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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
Abstract
In 1984, Phillip was offered a job working in the mountains of SW Colorado, at a very small gold operation,
where heap leach technology was used. Unfamiliar with this process, he jumped at the opportunity. Over
fifteen heap leach operations later, he would like to share lessons learned about being a good neighbour,
promoting safety, mitigating environmental risks, and maximizing value in heap leach operations.
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
Abstract
Chalcocite heap bioleaching is a complex process that utilizes oxidative chemical leaching and microbial
activities to extract copper from an ore bed. Mathematical modelling is an effective tool for identifying key
parameters that control the leaching performance to achieve optimization. HeapSim is a modelling tool that
incorporates multiple sub-processes that occur in a heap under leach, such as the movement of leaching
solution, chemical and microbial reactions, and heat transfer, to predict the leaching behavior of the heap.
In this study, the HeapSim model was applied to simulate chalcocite heap bioleaching at the Quebrada
Blanca mine located in the northern Chile. The Quebrada Blanca mine currently processes secondary copper
sulfides, mainly chalcocite, but is considering the processing of primary sulfides, mainly chalcopyrite, in
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
the next few years. The objective of this study was to simulate the current chalcocite leaching and identify
the key parameters that control heap temperature, which would provide insights into the possible leaching
of chalcopyrite by increasing heap temperature.
The main findings are that the leaching performance indicators used by the model, including copper
recovery, copper concentration, total iron, acid consumption, pH and Eh, could be calibrated using the site
historical leaching data with relatively high precision. Heap temperature was sensitive to the raffinate
temperature and the extent of reaction of finely divided pyrite flotation tails blended with agglomerated ore.
When the raffinate flow rate was high (9 L/m2/h), heap temperature was controlled by the raffinate
temperature; when the raffinate flow rate was low (1.8 L/m2/h), heat removal by the raffinate solution flow
was insignificant, and the heat generated by pyrite reaction accumulated and led to a sharp increase in the
heap temperature. For the current chalcocite leaching, aeration was stopped at 250 days and the raffinate
temperature was around 25C. It is recommended that raffinate be heated up to a higher temperature and
aeration be maintained for the entire life of a heap.
Introduction
With decreasing ore grades and limited freshwater availability, heap/dump leaching is becoming a
promising, environmentally-friendly way of processing large tonnages of low-grade copper ores (Ehrlich,
2001; Petersen, 2016). The successful application of heap leaching depends on a comprehensive
understanding of the complex fundamental processes underlying it. These fundamental processes include
the transport of fluid, solutes and heat, and the kinetics of chemical and microbial reactions. Significant
progress has been made towards understanding the fundamentals of heap leaching with the aid of
sophisticated mathematical models (Cross et al., 2006; Dixon, 2003). HeapSim is such a modelling tool
that incorporates these hydrological, chemical, biological and thermal factors that may affect mineral
leaching rates (Bouffard, 2008; Bouffard and Dixon, 2009; Petersen and Dixon, 2007). The two objectives
of this project were to simulate chalcocite heap leaching by using the HeapSim model at the Quebrada
Blanca mine, a copper heap bioleaching operation located in northern Chile, and to identify key operating
parameters that control heap temperature. The ultimate goal was to predict chalcopyrite leaching at high
temperatures using the information obtained through modelling.
Method
The above objectives were achieved using the HeapSim model. The work was carried out in the following
aspects:
Calibrate the model using the historical chalcocite leaching data provided by the operation.
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
Validate the model using the historical chalcocite leaching data provided by the operation.
Test the response of the heap temperature to the change in the raffinate temperature and to the
addition of finely divided pyrite to the agglomerated ore.
Provide recommendations for the current chalcocite leaching and future chalcopyrite leaching.
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
Design parameters: these are user-defined operating parameters and vary with each mine
operation, such as irrigation rate. Their values can be varied in the sensitivity study to test the
magnitude of the influence of each design parameter on the leaching performance.
Empirical parameters: these parameters are typically estimated based on operational experience
and laboratory or on-site testing. Their values can be adjusted in the model calibration process
in order to fit the model outputs with the site monitoring data.
Fundamental parameters: these are the parameters that represent the intrinsic properties of
materials and processes and are not expected to change from one operation to another, such as
reaction activation energy. The values for these parameters are typically available in scientific
literature.
Multiple indicators were used as model outputs to evaluate the performance of the leaching process.
These indicators fall into three categories: (1) PLS volume; (2) copper recovery, copper concentration, total
iron, acid concentration, pH, and Eh; (3) Heap temperature.
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
The HeapSim model was calibrated by adjusting various model parameters (the third category) until
the results gave a close fit to the historical heap leach data. Four heaps were selected for model calibration:
G-14, H-1, H3, and H-11. The validity of the calibrated model was then tested using data from another two
heaps: H-6 and H-9. These characteristics of the six heaps are shown in Table 1. The selection criteria
reflected the diversities in terms of irrigation area, geographic location, operation start date, and ore grade,
to ensure that the calibrated model is robust in describing chalcocite leaching.
The height of all six heaps was 8 m. Irrigation was provided by drip emitters arranged in a 55 by 55
cm grid. The whole heap was divided into various number of modules irrigated sequentially. Aeration and
irrigation were started at the same time, but aeration was stopped after 250 days. The average aeration rate
was 0.23 m3/m2/s. The average irrigation scheme, with variations among heaps, was: 0.20 L/m2/min for the
first 100 days; 0.15 L/m2/min from day 101 to day 245 (approximately); 0.03 L/m2/min from day 246 to
day 450 (approximately). The model handles varying leaching conditions through an Event Manager, the
interface of which is shown in Figure 3.
Research findings
Model calibration using chalcocite leaching data
The objective of the model calibration was to adjust the model parameters (from the third category) to fit
the simulated model outputs with the historical monitoring data. Figure 4 and Figure 5 show the calibration
results using Heap G-14 as an example. The calibrated results on PLS flow rate has been published
previously (Liu and Dixon, 2015). The model could satisfactorily describe copper recovery, copper
concentration, total iron, acid concentration, pH, and Eh, as shown in Figure 4. In the acid balance
calculation, the gangue acid consumption was not considered for the ore type at the Quebrada Blanca mine.
Pyrite oxidation was considered to generate 70% of sulfuric acid and 30% of elemental sulfur (Bouffard
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
and Dixon, 2009). Figure 5 shows the simulated average heap temperature and temperatures at the depths
of 2 m and 8 m.
Figure 3: Snapshot of the Event Manager for handling varying leaching conditions
The initial temperature of the heap was set at 12C, which was the same as the ambient temperature
at that time of the year (February). After irrigation was started, the heap temperature increased from the
initial temperature of 12C to 26C, similar to the raffinate temperature, within a month. The temperature
remained at around 26C until around day 245, after which the heap temperature started to decrease. This
was caused by less amounts of heat being carried by the raffinate to the heap resulting from the decrease in
the raffinate flow rate. The temperature at the depth of 2 m was lower than that at 8 m due to the heat loss
from the exposed surface to the environment through convection and radiation. This difference was
particularly obvious after day 245 when the raffinate flow rate was significantly reduced, with 20C on the
top and 27C at the bottom. The simulated temperature was very close to the top and bottom temperature
measured at QB previously. Their data show that the top temperature was around 17C and the bottom
27C. Therefore, the model can be used to describe heap temperature profile.
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
30 100 8
simulated simulated simulated
25
Cu concentration, g/L
Cu recovery, %
20
Acid, g/L
60
15 4
40
10
2
5 20
0 0 0
0 100 200 300 400 500 0 100 200 300 400 500 0 100 200 300 400 500
Time, days Time, days Time, days
3 4 850
simulated simulated simulated
monitored monitored 800 monitored
3
2
total Fe, g/L
750
Eh, mV
pH
2
700
1
1
650
0 0 600
0 100 200 300 400 500 0 100 200 300 400 500 0 100 200 300 400 500
Time, days Time, days Time, days
Figure 4: Model calibration results comparing model outputs (copper recovery, copper
concentration, total iron, acid concentration, pH, and Eh) with historical data for Heap G -14
40 40
Heap average temperature, C
30 30
20 20
10 10 2m
8m
0 0
0 100 200 300 400 500 0 100 200 300 400 500
Time, days Time, days
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
30 100 8
simulated simulated simulated
25
monitored 80 monitored monitored
Cu concentration, g/L
Cu recovery, %
20
Acid, g/L
60
15 4
40
10
2
20
5
0 0 0
0 100 200 300 400 500 0 100 200 300 400 500 0 100 200 300 400 500
Time, days Time, days Time, days
3 4 850
simulated simulated simulated
monitored monitored 800 monitored
3
2
total Fe, g/L
750
Eh, mV
pH
2
700
1
1
650
0 0 600
0 100 200 300 400 500 0 100 200 300 400 500 0 100 200 300 400 500
Time, days Time, days Time, days
Figure 6: Model calibration results comparing model outputs (copper recovery, copper
concentration, total iron, acid concentration, pH, and Eh) with historical data for Heap H -9
40 40
Heap average temperature, C
30 30
20 20
10 10 2m
8m
0 0
0 100 200 300 400 500 0 100 200 300 400 500
Time, days Time, days
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
within a shorter time frame. When testing the effect of raffinate temperature, all sulfides reactions were
turned off; when testing the effect of blended pyrite, no sulfide reactions other than pyrite reaction were
turned on.
Figure 8 (upper left graph) shows the effect of raffinate temperature on heap temperature. All three
raffinate temperatures tested (20C, 30C, 40C) were higher than the heap temperature (12C). In these
cases, the heat carried by the raffinate solution transferred to the heap, leading to an increase in the heap
temperature. The amount of heat carried and therefore its contribution to the heap temperature was
determined by the raffinate flow rate. When the flow rate was high (initial 245 days), the heat carried by
the raffinate was sufficient to maintain the heap temperature similar to the raffinate temperature. After day
246, the flow rate was significantly reduced and therefore the heat carried by the raffinate solution
decreases. In this case, heat loss to the colder ambient plays a more important role, resulting in a gradual
drop in the heap temperature. The heap temperature would eventually drop to the same as ambient
temperature, if flow rate was low enough.
80 80
Heap average temperature, C
Heap average temperature, C
40 40
20 20
0 0
0 100 200 300 400 500 0 100 200 300 400 500
80 80
Heap average temperature, C
Heap average temperature, C
The remaining three graphs in Figure 8 show the effect of both raffinate temperature and pyrite content
on heap temperature. At a high flow rate, any heat contributed by pyrite reaction would be carried away
from the heap by the raffinate flow. Therefore, the heap temperature was mainly determined by the raffinate
temperature and was just slightly higher than the raffinate temperature. When the raffinate flow rate was
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
low (from day 246 to day 450), the amount of heat removed by raffinate flow was insignificant. Therefore,
heap temperature was determined by pyrite reaction. In this case, heat was accumulated in the heap, leading
to a sharp increase in heap temperature.
100
80
Copper recovery, %
60
40 monitored
simulated
aeration
20
raffinate 40 C
raffinate 40 C & aeration
0
0 100 200 300 400 500
Time, days
Conclusion
The HeapSim model was calibrated using historical chalcocite leach data, with pregnant leach solution
(PLS) flow rate, copper recovery, copper concentration, total iron, acid, pH, Eh, and temperature as leaching
performance indicators. The calibrated model was capable of describing the chalcocite leaching at the
Quebrada Blance mine with relatively high precision. Heap temperature was sensitive to the raffinate
temperature and to pyrite reaction (assuming external reactive pyrite can be blended with agglomerated
ore). When the raffinate flow rate was high, heap temperature was controlled by the raffinate temperature;
when raffinate flow rate was low, heat removal by raffinate solution was insignificant, and the heat
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
generated by pyrite reaction was accumulated, leading to a sharp increase in the heap temperature. It was
recommended that aeration be maintained for the entire leach cycle of a heap and raffinate be heated up
from the current 26C to a higher temperature. The findings of this research also have implications for the
future leaching of chalcopyrite at QB. To simulate chalcopyrite leaching performance at higher
temperatures, the HeapSim model will need to be calibrated using experimental data from chalcopyrite
leaching.
Acknowledgements
This project was financially supported by Teck Resources. The data were provided by Teck Metals Applied
Research and Technology, based in Trail, BC, Canada.
References
Bouffard, S.C. 2008. Application of the HeapSim model to the heap bioleaching of the Pueblo Viejo ore deposit,
Hydrometallurgy 93(34): 116-123.
Bouffard, S.C. and Dixon, D.G., 2009. Modeling pyrite bioleaching in isothermal test columns with the HeapSim model,
Hydrometallurgy 95(34): 215-226.
Cross, M., Bennett, C.R., Croft, T.N., McBride, D. and Gebhardt, J.E., 2006. Computational modeling of reactive multi-phase
flows in porous media: Applications to metals extraction and environmental recovery processes, Minerals Engineering
19(10): 1098-1108.
Dixon, D.G. 2003. Heap leaching modelling the current state of the art, Hydrometallurgy 2003, Fifth International Conference
in Honor of Professor Ian Ritchie,TMS (The Minerals, Metals & Materials Society): 289-314.
Ehrlich, H.L. 2001. Past, present and future of biohydrometallurgy, Hydrometallurgy 59(23): 127-134.
Liu, W. and Dixon, D.G. 2015. Modelling solution flow in copper heap bioleaching a case study, Proceedings Third
International Heap Leach Solutions Conference, Reno, Nevada, USA: InfoMine: 63-72.
Lizama, H.M. 2001. Copper bioleaching behaviour in an aerated heap, International Journal of Mineral Processing 62(14): 257-
269.
Petersen, J. 2016. Heap leaching as a key technology for recovery of values from low-grade ores a brief overview,
Hydrometallurgy, September.
Petersen, J. and Dixon, D.G., 2007. Modelling zinc heap bioleaching, Hydrometallurgy 85(24): 127-143.
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HEAP LEACH MINING SOLUTIONS, 2016 LIMA, PERU
Abstract
There are many heap leach pad projects located in highly seismic regions; however, little is known about
the material dynamic properties and seismic behaviour of the heap, despite the fact that heap leach pads are
much more sensitive to seismic-induced displacements than other mine facilities, due to the critical potential
for tearing of the geomembrane liner during seismic events. Topics to be covered during this presentation
include dynamic properties, seismic coefficient discussion, seismic records and spectral matching, 1D-2D
and 3D seismic response analysis, seismic induced displacement calculation, comparison between rigorous
and simplified approach, among others.
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