production levels. The exact quantitative estimate is difficult to make. Successful root cause diagnostics of the disruptions of the Co removal circuit was achieved on my part. A number of modifications was realized to eliminate forever some organics- related and Zn- dust quality related factors playing crucial role in the functioning of the purification circuit at the Zinc Plant. The most significant of my projects on the go at present Name The estimated economic gain for the company, $ Notes
- 5. Flocculant optimization. >$200 000 per year (permanent gain) Finding a better flocculant type that would allow of cutting costs thanks to reduction in consumption or price or both. Copper & Zinc Recovery Project in the Gypsum/Iron precipitation circuit >$500 000 per year (permanent gain) The goal is a modification to the circuit to allow a substantially lower losses of copper and zinc. Reduction in the propane consumption in the cellhouse To be determined. The gain would be on the permanent basis. The present ventilation- cooling circuit in the cellhouse has a significant potential to be improved, especially for winter conditions.