INTRODUCTION TO

EVALUATION, DESIGN AND

OPERATION OF PRECIOUS METAL
HEAP LEACHING PROJECTS

Editors
Dirk J.A. van Zyl
Welsh Engineering Inc.
Denver, Colorado

Ian P.G.Hutchison
Steffen Robertson and Kirsten (Colorado)Inc .
Denver, Colorado

Jean E. Kiel
J .E. Kiel & Associates
Denver, Colorado

Society of Mining Engineers, Inc., Littleton, Colorado 1988

 Copyright O 1988 by the
Society of Mining Engineers, Inc.

Printed in the United States of America

by Cushing-Malloy, Inc., Ann Arbor, Michigan

All rlghts resewed. This book, or parts thereof, may not be

reproduced In any form wlthout permlsslon of the publisher.

Library of Congress Catalog Card Number 88-60773

ISBN 0-87335-074-X
Chapter 6

Heap Construction and Solution Application

Omar A. Muhtadi

6.1 INTRODUCTION

The t h r e e most c r i t i c a l f a c t o r s i n successful heap l e a c h i n g o p e r a t i o n s

are:

The methods employed t o p r e t r e a t o r e e . , c r u s h i n g and

agglomeration) ;
Placement of o r e on t h e l e a c h pad (heap b u i l d i n g t e c h n i q u e s ) ; and
N e t t i n g of t h e o r e w i t h c y a n i d e ( s o l u t i o n a p p l i c a t i o n t e c h n i q u e s ) .

Improper e x e c u t i o n o f any o f these i n i t i a l s t e p s may r e s u l t i n a s u b s t a n t i a l

s a c r i f i c e o f t o t a l metal e x t r a c t i o n o r , i n t h e worst case, i n p r o j e c t f a i l u r e .

Ore p r e p a r a t i o n i n terms o f c r u s h i n g and a g g l o m e r a t i o n was discussed i n

Chapter 5; t h i s c h a p t e r t h e r e f o r e focuses on commonly employed t e c h n i q u e s f o r
heap c o n s t r u c t i o n and s o l u t i o n a p p l i c a t i o n . The main o b j e c t i v e o f heap
c o n s t r u c t i o n i s t o o b t a i n t h e ~ i i o s t homogeneous heap p o s s i b l e . "Channel i n g " o f
1 eachate i n heaps w i t h p r e f e r e n t i a l seepage paths l e a d s t o p r e f e r e n t i a l
l e a c h a t e d i s t r i b u t i o n and uneven/incomplete e x t r a c t i o n . The two main
c o n t r i b u t i n g causes o f c h a n n e l i n g a r e inadequate a t t e n t i o n to heap
c o n s t r u c t i o n and uneven s o l u t i o n a p p l i c a t i o n . These p i t f a l l s can b e s t be
avoided t h r o u g h a knowledge of t h e v a r i o u s techniques available and t h e
a p p l i c a b i l i t y and success o f these t e c h n i q u e s w i t h v a r i o u s o r e t y p e s and s i t e
c o n d i t i o n s . The remainder o f t h i s c h a p t e r provides a d i s c u s s i o n on these two
subjects.

6.2 HEAP B U I L D I N G TECHNIQUES

S ~ ~ c c e s s f uheap
l b u i l d i n g t e c h n i q u e s v a r y w i t h t h e t y p e o f o r e and, s i n c e
no two o r e b o d i e s a r e e x a c t l y a l i ke, some s l i g h t m o d i f i c a t i o n s a r e u s u a l l y
necessary f o r each s p e c i f i c p r o j e c t . However, i t i s p o s s i b l e t o g e n e r a l i z e i n
terms o f t h e a p p r o p r i a t e techniques t o be used w i t h o r e s h a v i n g s i m i l a r
c h a r a c t e r i s t i c s . T h i s s e c t i o n d i s c u s s e s t h e t h r e e most commonly used methods
o f heap c o n s t r u c t i o n and p r o v i d e s some guide1 i n e s w i t h r e g a r d t o o r e t y p e s ,
c o n s t r u c t i o n c o n s t r a i n t s , and l i f t h e i g h t parameters f o r each of t h e t h r e e .

6.2.1 Run-of-Mine Dumping and D o z i n g

The run-of-mine method of heap b u ' i l d i n g can o n l y be used w i t h o r e o f a

h i g h l y s i l i c i o u s n a t u r e (i.e., o r e which w i l l n o t g e n e r a t e a l a r g e amount o f
92
 HEAP CONSTRUCTION AND SOLUTION APPLICATION 93

f i n e s , even w i t h a t r a c t o r and dozer l e v e l i n g t h e t o p o f t h e heap). The b a s i c

c o n s t r u c t i o n o f t h i s t y p e o f heap i s d e p i c t e d i n F i g u r e 6.1. A ramp i s b u i l t
t o access one o f t h e ends o f t h e heap, t y p i c a l l y u s i n g waste r o c k t o b u i l d i t
up t o t h e h e i g h t o f t h e f i r s t l i f t o f o r e , as shown i n t h e f i g u r e . A n a r r o w
roadway i s e s t a b l i s h e d a c r o s s t h e t o p o f p r e v i o u s l y dumped o r e so t h a t o r e
haulage t r u c k s may d r i v e t o t h e edge o f t h e ramp and dump o r e down t h e i n s i d e
s l o p e o f t h e heap o n t o t h e pad a t t h e a n g l e o f repose. Successive dumping i n
t h i s f a s h i o n a l l o w s t h e heap t o extend inwards towards t h e c e n t e r o f t h e heap
u n t i l t h e b o t t o m o f t h e pad i s c o m p l e t e l y covered w i t h t h e f i r s t o r e l i f t .

As t h e dump face advances inward, a t r a c t o r / d o z e r i s used t o l e v e l t h e

a d v a n c i n g t o p o f t h e heap. L e v e l i n g i s f o l l o w e d by deep r i p p i n g o f t h e o r e .
L a t e r a l s p r e a d i n g o f t h e o r e t o t h e e x t e n t necessary i s a c h i e v e d w i t h t h e
t r a c t o r / d o z e r as w e l l . I n o r d e r t o l i n i i t compaction o f t h e t o p o f t h e heap,
o r e h a u l a g e t r u c k s a r e l i m i t e d t o t h e e s t a b l i s h e d narrow access roadway.

The p r e p a r e d l i f t i s u s u a l l y sprayed w i t h s o l u t i o n i m m e d i a t l e y a f t e r
r i p p i n g i n o r d e r t o p r o v i d e t h e b e s t c o n d i t i o n s f o r even p e n e t r a t i o n and
p e r c o l a t i o n o f t h e c y a n i d e s o l u t i o n t h r o u g h t h e o r e . Successive o r e l i f t s a r e
b u i l t i n t h e same manner, and s p r a y l i n e s on l o w e r l i f t s a r e removed and
rep1 aced on h i g h e r l a y e r s as t h e upper o r e l a y e r s advance.

6.2.2 P l ug Dumpi ng/Pl ug Dumping w i t h Doter L e v e l in g

The p l u g dumping method ( o r i t s v a r i a t i o n , t h e p l u g dumping w i t h d o z e r

l e v e l i n g method) i s used where t h e o r e i s 1 i k e l y t o generate e x c e s s i v e f i n e s
d u r i n g h a n d l i n g , as w e l l as w i t h crushed and agglomerated o r e n e e d i n g a v e r y
low l e v e l o f physical handling p r i o r t o leaching, Construction o f t h i s type o f
heap i s d e p i c t e d i n F i g u r e 6.2 and b e g i n s w i t h t h e placement o f a 12-18 i n c h
(30-50 cm) l a y e r o f c r u s h e d o r e o v e r t h e s y n t h e t l c 1 i n e r i n o r d e r t o p r o t e c t
i t f r o m t h e f o r c e o f l a t e r p l u g dumping. Once t h e i n i t i a l l a y e r o f c r u s h e d o r e
i s i n p l a c e , o r e h a u l a g e t r u c k s d r i v e o n t o t h e l e a c h pad, d e p o s i t i n g t h e i r
l o a d s i n s m a l l heaps. Each t r u c k d r i v e s as c l o s e as p o s s i b l e t o a p r e v i o u s l y
dumped o r e p i l e and r e l e a s e s i t s l o a d , t h u s p r o v i d i n g some o v e r l a p w i t h
a d j a c e n t p i l e s ( F i g u r e 6.2). P i l e s ( o r p l u g s ) a r e g e n e r a l l y about 6 f t ( 2 m)
deep, w i t h t h e t o p o f t h e heap c o n s i s t i n g o f a s e r i e s o f mounds and f u r r o w s .
As p r e v i o u s l y n o t e d , t h 4 s method o f heap c o n s t r u c t i o n r e s u l t s i n v e r y l i t t l e
h a n d l i n g o f t h e o r e , and no t r a f f i c compaction o c c u r s on t o p o f t h e heap.

P l u g dumping w i t h l e v e l i n g i s a v a r i a t l o n o f t h e heap c o n s t r u c t i o n
method d e s c r i b e d above. T h i s v a r i a t l o n a l l o w s f o r l e v e l i n g o f t h e f i r s t l i f t
a f t e r l e a c h i n g o f t h a t 1 i f t has been completed, t h u s p r o v i d i n g a f l a t s u r f a c e
f o r a second 1 i f t , The manner i n which t h i s i s accomplished i s t o c o n s t r u c t an
access ramp t o t h e h e l g h t o f t h e e x i s t i n g plug-dumped heap and, u s i n g t h i s
ramp f o r access, t o l e v e l and t h o r o u g h l y r i p t h e o r e b e f o r e b e g i n n i n g a second
l i f t . Ore i n t h e second l i f t i s t h e n end dumped i n rows across t h e w i d t h o f
t h e heap, a s d e s c r i b e d p r e v i o u s l y , B e f o r e each row o f t h e new l l f t i s added,
t h e o r e b e n e a t h t h a t a r e a i s r i p p e d t o a l l e v i a t e compaction caused by t r a f f i c ,
The end r e s u l t o f t h e second l i f t i s a s e r i e s o f mounds and furrows s i m i l a r t o
t h a t o f t h e f i r s t l i f t p r i o r t o l e v e l i n g . A t h i r d and even a f o u r t h l i f t may
be added i n t h i s same manner.

The p o t e n t i a l e x i s t s f o r d i m i n i s h e d p e r c o l a t i o n t h r o u g h t h e l o w e r l i f t s ,
p a r t i c u l a r l y t h e b o t t o m l i f t , when t h e p l u g dumping w i t h dozer l e v e l i n g
 PRECIOUS METAL HEAP LEACHING PROJECTS

FINAL
ROADWAY
-',

FIGURE 6.1

HEAP BUILDING BY RUN-OF-MINE, TRUCK DUMPING.

 HEAP CONSTRUCTION AND SOLUTION APPLICATION 95

v a r i a t i o n i s employed. The e x t e n t t o which t h i s i s a problem w i l l depend on

t h e f r i a b i l i t y o f t h e o r e , as w e l l as on i t s s u s c e p t i b i l i t y t o compaction. I n
cases where t h e s e c r e a t e a problem, i t i s b e s t n o t t o l e v e l and add a d d i t i o n a l
1 if t s , u n l e s s lower extraction r a t e s can be accepted. Under most
c i r c u m s t a n c e s , each o r e l i f t s h o u l d be a l m o s t t o t h e end o f i t s l e a c h c y c l e
p r i o r t o t h e c o n s t r u c t i o n o f t h e new l i f t i n o r d e r t o maximize g o l d (and
silver) extraction.

A n o t h e r v a r i a t i o n o f t h e p l u g dumping method i s t o dump o r e a t t h e t o e

o f t h e heap and t h e n t o use a l o a d e r t o s t a c k t h e o r e . T h i s method r e s u l t s i n
h i g h e r heaps t h a n does c o n v e n t i o n a l p l u g dumping, w i t h 14 f t (4.3 m) l i f t s as
opposed t o t h e 6 f t ( 2 m) l i f t s p r e v i o u s l y d i s c u s s e d . A smoother heap s u r f a c e
i s a l s o achieved, p a r t i c u l a r l y when s k i l l e d equipment o p e r a t o r s a r e
r e s p o n s i b l e f o r heap c o n s t r u c t i o n . Disadvantages t o t h i s v a r i a t i o n c e n t e r
around t h e f a c t t h a t o r e must be handled more, p o t e n t i a l l y c a u s i n g p a r t i c l e
s e g r e g a t i o n and breakage. I n a d d i t i o n , a l o a d e r i s r e q u i r e d . I f t h e o r e can
w i t h s t a n d t h e e x t r a h a n d l i n g , t h i s method i s a c t u a l l y p r e f e r r e d due t o t h e
f a c t t h a t l e s s t i m e i s s p e n t i n heap c o n s t r u c t i o n because o f t h e h i g h e r l i f t s
which can be a c h i e v e d .

6.2.3 Conveyor S t a c k i n g

Conveyor s t a c k i n g systems have become i n c r e a s i n g l y more common o v e r t h e

l a s t few y e a r s as a method o f heap b u i l d i n g . These systems had t h e i r i n c e p t i o n
a t t h e O r t i z P r o j e c t ( G o l d F i e l d s M i n i n g Company) i n New Mexico where a
s p e c i a l overhead m e c h a n i c a l s t a c k e r was designed t o meet t h e s p e c i a l i z e d needs
o f t h e p r o j e c t ( H i c k s o n , 1981). Conveyor s t a c k i n g systems have been found t o
be a p p r o p r i a t e f o r heap b u i l d i n g w i t h crushed o r e s , crushed and agglomerated
ores, and a g g l o m e r a t e d t a i l i n g s . These systems t r e a t t h e o r e s g e n t l y and w i t h
a minimum o f hand1 i n g . A1 t h o u g h each conveyor s t a c k i n g system d i f f e r s t o some
e x t e n t , a l l use t h e g e n e r a l p r i n c i p l e s d e s c r i b e d i n t h e f o l l o w i n g p a r a g r a p h s
and d e p i c t e d i n F i g u r e s 6.3, 6.4, and 6.5.

Once t h e o r e i s d i s c h a r g e d from e i t h e r an o r e hopper ( i n t h e case o f

crushed o r e ) o r an a g g l o m e r a t i n g drum ( i n t h e case o f agglomerated o r e ) i t i s
r e c e i v e d by a p r i m a r y conveyor b e l t , one o f t h e p i v o t 0 1 components o f t h e
conveyor system ( F i g u r e 6.3). From t h i s p r i m a r y conveyor b e l t , t h e o r e i s
usual l y conveyed o n t o a s e r i e s o f " z i g-zagging" i n t e r m e d i a t e conveyors t o a
r a d i a l arm c o n v e y o r / s t a c k e r ( F i g u r e 6.3). 'The r a d i a l arm s t a c k e r has power
d r i v e n wheels, a l l o w i n g i t t o move f r o n t t o back, as w e l l as from s i d e t o s i d e
( b y t u r n i n g t h e wheels a h a l f a r e v o l u t i o n ) . A t e l e s c o p i n g s e c t i o n a t t h e end
of t h e s t a c k e r a l l o w s i n c r e a s e d f l e x i b i l i t y i n terms o f o r e placement ( F i g u r e
6.3).

I n a t y p i c a l s t a c k i n g c o n f i g u r a t i o n , t h e s t a c k e r i s used t o b u i l d two
cones on two c o r n e r s o f t h e pad ( F i g u r e 6.3). The cones a r e c o n t i n u o u s l y
e n l a r g e d u n t i l t h e y meet. A t t h i s p o i n t , a c o n t i n u o u s r i d g e of o r e e x i s t s on
t h e pad r u n n i n g f r o m s i d e t o s i d e a t t h e p r e f e r r e d l i f t h e i g h t , t y p i c a l l y 20
ft ( 6 m) ( F i g u r e 6.4). 'The s t a c k e r t h e n p l a c e s o r e on t h e pad i n a z i g - z a g g i n g
f a s h i o n , c o n t i n u o u s l y e n l a r g i n g t h e r i d g e t o f i l l t h e pad ( F i g u r e 6.5). P r o p e r
s t a c k e r o p e r a t i o n w i l l r e s u l t i n a f a i r l y smooth heap s u r f a c e . As t h e s t a c k e r
i s moved back ( i .e., as t h e o r e p i l e advances t o w a r d t h e s t a c k e r , F i g u r e 6.5),
s e c t i o n s o f " i n t e r m e d i a t e " c o n v e y o r s can be removed w i t h a minimum o f down
time.
 PRECIOUS METAL HEAP LEACHING PROJECTS

PLUQ-DUMPING
OVERLAPPlNQ MOUNDS

LINER
PERIMETER

PLAN V I E W

PLUG-DUMPED ORE

12' - 18' OF P R O T E C T I V E LINER

CROSS-SECTION

FIGURE 6.2

PLUG-DUMPINQ 'PLAN VIEW" SHOWS OVERLAPPING MOUNDS OF ORE,

WHILE 'CROSS-SECTION' SHOWS CONFlOURATlON WITH LINER PROTECTION.
 HEAP CONSTRUCTION AND SOLUTION APPLICATION 97

A v a r i a t i o n o f t h e conveyor s t a c k i n g system i s employed a t t h e F l o r i d a

Canyon P r o j e c t (Pegasus Go1 d C o r p o r a t i o n , o p e r a t o r ) near W i nnemucca, Nevada. A
conveyor system a t t h i s p r o j e c t t r a n s p o r t s crushed and a g g l o m e r a t e d o r e f r o m
t h e mine d i r e c t l y t o a s e m i c i r c u l a r l e a c h i n g pad. The c o n v e y o r system i s
c r a w l e r mounted and p i v o t s i n t h e c e n t e r o f t h e heap. A " t r i p p e r " , w h i c h
i n c l u d e s a s l e w i n g conveyor, t r a v e l s t h e l e n g t h o f t h e conveyor t o d i s c h a r g e
t h e o r e . The e n t i r e conveyor moves under i t s own power as t h e l e a d i n g edge o f
t h e p i l e advances. T h i s system has t h e advantage o f c o n t i n u o u s s t a c k i n g o f o r e
i n a c o n t r o l l e d f a s h i o n t o form a homogeneous heap.

The o r i g i n a l design o f t h e F l o r i d a Canyon conveyor s t a c k i n g system

c a l l e d f o r t h e s o l u t i o n a p p l i c a t i o n pipes and sprinklers t o be p u l l e d b e h i n d
t h e s t a c k e r . A l t h o u g h t h i s aspect o f t h e d e s i g n i s n o t c u r r e n t l y employed a t
F l o r i d a Canyon, i t does have p o t e n t i a l m e r i t f o r a p p l i c a t i o n a t o t h e r
p r o j e c t s . T h i s o r i g i n a l concept i s d e p i c t e d i n F i g u r e 6.6.

6.3 APPLICATION OF SOLUTION TO HEAPS

P r o p e r l y designed s o l u t i o n a p p l i c a t i o n t e c h n i q u e s p r o v i d e maximum
c o n t a c t between o r e s t a c k e d on t h e pad and t h e sodium c y a n i d e s o l u t i a n w h i c h
serves t o d i s s o l v e t h e g o l d and d e l i v e r i t t o t h e pregnant s o l u t i o n pond, When
a heap i s leached, a s o l u t i o n f l o w p a t t e r n develops t h r o u g h t h e heap;
i n e v i t a b l y some p o r t l o n s o f t h e o r e g e t l e s s exposure t o t h e c y a n l d e s o l u t i o n
than do o t h e r s . The p r o p e r c h o i c e o f an a p p l i c a t i o n system, a l o n g w i t h
adequate f l o w r a t e and system upkeep, can and w i l l m i n l m i z e s h o r t c i r c u i t i n g
and improper/uneven heap w e t t i n g .

I n f o r m a t i o n on r e q u i r e d r a t e o f s o l u t i o n a p p l i c a t i o n i s u s u a l l y o b t a i n e d
d u r i n g m e t a l l u r g i c a l t e s t i n g pragrams and then f u n n e l l e d i n t o t h e d e s i g n o f a
s p r i n k l i n g system f o r any g i v e n p r o j e c t . Unless t h e o r e p r e s e n t s d i f f i c u l t
p e r c o l a t i o n c o n d i t i o n s ( e g g , excessive f i n e s o r clays i n unagglomernted ares),
most g o l d / s i l v e r ores w l l l r e q u i r e between 0.002 and 0.01 g a l l a n s o f l e a c h n g
s o l u t i o n per s q ft o f heap s u r f a c e area p e r m i n u t e (0.001 t o 0.006 l / s e c / m ) . d
T h i s range has been found t o y i e l d optimum l e a c h i n g k i n e t i c s f o r m o s t p r e c i o u s
metals o r e s .

I n p r a c t i c e , s o l u t i o n appl i c a t i o n may be a c h i e v e d t h r o u g h s e v e r a l
d i f f e r e n t methods ( 1 ,e, , f l o o d i n g o r ponding, lgWobblers", " W i g g l e r s " , r e g u l a r
lawn s p r i n k l e r systems, and d r f p i r r i g a t i o n systems--whfch, f o r t h e purposes
o f t h i s d i s c u s s i o n a r e r e f e r r e d t o as p r e s s u r e e m i t t e r s ) , B r l e f m e n t i o n i s
made h e r e o f f l o o d i n g and w i g g l e r s a s s o l u t l o n app1 1ca t i o n t e c h n i q u e s ;
however, i t i s t h e Wobbler and Pressure E m i t t e r systems t h a t a r e m o s t commonly
~ s e d and most s u c c e s s f u l , and t h e r e f o r e t h e s e methods a r e d i s c u s s e d i n
g r e a t e s t d e t a i 1.

F l o o d i n g , a l t h o u g h n o t w i d e l y p r a c t i c e d , i s used a t t h e P i c a c h o Peak
Mine o f Chemgald, I n c , n e a r Yuma, Arizona. A l t h o u g h e v a p o r a t i o n l o s s e s a r e
high i n t h e d e s e r t c l i m a t e a t t h i s l o c a t i o n , even h i g h e r e v a p o r a t i v e l o s s e s
would o c c u r i f a f i n e s p r a y were t o be used i n a p p l y f n g t h e s o l u t i o n ;
t h e r e f o r e , f l o o d i n g i s an a p p r o p r i a t e application method a t t h i s p a r t i c u l a r
p r o j e c t . I n a d d i t i o n t o t h e e v a p o r a t i v e s c e n a r i o , o r e c h a r a c t e r i s t i c s must be
e v a l u a t e d i f f l o o d i n g i s t o be considered. F l o o d i n g can o n l y be used i f t h e
p e r m e a b i l i t y o f t h e heap i s low enough t o l i m i t i n f i l t r a t i o n . F l o o d i n g w i l l
 PRECIOUS METAL HEAP LEACHING PROJECTS

C O N E S O F ORE
PLACED ON
CORNER8 O F PAD

TELESCOPINQ
STACKER
INTERMEDIATE /
.SECTIONAL*
CONVEY ORB

AaaLOMERATlNa DRIVE
OR ORE H O P P E R

FIGURE 6.3
INITIAL STAQE OF CONVEYOR STACKINO.

ORE N O W F O R M S A
R l D Q E A C R O S S PAD

FIGURE 6.4
---

INTERMEDIATE STAOE OF CONVEYOR STACKINO.

 HEAP CONSTRUCTION AND SOLUTION APPLICATION 99

n o t work on a v e r y porous o r e because o f h i g h i n f i l t r a t i o n and t h e subsequent

r i s e i n t h e w a t e r l e v e l w i t h i n t h e heap. Heap i n s t a b i l i t i e s can be c r e a t e d
when t h i s happens.

Wigglers are s u r g i c a l tubes i n s e r t e d i n holes i n t h e a p p l i c a t i o n p i p e

network. Even d i s t r i b u t i o n o f s o l u t i o n i s t h e o r e t i c a l l y o b t a i n e d due t o t h e
random " w i g g l i n g " o f t h e t u b e s . I n a c t u a l a p p l i c a t i o n , t h e s e systems a r e n o t
w i d e l y used.

The Wobbler, m a r k e t e d by S e r ~ n i n g e r I r r i g a t i o n , I n c . o f Orlando, F l o r i d a ,

and r e f e r r e d t o as t h e Senninger Wobbler, i s an o f f - c e n t e r r o t a r y - a c t i o n
s p r i n k l e r w h i c h has found wide a p p l i c a t i o n i n t h e heap l e a c h i n g i n d u s t r y .
Because o f i t s o f f - c e n t e r r o t a r y a c t i o n , i t i s i m p o r t a n t t h a t t h e Wobbler be
s e c u r e l y mounted on s t e e l r i s e r s no h i g h e r t h a n 4 f t ( 1 m) above t h e ground
surface.

The Wobbl e r p r o v i d e s s o l u t i o n appl i c a t i o n i n f a i r l y 1a r g e drops, w h i c h

minimize evaporation. The Wobblers come i n d i f f e r e n t numbers d e s i g n a t i n g t h e
a p p l i c a t i o n r a t e s a t g i v e n p r e s s u r e s . Experience i n t h e f i e l d has shown t h a t
improved u n i f o r m i t y o f s o l u t i o n d i s t r i b u t i o n on t h e heaps i s b e s t a c h i e v e d b y
i n s t a l l i n g each Wobbler w i t h i t s own i n d i v i d u a l p r e s s u r e r e g u l a t o r .

P r e c i s e s o l u t i o n a p p l i c a t i o n r a t e s f o r i n d i v i d u a l p r o j e c t s can be s e t
t h r o u g h t h e s e l e c t i o n o f s p r i n k l e r p a t t e r n s and t y p e s , a l o n g w i t h t h e p r o p e r
o p e r a t i n g p r e s s u r e s and s p a c i o g . The s p r i n k l e r s s e l e c t e d s h o u l d g i v e a u n i f o r m
appl i c a t i o n r a t e w i t h i n t h e i r own o p e r a t i n g r a d i u s . F i g u r e 6.7 ( M i l 1 i g a n and
M i l l i g a n , 1987) shows t h e b a s i c concepts n e c e s s a r y t o a t t a i n t h e d e s i r e d f l o w
p a t t e r n s . I n o r d e r t o p o s i t i o n s p r i n k l e r s p r o p e r l y , i t i s necessary t o f i r s t
s t a r t w i t h s p r i n k l e r heads a t each c o r n e r o f t h e t o p o f t h e heap. Based on
t h i s i n i t i a l p o s i t i o n i n g , o t h e r s p r i n k l e r s can be p l a c e d a l o n g t h e p e r i m e t e r
( b u t s e t back from t h e p e r i m e t e r edge i n o r d e r t o a v o i d e x c e s s i v e edge
o v e r s p r a y i n g ) a t t h e d e s i r e d s p a c i n g t o p r o v i d e t h e predetermined o v e r 1 ap. The
m i d d l e o f t h e p a t t e r n i s t h e n f i l l e d i n t o a t t a i n f u l l coverage. A c e r t a i n
amount o f o v e r s p r a y i n g i s o f t e n done p a s t t h e t o p o f t h e heap t o enhance t h e
edge c o n t a c t w i t h t h e s o l u t i o n , due t o t h e f a c t t h a t heap edges a r e o f t e n a
problem a r e a w i t h r e g a r d t o e x t r a c t i o n r a t e s and adequate s o l u t i o n c o n t a c t .

P r e s s u r e e m i t t e r s can be equated w i t h a g r i c u l t u r a l d r i p i r r i g a t i o n
systems. The a c t u a l p r e s s u r e e m i t t e r mechanisms a r e t u r b u l e n t f l o w d e v i c e s
which a t t a c h i n - l i n e t o p r o v i d e even s o l u t i o n d i s t r i b u t i o n . F i g u r e 6.8
i l l u s t r a t e s e m i t t e r c o n s t r u c t i o n . P r e s s u r e e m i t t e r s work on t h e p r i n c i p l e t h a t
w a t e r d r o p l e t s work t h e i r way t h r o u g h a t o r t u o u s r o u t e , l o s i n g p r e s s u r e , and
d r i p o u t a t a f a i r l y slow r a t e . Lines w i t h i n s t a l l e d e m i t t e r s operates a t a
f a i r l y l o w p r e s s u r e ( t y p i c a l l y , 15-20 p s i g 100-140 kPa). Plan views and c r o s s
s e c t i o n s o f t y p i c a l 1 i n e c o n f i g u r a t i o n s used w i t h p r e s s u r e e m i t t e r s a r e shown
i n F i g u r e s 6.9, 6.10, and 6.11. L i n e s shown i n t h e s e f i g u r e s a r e o f t e n b u r i e d
i n t h e o r e t o a d e p t h o f a b o u t 8-10 i n c h e s (20-25 cm), a l t h o u g h s u r f a c e
i n s t a l l a t i o n o f e m i t t e r s i s a l s o p r a c t i c e d . F i g u r e s 6.12 and 6.13 i l l u s t r a t e
b o t h s u r f a c e and underground i n s t a l l a t i o n o f t h e p r e s s u r e e m i t t e r s . P r o b a b l y
t h e most s i g n i f i c a n t f a c t o r i n d e t e r m i n i n g whether t o b u r y e m i t t e r s o r n o t i s
t h e c l i m a t e o f t h e area i n q u e s t i o n . I n c l i m a t e s w i t h harsh w i n t e r c o n d i t i o n s ,
s e v e r a l e x t r a months o f o p e r a t i n g t i m e may be achieved by b u r y i n g t h e l i n e s .

The placement and number o f e m i t t e r s on a heap i s c a l c u l a t e d f r o m t h e

flow r a t e r e q u i r e d t o a c h i e v e t h e r a t e o f 0.005 gpm per sq f t (0.003 l / s e c / m 2 )
 PRECIOUS METAL HEAP LEACHING PROJECTS

STACKER Z I Q - Z A Q Q I M Q
P L A C I N Q O R E O N PAD 7

' T W O INTERMEDIATE
C O N V E Y O R 8 READY
FOR REMOVAL

FIGURE 6.5
FINAL STAGES OF CONVEYOR STACKING.
 HEAP CONSTRUCTION AND SOLUTION APPLICATION

CRAWLER MOUNTlD CONVPVOR/ST ACKER ARRANQEMBWT.

{From Flehco, 8pokane, Wa. lor Florlds Canyon Project)
 PRECIOUS METAL HEAP LEACHING PROJECTS

I U N I F O R M APPLlCATlON SPRINKLER 1

I
SPRINKLERS W I T H N O OVERLAP I

SPRINKLERS WITH OVERLAP 1

FIGURE 6 . 7
SPRINKLER APPLICATION
Cfrom M l l l l g r n ii M l l l l ~ l nl e e ? )
HEAP CONSTRUCTION AND SOLUTION APPLICATION

ENVELOPE

CORE

FIGURE 6.8

EMITTER CONSTRUCTION.
 PRECIOUS METAL HEAP LEACHING PROJECTS

HEAP O U T L I N E

--

EMITTER L I N E 8

FIQURE 6.0 - PLAN VIEW - TYPICAL INSTACLATlON

P V C HEADER PlPE

PVC
MAINLINE

EMITTER LINES

FIQURE 6 . 1 0 - CROSS-SECTION A-A'

P V C HEADER P l P E

PREQNANT

FlQURE 6 . 1 1 - CROSS-SECTION B-B'

 HEAP CONSTRUCTION AND SOLUTION APPLICATION

ORE BED

F I G U R E 6.1 2
EMITTER SURFACE INSTALLATION

O R E BED

FIGURE 6.1 3
EMITTERS COVERED WITH ORE
106 PRECIOUS METAL HEAP LEACHING PROJECTS

o f s u r f a c e a r e a . E m i t t e r s a r e t h e n spaced t o g i v e a u n i f o r m d i s t r i b u t i o n on
t h e s u r f a c e o f t h e heap.

The p r i m a r y advantage t o t h e u s e o f e m i t t e r s i s t h a t t h e system provides

c o n t i n u o u s d r i p p i n g w i t h a minimum o f d r o p impact, t h u s m i n i m i z i n g f i n e s
m i g r a t i o n and channel1 i n g . As a r e s u l t o f t h e c o n t i n u o u s d r i p p i n g , t h e o r e heap
i s w e t t e d l a t e r a l l y and v e r t i c a l l y b y c a p i l l a r y a c t i o n , a t r a t e s v e r y s i m i l a r
t o t h o s e produced by s p r a y n o z z l e s . A d d i t i o n a l advantages t o t h e use of
p r e s s u r e erni t t e r s in c l ude:

The a b i l i t y t o a l l o w w i n t e r o p e r a t i o n s ;
The r e d u c t i o n i n w a t e r e v a p o r a t i o n l o s s e s ; and
A r e d u c t i o n i n UV d e g r a d a t i o n .

These advantages a r e s i g n i f i c a n t when the factors identified above are

included i n the o v e r a l l cost equation.

The m a j o r p o t e n t i a l drawback t o t h e use o f e m i t t e r s i s t h a t c a l c i t e

f o r m a t i o n can o c c u r I n t h e s m a l l c h a n n e l s i n which t h e s o l u t i o n f l o w s before
e x i t i n g t h e heap. I t i s , t h e r e f o r e , i m p e r a t i v e t o m a i n t a i n a good s o l u t i o n
t r e a t m e n t / d e s c a l i n g system i n o p e r a t i o n ( r e f e r t o C h a p t e r 7).

The f i r s t m a j o r i n s t a l l a t i o n o f p r e s s u r e e m i t t e r s was a t t h e Rochester

Mine (Coeur d ' A l e n e M i n i n g Company) n e a r Lovelock, Nevada. The system, which
has been i n o p e r a t i o n f o r two y e a r s has proved v e r y s u c c e s s f u l , a l l o w i n g
minimum m a i n t e n a n c e t i m e and f u l l w i n t e r o p e r a t i o n . O v e r a l l , i t appears t h a t
p r e s s u r e e m i t t e r s may become t h e most used s o l u t i o n a p p l i c a t i o n system i n t h e
y e a r s t o come, due t o t h e s i g n i f i c a n t advantages p r e s e n t e d i n t h i s d i s c u s s i o n .

6.4 ACKNOWLEDGEMENTS

F i g u r e s 6.8 t h r o u g h 6.13 were used w i t h p e r m i s s i o n from Wade

M a n u f a c t u r i n g Company, Ore' Max Division, Fresno, Cal i f o r n i a . Their
c o o p e r a t i o n and a s s i s t a n c e i s g r a t e f u l l y acknowledged.

6.5 REFERENCES

Hickson, Robin J., J r . (1981) Heap l e a c h i n g p r a c t i c e s a t O r t i z Gold Mine,

Santa Fe County, New Mexico, i n I n t e r f a c i n g t e c h n o l o g i e s i n s o l u t i o n
m i n i n g , ed. W.J. S c h l i t t and ~ . ~ y ~ i s k eAIME,
y . New York, PP. 209-222.

Mi11 i g a n , J.A. and D.A. Mi1 1 i g a n (1987). Microcomputer programs for heap
l e a c h o p e r a t i o n s , MATCHES, Edmond, Oklahoma. 65 pp. p l u s appendix.