Properties governing the flow of solution through crushed ore for heap leaching: Part III – Low-permeability ores

Abstract

Heap leaching is used extensively for the processing of low-grade copper and gold ores. If the ore has low permeability, it may lead to underperformance or even project failure. Poor permeability is caused by a high fines content, resulting in a high steady-state moisture hold-up which causes the bed to operate close to saturation. The problem of low permeability can be addressed by either desliming (removal of the fines by wet screening), or by agglomeration (binding the fines together) with a cementitious binder. Fines removal by desliming is shown to reduce the steady-state moisture hold-up, resulting in the bed operating further away from saturation and increasing the maximum solution application rate. Agglomeration with Ordinary Portland Cement modified with additives resulted in fine particles binding together as lumps or coatings onto coarser rocks. These bonds were not destroyed after prolonged exposure to dilute sulphuric acid, due to the pozzolanic properties of the additives (e.g. fly ash), which cause cementitious Ca-bonds to be substituted with more stable Al- or Mg-bonds. Agglomeration with cementitious binder was also found to reduce slumping in leach column tests. This resulted in a higher bed porosity, higher limits on the solution application rate and higher copper dissolution rates. Agglomeration with modified cement may provide a novel, cost-effective method for the treatment of low-permeability ores in acid medium (e.g. copper, uranium and nickel), since cement agglomeration has only been applied commercially in alkali medium (e.g. cyanide solutions for gold ores) to date. Desliming is less attractive due to the high losses of the target metal to the fines.