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Preprint 04-141
FLUID FLOW ANALYSIS OF A MODEL LEACH PAD USING TEMPERATURE PROBES
M.G. Nelson
G.G. Gold
Univ. of Utah
Salt Lake City, UT
ABSTRACT
A leach pads fluid flow characteristics greatly affect the recovery of metals from heap leaching. However, because there are other
factors such as particle size distribution, application rate and method,
and chemical reactions to consider, mining companies often overlook
potential problems associated with fluid flow until it is too late. In an
effort to better understand the dynamics of fluid flow in leach pads, a
series of experiments were preformed using temperature probes.
A model leach pad was set up using a particle size distribution,
fluid application rate, and application method common to modern
leaching methods. Variable water temperatures were applied in succession and data gathered from the three dimensional grid of temperature probes built in to the model. Current work is analyzing these
data along with visual observations of the model, computer simulations, past mining experiences, and other related research, in an
attempt to develop a low cost test that could be performed prior to
large scale leaching to determine the fluid flow characteristics of a
particular ore. This paper will summarize the work and findings to this
point as well as suggest areas of additional related research.
INTRODUCTION
Heap leaching allows ores previously thought useless to be
mined economically. High volumes of very low grade ore are mined
and placed on large piles. A leach solution is applied to the tops of
the piles causing a chemical reaction that dissolves the precious
metal. The pregnant solution is then collected as it exits the pile
where it is processed into a saleable product. Recent statistics show
that about 12% of gold and 15% of copper production in the world is
from heap leaching operations.
This simple sounding process does have difficulties, which the
mining industry has not solved to this point. After 30 years of continuous improvement, the current status of heap leach design can be
characterized more as educated guess work than art, there is still
much to learn (Scheffel 2002). One area of heap leaching that is not
properly understood is the fluid flow inside the pad. A better understanding of the fluid flow characteristics could increase the percent
recovery and profitability of current leaching operations. It could also
lower the cutoff grades of these types of operations, which would
increase reserves and create new projects.
In the past several decades, considerable research has
been devoted to improving the recovery of precious metals from heap
leaching. Much of this research centers on optimizing the particle size
distribution, with a primary goal of achieving good mineral liberation.
Column tests are performed to test this liberation with laboratory
recoveries usually above 90%. However, numerous sources report
that recovery at operating leach pads typically range from 65 85%
for gold and copper. This discrepancy may in large part be due to
METHOD
Materials and Equipment
The rock materials used in the model are very important to the
results. As mentioned earlier, fluid flow characteristics are very sensitive, so drastically different results can occur from small changes in
the rock material used. Several aggregate products were acquired
and sieved to known size distributions. These products were then
mixed in a standard cement mixer in percentages calculated to produce an ore that was very close to Millers ultimate size distribution
(XMT-2). Miller (2002) shows the sieve analysis of this distribution.
Table II shows the actual products mixed to approximate the distribution of the XMT-2, and a simulated agglomerated product that was
also prepared, eliminating the fines for better permeability.
(2002).
Model Setup
The model leach pad was constructed on a small platform build
of plywood. The platform dimensions are 94 cm by 102 cm with 5-cm
sides to prevent spillage. The platform was placed at small angle to
encourage the water to move toward the exit point. A plastic liner was
placed on the platform and covered by a layer 1 to 2.5-cm layer of
drain materials. The drain materials contained stone from 0.5 to 1cm
with no fines. This enabled water to quickly move to the outlet of the
pad after it had moved through the leach material. A 3.8-cm layer of
ore was then placed on the drain materials with the first level of thermistors on top. Then a 5-cm layer of ore, a second level of thermistors, a 5-cm layer of ore, a third level of thermistors, and finally a 2.5cm layer of ore were added in succession. The top of the pad had
dimensions of 37.5 cm by 45 cm. A basic diagram of this configuration can be seen in Figure 2.
Thermistor Array
As seen in Figure 2, the thermistors were placed in three horizontal levels in the model. The bottom level had 13 probes, while the
middle and upper levels had 12 probes each. The probes were placed
in three rows of four probes each, except in the bottom level where
the middle row had five probes. A top view of the middle level of the
thermistor grid with the position of the drip point can be seen in
Figure 3. The drip point is approximately 7.5 cm above the middle
level of probes. Each level had slightly different spacing but known
distances were maintained between the probes in each row and
between the rows for experiments 2 4. This grid was designed to try
to capture horizontal and vertical spread of fluids from the emitter
point.
Three other thermistors were place in other positions to record
data important to the experiment. One probe was placed on the surface, directly in the water dripping from the emitter. Another was
placed in the outlet of the model heap. A final probe was in close
proximity to the model to measure the ambient air temperature during the experiments.
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Experimental Runs
A total of five experiments were performed. The first experiment
was a test run to ensure all the equipment was working properly. The
results of this test were not analyzed; however, several important
things were learned. These include thermistor grid spacing, proper
duration of hot or cold water application (100-minutes), number of
times water temperature should be changed during an experiment
(4), and the optimal time interval for scans (5-seconds). The drain
materials were changed to a coarser size and the angle of the pad
increased for the remaining experiments, based on findings from
experiment 1.
Experiments 2 & 4 used a heap built of non-agglomerated ore
while experiments 3 & 5 used agglomerated ore. Experiment 4 had
two impermeable caps, or blocking devices, one placed below a
thermistor to pool water around it, and one placed above a thermistor to keep flow from the thermistor. Experiments 3 & 5 were built to
see if similar results could be duplicated using all the same techniques. The same grid spacing, scan intervals, water temperatures,
application rate, application method, and construction techniques
were used in all three experiments so the data could be analyzed
based on these known differences.
These four experimental runs allowed three different comparisons. A comparison between the results of experiments 3 and 5
would indicate whether or not the models could be built in manner
which would produce similar results. This was not yet complete at the
time of publishing, but will be found in Gold (2004). Comparing the
results of experiments 2 and 3 or 5 would indicate whether differences between agglomerated and non-agglomerated ore can be
seen with this technique. Comparing the results of experiments 2 and
4 would allow one to see if the technique could be used to identify
problem areas in a leach pad.
Miller, J.D., Lin C.L., Garcia, C., and H. Arias. 2002. Ultimate
recovery in heap leaching operations as established from mineral
exposure analysis by x-ray microtomography. SME Annual Meeting.
Preprint 02-170.
Miller, J.D., Lin C.L., Roldan, C., and Garcia, C. 2003.
Estimation of ultimate recovery in heap leaching operations using
high resolution cone beam x-ray microtomography (XMT). SME
Annual Meeting. Preprint 03-066.
Scheffel, R.E. 2002. Copper heap leach design and practice.
Proceedings Mineral Processing Plant Design, Practice, and
Control. Vol. 2. 1571-1605.
REFERENCES
Gold, G.G. 2004 (to appear). Fluid flow analysis of a model
leach pad using a 3-D thermistor array. M.S. Thesis. University of
Utah, Salt Lake City.
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