A method and system for in-SITU recovery of metals

Abstract

The present disclosure relates to a method and a flow control device for in-situ recovery ('ISR') of metals from an orebody. The method comprises drilling at least one vertical parent well into a formation comprising the orebody, and subsequently, drilling a plurality of lateral wells for performing a blasting operation to create a fractured rock silo within the formation. Next, an ISR drilling operation is carried out within the fractured rock silo by drilling further wells, including injection and production wells. Carrying out an ISR process, where casing strings comprising the flow control device is run into the injection and production wells, where the casing strings within injection wells are for injecting a fluid into each ISR well to dissolve the metal therein, and subsequently collecting a pregnant solution, comprising the dissolved metal, from the orebody via the production well and the casing strings therein.

Description

A METHOD AND SYSTEM FOR IN-SITU RECOVERY OF METALSPRIORITY DOCUMENTS

[0001] The present application claims priority from Australian Provisional Patent Application No. 2024902113 titled “A METHOD AND SYSTEM FOR IN-SITU RECOVERY OF METALS” and filed on 9 July 2024, the content of which is hereby incorporated by reference in its entirety.TECHNICAL FIELD

[0002] The present disclosure relates to a method and a device for in-situ recovery of metals. In a particular form the present disclosure relates to a method and a flow control device, wherein the flow control device may be configured to inject a fluid to aid in the in-situ recovery of metals from an orebody.BACKGROUND

[0003] Conventional, open cut, and underground mining methods are often undesirable due to their large environmental footprint, need for processing of large volumes of material, and requirement for permanent infrastructure. Additionally, these methods often comprise several challenges when they are located close to existing communities and environmentally sensitive locations. Furthermore, these methods are also often not feasible for processing mineral deposits of declining grade, challenging mineralogy, or those that occur at increasingly greater depths.

[0004] In-Situ Recovery (ISR) is an in-place extraction method of metals from underground orebodies, that is also known as in-situ “leaching”, or solution mining. ISR involves dissolving a metal from the orebody using a lixiviant (a solution that contains components that assist the metal to dissolve and remain in solution), in a manner that permits the orebody to remain in place while the lixiviant is pumped through the ore and back to the surface for further processing. ISR is considered a modem and proven mining method that substantially lowers environmental footprint and requires little infrastructure when extracting minerals from a resource. ISR can be particularly advantageous when utilised for extraction of metallic constituents such as copper and gold from its ores at locations that may have been previously considered uneconomical to mine.

[0005] However, existing ISR methods comprise several technical challenges often relating to the use of lixiviants to extract metal(s) from deposits formed within “hard rock” formations that have poor porosity and permeability (which are usually those orebodies containing gold and copper) and ensuring that the lixiviant reaches the metals of interest and efficiently extracts the target metal(s).

[0006] It is against this background and the problems and difficulties associated therewith, that the present invention has been developed.SUMMARY

[0007] Embodiments of the present disclosure relate to a method for in-situ recovery (‘ISR’) of metals from an orebody. The method being particularly suitable for in-situ recovery of copper from an orebody in a hard-rock formation, and in those locations where conventional mining methods are undesirable or the prospect has been previously considered uneconomical to mine. The method comprises drilling at least one vertical parent well into a formation comprising the orebody, and subsequently, originating from the vertical parent well, a plurality of lateral wells are drilled for the purposes of performing a blasting operation to create a fractured rock silo within the formation. Next, an ISR drilling operation is carried out within the fractured rock silo by drilling several further wells comprising injection and production wells, wherein these ISR wells are located within or adjacent to the orebody. Further, an ISR process is carried out, where a casing string is run into the ISR wells, each casing string comprising at least one flow control device particularly configured for injecting a fluid into each ISR well to dissolve the metal (i.e. copper) therein via the injection wells, and subsequently collecting a pregnant solution, comprising the dissolved metal, from the orebody via the production well.

[0008] Additionally, embodiments of the present disclosure also relate to a flow control device that is particularly configured for injecting a fluid into ISR wells for the purposes of enhancing in-situ recovery of metals from an orebody. The flow control device comprising a tubular member that is disposed within a sleeve member, wherein, in use, the tubular member is rotatable within the sleeve member. The tubular member comprises one or more flow ports that correspond to one or more angled screens on the sleeve, wherein, in use, the tubular member is rotated within the sleeve to a first position where a first flow port aligns with a corresponding first angled screen to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member. In this way, the flow control device is capable of injecting or collecting a fluid that has been circulated through an orebody for the purposes of in-situ recovery of metals from therein, by controlling a fluid flow rate of the injected fluid via surface pumping equipment to advantageously minimise a pressure drop at an interface between each of the angled screens and its corresponding flow port.

[0009] According to a first aspect, there is provided a method for in-situ recovery of metals from an orebody, the method comprising: drilling at least one vertical well and a plurality of lateral wells originating from the at least one vertical well within a formation comprising the orebody; performing a blasting operation within the lateral wells to create a fractured rock silo; drilling at least one injection well and at least one production well within the fractured rock silo, wherein the injection and production wells are within or adjacent to the orebody; running a casing string comprising at least one flow control devicewithin each injection well, wherein the flow control devices are orientated to a first position to inject a fluid at a controlled fluid flow rate through the orebody to dissolve at least one metal therein, and subsequently collecting a solution containing the dissolved metal from the orebody via the production well.

[0010] In one embodiment, the fractured rock silo increases porosity and surface area of the orebody, such that the controlled fluid flow rate is optimised to maximise contact between the fluid and the orebody to dissolve the at least one metal therein.

[0011] In one embodiment, the blasting operation, the fluid, and the controlled fluid flow rate are selected to maximise pore volume exchanges as the fluid is injected through the orebody to dissolve the at least one metal therein.

[0012] In one embodiment, the fluid is selected based on the properties of the formation and the orebody to enhance permeability and alleviate passivation issues with the recovery of metals from the orebody.

[0013] In one embodiment, the controlled fluid flow rate is a pulsed injection rate that injects the fluid through the orebody to dissolve the at least one metal therein. In this embodiment, the pulsed injection rate is created by sequential changes in the controlled fluid flow rate via surface pumps, that create engineering-induced flow fluctuations, resulting in improved fluid coverage and improved fluid contact with the one or more metals within the orebody.

[0014] In one embodiment, the pulsed injection rate of the fluid maximises contact between the fluid and the orebody to dissolve the at least one metal therein.

[0015] In one embodiment, the controlled fluid flow rate optimises a residence time of the fluid within the orebody.

[0016] In one embodiment, the fluid comprises a first fluid and a second fluid, wherein the first fluid is a chemical leaching solution and the second fluid is a bacterial leaching solution, wherein, in use, the first and second fluids are sequentially injected through the orebody to enhance permeability and alleviate passivation issues with the recovery of metals from the orebody.

[0017] In one embodiment, the fluid is a lixiviant that is used for recovering copper from the orebody.

[0018] In one embodiment, the method further repeats a step of orientating the fluid control device to subsequent positions to inject the fluid at a controlled fluid flow rate through subsequent sections of theorebody to dissolve at least one metal therein, and subsequently collecting a solution containing the dissolved metal from the orebody via the production well.

[0019] In one embodiment, each flow control device comprises: a tubular member disposed within a sleeve member, wherein the tubular member is rotatable within the sleeve member; the tubular member comprising one or more flow ports and one or more corresponding sealing elements, wherein each flow port is positioned along a vertical axis of the tubular member and are each offset from one another along a horizontal axis of the tubular member; the sleeve member comprising one or more angled screens, wherein each angled screen is positioned along a vertical axis of the sleeve member and each corresponding to an associated flow port; wherein, in use, the tubular member is rotated to the first position to align a first flow port with a corresponding first angled screen to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member.

[0020] In one embodiment, the angle of the screens is selected based on the controlled fluid flow rate to minimise a pressure drop at an interface between each angled screen and its corresponding flow port.

[0021] In one embodiment, the combination of the angled screens and the controlled fluid flow rate minimise precipitation of gangue minerals at the interface between each angled screen and its corresponding flow port.

[0022] In one embodiment, the flow control devices utilise at least one sealing element to restrict flow of the injected fluid to the first position of the flow control device.

[0023] In one embodiment, a casing string comprising at least one flow control device is run within each of the production wells. In this embodiment, the fluid control devices within the production wells are orientated to collect the solution containing the dissolved metal from the orebody.

[0024] In one embodiment, the blasting operation within the lateral wells is performed by introducing an explosive into one or more of the lateral wells and detonating the explosive to create the fractured rock silo.

[0025] In one embodiment, the detonating of the explosive creates a shock wave through formation and the orebody therein to create fractures and the fractured rock silo.

[0026] In one embodiment, the blasting operation creates fractures within the formation to increase fluid flow throughout the fractured rock silo.

[0027] In one embodiment, the blasting operation increases the pore volume within the formation and orebody to aid in the recovery of metals.

[0028] In one embodiment, the injection and production wells are in fluid communication with each other.

[0029] In one embodiment, the solution containing the dissolved metal from the orebody is collected via the production well and is processed at a surface location.

[0030] In one embodiment, the method further includes, after creating the fractured rock silo, injecting a grout or cement barrier within the wells to secure the fractured rock silo from collapse.

[0031] According to a second aspect, there is provided a flow control device for in-situ recovery of metals from an orebody, the device comprising: a tubular member disposed within a sleeve member, wherein the tubular member is rotatable within the sleeve member; the tubular member comprising one or more flow ports and one or more corresponding sealing elements, wherein each flow port is positioned along a vertical axis of the tubular member and are each offset from one another along a horizontal axis of the tubular member; the sleeve member comprising one or more angled screens, wherein each angled screen is positioned along a vertical axis of the sleeve member and each corresponding to an associated flow port; wherein, in use, the tubular member is rotated to a first position to align a first flow port with a corresponding first angled screen to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member.

[0032] In one embodiment, the sealing elements are packing elements that restrict flow between a flow port and its corresponding angled screen.

[0033] In one embodiment, the angle of the screens is selected based on a controlled fluid flow rate to minimise a pressure drop at an interface between each angled screen and its corresponding flow port.

[0034] In one embodiment, each flow port comprises a corresponding upper and lower sealing element.

[0035] In one embodiment, the sleeve member further comprises an upper and lower thread that enables several sleeve members to be connected in series.

[0036] In one embodiment, the tubular member further comprises an upper and lower thread that enables several tubular members to be connected in series.

[0037] In one embodiment, the upper thread enables the tubular member to be connected to other tubulars that enable the tubular member to be rotated within the sleeve member.

[0038] In one embodiment, in use, subsequent rotations of the tubular member within the sleeve member are subsequent positions that align subsequent flow ports with corresponding angled screens to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member.

[0039] According to a further aspect, there is provided a method for in-situ recovery of metals from an orebody, the method comprising: forming at least one vertical well and a plurality of lateral wells originating from the at least one vertical well within a formation comprising the orebody; performing a blasting operation within the lateral wells to create a fractured rock silo; forming at least one injection well and at least one production well within the fractured rock silo, wherein the injection and production wells are within or adjacent to the orebody; running a casing string comprising at least one flow control device within each injection well, wherein the flow control devices are orientated to a first position to inject a fluid at a controlled fluid flow rate through the orebody to dissolve at least one metal therein, and subsequently collecting a solution containing the dissolved metal from the orebody via the production well.BRIEF DESCRIPTION OF DRAWINGS

[0040] Embodiments of the present disclosure will be discussed with reference to the accompanying drawings wherein:

[0041] Figure 1 is a perspective view of a flow control device according to an embodiment;

[0042] Figure 2 is a side view of the flow control device of Figure 1;

[0043] Figure 3 is a side sectional view of the flow control device of Figure 2 along lines A-A;

[0044] Figure 4 is a perspective view of a tubular member of the flow control device of the previous Figures;

[0045] Figure 5 is an alternative perspective view of the tubular member of Figure 4;

[0046] Figure 6 is another perspective view of the tubular member, wherein the tubular member comprises inflated or activated sealing elements or packers;

[0047] Figure 7 is a side view of the tubular member of Figures 4 and 5;

[0048] Figure 8 is a side sectional view of the tubular member of Figure 7 along lines A-A;

[0049] Figure 9 is a perspective view of a sleeve member of the flow control device of Figures 1 to 3;

[0050] Figure 10 is a side view of the sleeve member of Figure 9;

[0051] Figure 11 is a side sectional view of the sleeve member of Figure 10 along lines A-A;

[0052] Figure 12 is a perspective view of the flow control device of Figures 1 to 3, wherein the internal parts of the device are illustrated in cut-away form;

[0053] Figure 13 is a perspective view of the flow control device of Figure 12, wherein a directional arrow is illustrated to represent a direction the tubular member of the flow control device may be rotated when in use;

[0054] Figure 14 is a sectional view of the flow control device of any one of Figures 1 to 3, 12 and 13, wherein directional arrows are illustrated to represent a flow path of a fluid when the device is in a first position to inject the fluid;

[0055] Figure 15 is a sectional view of the flow control device of any one of Figures 1 to 3, 12 and 13, wherein directional arrows are illustrated to represent a flow path of a fluid when the device is in a second position to inject the fluid;

[0056] Figure 16 is a diagrammatic sectional view of a pair of flow control devices, wherein a first flow control device is utilised within an injection well to inject a fluid through an orebody and a second flow control device is utilised within a production well to receive a solution comprising the fluid and at least one metal dissolved therein, directional arrows are illustrated to represent fluid flow;

[0057] Figure 17A is a top view of an embodiment of the flow control device, wherein a directional arrow represents a direction of the tubular member of the flow control device rotated when in use;

[0058] Figure 17B is an alternate top view of the flow control device, following that of Figure 17A, wherein a directional arrow represents a direction of the tubular member of the flow control device rotated when in use;

[0059] Figure 17C is a further alternate top view of the flow control device, following that of Figure 17B, illustrating a configuration of the flow control device wherein a flow port of the tubular member is in alignment with a corresponding angled slot of the sleeve member;

[0060] Figure 18A is a schematic view of a method for in-situ recovery of metals from an orebody, illustrating a step of drilling a vertical well within a formation;

[0061] Figure 18B is a subsequent schematic view for the next step in the method, illustrating drilling of two lateral wells from the vertical well;

[0062] Figure 18C is a subsequent schematic view for the next step in the method, illustrating drilling of further lateral wells from the vertical well;

[0063] Figure 18D is a subsequent schematic view for the next step in the method, illustrating drilling a fractured formation resultant of performing a blasting operation within the lateral wells;

[0064] Figure 18E is a subsequent schematic view for the next step in the method, illustrating the drilling of several in-situ recovery (‘ISR’) wells comprising injection and production wells within the fractured formation;

[0065] Figure 18F is a subsequent schematic view for the next step in the method, illustrating the use of a pair of ISR injection wells and a central ISR production well to recover metal from the orebody located within the fractured formation, wherein directional arrows represent a direction of fluid flow; and

[0066] Figure 18G is a final schematic view for the next step in the method, illustrating that subsequent sections of the fractured rock silo is effectively mined via the ISR method by repetition of steps within the method for each successive section of an orebody from which at least one metal is to be recovered from.

[0067] In the following description, like reference characters designate like or corresponding parts throughout the figures.DESCRIPTION OF EMBODIMENTS

[0068] Referring to any one of the Figures, there is disclosed a method and a flow control device for in- situ recovery (herein after interchangeably referred to as ‘ISR’) of metals from an orebody. The disclosed method and flow control device being particularly suitable for ISR of copper from an orebody in a hard- rock formation, and in those locations where conventional mining methods may be considered undesirable or that the prospect has been previously considered uneconomical to mine. The disclosure has a focus on improving metal recovery from these hard-rock formations, and converting once uneconomical prospects into economic ones while minimising environmental footprint further than previously known ISR methods.

[0069] In an embodiment, the present disclosure relates to a method for in-situ recovery of metals from an orebody (100). The method comprising several steps, initially the method involves drilling a vertical ‘parent’ well (20) into a formation (110) comprising the orebody (100). Subsequently, originating fromthe vertical well (20), drilling a plurality of lateral ‘child’ wells (30) for the purposes of performing a blasting operation to create a fractured rock environment (120) within the formation (110). Next, an ISR drilling operation is carried out within the fractured rock environment (120), which comprises the drilling of several further wells comprising both injection and production (or extraction) wells. These ISR wells are located within or adjacent to the orebody (100) residing within the fractured rock environment (120). As a next step within the method, an ISR process is carried out, where a casing string is run into the ISR wells, each of these casing strings comprising at least one flow control device (10), where the flow control device (10) is configured for injecting a fluid into each of the ISR wells to dissolve the metal therein via the injection wells. After this injection, a pregnant solution containing the dissolved material is collected from the orebody (100) via the production wells.

[0070] It will be appreciated that, although references within the present disclosure are made to the wells being ‘drilled’, these wells could also be ‘formed’ via other methods such as being ‘excavating’ or ‘digging’.

[0071] It will also be appreciated that, although references within the present disclosure are made to the ISR wells being located ‘within or adjacent to’ the orebody (100), these ISR wells may be located at any location within the fractured rock environment (120), i.e. within the formation (110), such as also being ‘proximal to’ the orebody (100), so that the ISR wells are usable for the ISR process to be carried out.

[0072] Additionally, in another embodiment, the present disclosure also relates to a flow control device (10) that is particularly configured for injecting a fluid into ISR wells for the purposes of enhancing in- situ recovery of metals from the orebody (100). The flow control device (10) comprising a tubular member (11) that is disposed within a sleeve member (12). In use, the tubular member (11) is rotatable within the sleeve member (12). The tubular member (11) comprises one or more flow ports (13) that correspond to one or more angled screens (14) that are on the sleeve member (12). In use, when the tubular member (11) is rotated within the sleeve member (12), to a first position, a first flow port (13) aligns with a corresponding first angled screen (14), so as to provide fluid communication between an interior (15) of the tubular member (11) and an exterior of the sleeve member (12). In this way, the flow control device (10) is capable of injecting or collecting a fluid that has been circulated through the orebody (100) for the purposes of in-situ recovery of metals from therein. That is, by controlling a fluid flow rate of the injected fluid, via surface pumping equipment, to advantageously minimise a pressure drop at an interface between each of the angled screens (14) and its corresponding flow port (13). The fluid control device (10) comprises subsequent positions, following the first position, where subsequent flow ports (13), such as a second flow port (13), aligns with subsequent corresponding angled screens(14), such as a second angled screen (14), to thereby enable fluid communication between the interior(15) of the tubular member (11) and the exterior of the sleeve member (12). These subsequent positions are available when the fluid control device (10) is in use, and the tubular member (11) is rotated withinthe sleeve member (12). As illustrated in the Figures, in these subsequent positions, flow ports (13), and angled screens (14) extend along a length of the fluid control device (10).

[0073] The in-situ recovery (ISR) references within this disclosure refer to the recovery of metals (for example, copper and gold) by dissolving the metal (may also be considered a commodity or a prospect), within the orebody, in place (hence, ‘in-situ’), and then subsequently extracting the dissolved metal using a system of injection and extraction wells. Typically, ISR accelerates a process that is naturally occurring within a formation, and this proven technology has been used in various mining industries to recover metals in a closed loop system using minimal infrastructure when compared to more conventional mining methods. It will become apparent to those skilled in the art that the present disclosure, containing a method and a flow control device (10), is an advantageous improvement on this existing technology, that also extends the application of this existing technology to further overcome several technical challenges of existing technology, while enhancing the recovery of metals from hard-rock formations that have poor porosity and permeability.

[0074] The created fractured rock environment (120), referenced in this disclosure, may interchangeably be considered a fractured rock ‘silo’ (120), as it is a created region within the formation (110) where the orebody (100) of interest resides. In a further alternative, the fractured rock environment (120) could simply be considered a created fractured rock formation (120). Further alternate terms could be interchangeably utilised to describe this, however those skilled in the art will appreciate that fractured rock environment (120) is a designed, or modelled, fractured underground rock, within the formation (110) that comprises the orebody (100) of interest resides. The extent, or size, of the fractured rock silo (120) will be determined by those skilled in the art based on data and experience of mining, or geology, in a location that the target fractured rock silo (120) resides.

[0075] The following passages discuss various embodiments of the method and flow control device of the present disclosure in further detail.

[0076] Referring now to Figures 18A to 18G, in one embodiment, an exemplary method for in-situ recovery of metals from an orebody (100) may comprise the steps of: a) drilling at least one vertical well (20) and a plurality of lateral wells (30) originating from the at least one vertical well (20), where the wells (20, 30) are drilled within a formation (110) comprising the orebody (100); b) performing a blasting operation within the lateral wells (30) to create a fractured rock silo (120);c) drilling at least one injection well (40) and at least one production well (50) within the fractured rock silo (120), wherein the injection (40) and production (50) wells are within or adjacent to the orebody (100); d) running a casing string comprising at least one flow control device (10) within each injection well (40), wherein the flow control devices (10) are orientated to a first position to inject a fluid at a controlled fluid flow rate through the orebody (100) to dissolve at least one metal therein, and subsequently collecting a solution containing the dissolved metal from the orebody (100) via the production well.

[0077] The at least one vertical well in the above method may be considered a ‘parent’ vertical well, and the plurality of lateral wells originating therefrom may be considered ‘child’ lateral wells that extend from the ‘parent’ vertical well. It will be appreciated that, although referred to as ‘vertical’, the vertical well may be near vertical, or closer to vertical than to lateral or horizontal. It will also be appreciated that, when reference is made to ‘lateral’ for the lateral wells, these wells are not ‘vertical’, and that they are wells that are drilled or constructed horizontally or at an angle away from the originating ‘vertical’ parent well.

[0078] The plurality of lateral wells may be considered a ‘network’ or ‘array’ of lateral wells that extend and originate from the vertical well, as best illustrated by Figure 18C. The plurality of lateral wells extending and originating from the vertical well may also be considered multilateral wells, that may comprise various configurations commonly utilised in oil, gas, and mining industries.

[0079] In the above method, in one embodiment, at step a) which corresponds to the illustrations in Figures 18A to 18C consecutively, the at least one vertical well (20) may be a large diameter hole, up to one meter in diameter, is drilled through the formation (110) comprising the orebody (100) of interest. The vertical well (20) may be drilled using conventional vertical hole drilling methods such as Reverse Circulation (‘RC’) drilling techniques. RC drilling techniques may employ equipment such as ‘Jumbo’ drilling units commonly utilised in the mining industry. The vertical well (20) may also be drilled using a drilling rig, such as one commonly utilised in oil and gas drilling operations. The vertical well (20) may also be drilled using a coiled tubing drilling unit, and appropriately associated drilling techniques. It will be appreciated that other vertical, or near vertical, well drilling techniques are envisaged, beyond those disclosed herein.

[0080] The vertical well (20) facilitates the subsequent drilling of the plurality of lateral wells (30) that originate therefrom. Once the vertical well (20) is drilled, the well (20) may be re-entered with appropriate drilling equipment to subsequently drill the lateral wells (30) extending and originating from the vertical well (20). In one example, each of the lateral wells (30) are drilled in succession, originating from the ‘parent’ vertical well (20), using drilling equipment such as Vertical to horizontal (‘V2H’)drilling methods to drill the angled, or near horizontal, or horizontal, lateral wells (30). In another example, each of the lateral wells (30) may be drilled in succession, using a drilling rig and directional drilling equipment commonly utilised in oil and gas operations. In another example, each of the lateral wells (30) may be drilled in succession using a coiled tubing drilling unit, and appropriately associated drilling techniques. It will be appreciated that other, lateral, horizontal, or directional drilling techniques are envisaged, beyond those disclosed herein. This is best illustrated in Figures 18B and 18C, where successive lateral wells (30) are drilled from the vertical well (20), to create a ‘network’ or ‘array’ of lateral wells (20) that are splayed, or distributed, around the central vertical well (20).

[0081] In addition to the above, those skilled in the art will understand that the vertical (20) and lateral (30) wells may be drilled utilising the same drilling unit, system or technique. For example, in the instance that a drilling rig or coiled tubing drilling unit is utilised to drill the wells (20, 30), the same rig or unit may be used to drill all the wells (20, 30), either in a single trip, such as with a directional drilling bottom hole assembly commonly utilised in the oil and gas assembly, or the wells (20, 30) may be drilled in separate trips by drilling each well in succession based on depth and geological condition limitations.

[0082] The vertical (20) and lateral (30) wells may be drilled to depths, or lengths depending on orientation of the wells (20, 30), based on the formation (110) within which the orebody (100) resides. That is, during a design phase, or planning phase, of the wells (20, 30), considering the target orebody (100), and the planned injection (40) and production (50) wells, the depths, lengths, and orientations of each vertical (20) and lateral (30) well may be decided. It will be appreciated by those skilled in the art that there are various ways in which these wells (20, 30, 40, 50) could be designed, planned, and executed, based on the target orebody (100), the formation (110), and other external environmental factors (such as geology, location of wells to existing infrastructure, etc.).

[0083] The number of drilled vertical (20) and lateral (30) wells, within the formation comprising the orebody (100), may be determined by expected rock fracture rate and estimated, or calculated porosity of the formation and the orebody. The wells (20, 30) may be designed, or planned, such that they are drilled at differing relative levels to create a horizontal, radial array of wells (30) that encompass an area, such as formation (110) within the Figures, that is considered the ‘mining area’ comprising the orebody (100) of interest / being the target of the method.

[0084] At step b) of the method, best illustrated by Figure 18D, the blasting operation is carried out within the network, or array, of wells (20, 30) illustrated in prior Figure 18C. In one embodiment, each of the lateral wells (30) may be considered ‘blast holes’, or ‘blast wells’, and within these wells (30) a charge, or explosive, may be set (or introduced) and subsequently detonated to carry out the blasting operation, so as to create the fractured rock silo (120) as illustrated in Figure 18D. This blasting operation may be considered a ’localised’ blasting operation, where down hole, or subsurface, charges or explosivesare set within one or more of the lateral wells (30) to create openings, or fractures, that create the fractured rock silo (120). It will be appreciated that the charges or explosives utilised at this step, within the lateral wells (30), to create the fractured rock silo (120) may be any one of those conventionally used in the mining industry. It will also be appreciated that these charges or explosives, may alternatively be other down hole fracturing methods, such as hydraulic fracturing, as one example only, so as the desired fractured rock silo (120) is created within the formation (110) comprising the orebody (100).

[0085] In one embodiment, the charges or explosives utilised within the lateral wells (30) are detonated to create a shock wave through the formation (110) and the orebody (100) therein to create fractures and the fractured rock silo (120). An advantage of this step b), by performing the blasting operation, is to create fractures within the formation (110) to increase fluid flow throughout the fractured rock silo (120), for the in-situ recovery of metals from the orebody (100). It will be appreciated that the fractured rock silo (120) is created so as to increase fluid access points, porosity, permeability, and pore volume of the formation (110) and / or the orebody (100) therein to aid in the recovery of metals. Those skilled in the art will appreciate that by creating the fractured rock silo (120), the formation (110) comprising the orebody (100) both have their respective surface areas increased, due to fragmentation of the formation and orebody by the blasting operation, which advantageously increases the porosity (and permeability), such that in subsequent steps of the method, the fragmented / fractured rock silo with increased surface area maximises the available contact area of the orebody, to optimise and / or maximise the ability of the injected fluid to dissolve the at least one metal within the orebody (100) to be recovered.

[0086] The blasting operation at step b) of the method may be considered as a ‘block caving technique’ as known for fracturing rock in mining operations. In this embodiment, where step b) involves the use of ‘block caving’, the formation (110) comprising the orebody (100) is undermined to allow it to collapse under its own weight into a series of chambers, or fractures, from which the one or more metals within the orebody (100) may be subsequently extracted via the subsequent steps in the method. It will be appreciated that other alternate methods or techniques are envisaged at this blasting operation step b) of the method, beyond those that are discussed herein. It will be understood that one of the purposes of step b) of the method is to create the fractured rock silo (120), and that there may be several methods or techniques that could be substituted, or used, in the blasting operation to create this.

[0087] In one embodiment, where a conventional drilling rig, or a coiled tubing drilling unit, is utilised within the method, the blasting operation at step b) may be a hydraulic fracturing operation that is carried out within one or more of the lateral wells (30) to create the fractured rock silo (120).

[0088] Optionally, in one embodiment between steps b) and c) of the method, additional wells, not illustrated, may be drilled to inject a grout barrier, or a cement barrier, within the fractured rock silo (120) to secure and contain the silo (120), and the wells (20, 30) therein, and contain this area that willultimately be ‘mined’ via in-situ recovery of metals from the orebody (100). It will be appreciated that this optional step, being between steps b) and c), may be required in those instances where the formation (110), the drilled wells (20, 30), and / or the orebody (100) require additional barriers (such as cement or grout) to aid in securing and containing the area from within the formation (110) that is to be mined. It will also be appreciated that this optional step may be strategically utilised to create ‘zones’ (not illustrated) within the fractured rock silo (120) to aid in subsequent steps of the method where the metal is extracted from the orebody (100).

[0089] At step c) of the method, which is best illustrated by Figure 18E, once the fractured rock silo (120) is created, at least one injection well (40) and at least one production well (50) are drilled within the fractured rock silo (120). In the illustration, one central injection well (40) and a plurality of surrounding production wells (50) are shown within the fractured rock silo (120), however, it will be understood that this is for illustrative and exemplary purposes only, and that any arrangement of wells (40, 50) are envisaged to be drilled within the fractured rock silo (120) so as to optimise proximity to and planned recovery of metals from the orebody (100).

[0090] It will be appreciated that the injection (40) and production (50) wells are drilled using methods as previously discussed for drilling the vertical and lateral wells (20, 30). That is, the injection and production wells (40, 50) may be drilled using RC drilling techniques, conventional drilling techniques with a drilling rig, or a coiled tubing drilling unit. It will also be appreciated that typically the same drilling method will be utilised for all the wells (20, 30, 40, 50) so as to optimise time spent in setting up (or rigging up) equipment for the drilling operation and minimise operational costs of utilising several different drilling techniques / methods. It will also be appreciated that, in some examples, alternate drilling methods may be utilised for certain wells (20, 30, 40, 50) so as to minimise certain drilling risks that may be associated with a particular geology, or subsurface environment, of the formation (110) comprising the orebody (100). Such as, for example, an RC drilling method may be utilised to drill the vertical, or near vertical, wells (20, 40, 50), and a coiled tubing drilling unit utilising a directional drilling bottom hole assembly is utilised to drill the lateral, horizontal, or deviated wells (30). Those skilled in the art will appreciate that other drilling techniques are envisaged for drilling any of the wells (20, 30, 40, 50) beyond those disclosed herein, and will typically be selected based on several factors such as economics of a mining project, and geological or subsurface factors.

[0091] In one embodiment, the injection (40) and production (50) wells may be drilled using a ‘casing while drilling’ or ‘casing advance’ technique. In these embodiments, where these techniques are employed, a casing string, that will ultimately be set within the wells (40, 50), is run into the wells in the same operational step as the wells (40, 50) being drilled. Typically, these techniques employ an inner drill string and an outer casing string, where the entire string enables wells to be drilled and cased in a single operational step. This is particularly advantageous for being economic in terms of saving operational timeand increases efficiency of completing / drilling the wells (40, 50) in a single step that would otherwise have taken two steps to initially drill, and then case. In these embodiments, the flow control device (10) that is utilised in subsequent steps, may be run such that an inner drill string (not illustrated) of these drilling techniques may be connected to the tubular member (11) of the flow control device (10) and the outer casing string (not illustrated) may be connected to the sleeve member (12) of the flow control device (10). In this way, manipulation / rotation / orientation of the inner drill string results in the same of the tubular member (11), and manipulation / rotation / orientation of the outer casing string results in the same of the sleeve member (12).

[0092] In one embodiment, during the drilling of the injection (40) and production (50) wells through the fractured rock silo (120), sampling may occur at various intervals during the drilling operation to determine mineable level within the fractured rock silo (120). That is, during the drilling of these wells (40, 50), data is collected, via sampling, to determine the geology of the formation (110) and other downhole properties of the subsurface, and ultimately the desired target orebody (100) that will be mined via the in situ recovery method in subsequent steps. Additionally, in one embodiment, during this sampling process while drilling, groundwater samples may be taken for bacterial, or biological, analysis if, in subsequent steps of the method, ‘bio leaching’ may be necessary to aid in the in-situ recovery of metals from the orebody (100). Further, the sampling process may aid in design, formulation, and selection of the fluid that is subsequently injected via the injection wells (40) to dissolve the one or more metals from the orebody (100) in the following steps of the method.

[0093] In one embodiment, where the injection (40) and production (50) wells are drilled using the ‘casing while drilling’ or ‘casing advance’ techniques, once the mineable level or target orebody (100) within the fractured rock silo (120) is identified during the sampling process, the angled screens (14) of the flow control device (10) that is run with these drilling techniques may be ‘positioned’ or ‘located’ within the wells (40, 50), such that these screens (14) are in alignment with mineable levels (or mineable sections) of the fractured rock silo (120), so that during subsequent steps of the method the flow control devices (10) within the wells (40, 50) are orientated to desired positions and inject the fluid that will ultimately dissolve the one or more metals within the orebody (100) for in situ recovery.

[0094] In one embodiment, one or more of the injection (40) and production (50) wells may be ‘monitoring’ wells. Where, in use, these monitoring wells are utilised to monitor down hole conditions, or subsurface conditions, within the formation (110) and orebody (100) therein as required during steps or operations in the disclosed method. For example, the monitoring wells may be utilised to install down hole monitoring equipment that is capable of providing baseline data within the formation (110), and detect flows of fluids throughout the formation (110) and orebody (100) during subsequent method steps. Advantageously, the use of one or more monitoring wells may be utilised to detect if fluid flow, includingfluid flow that comprises dissolved metals, may potentially be leaking, or lost, to the formation (110) to undesirable regions within the subsurface such as bodies of water.

[0095] It will be understood by those skilled in the art that, the injection (40) and production (50) wells are positioned within the fractured rock silo (120) such that they are in fluid communication with each other. That is, if a fluid is injected via one or more of the injection wells (40), that injected fluid may be able to flow through the fractured rock silo (120) to be received / captured / extracted by the production well (50), due to the natural porosity and permeability of the formation (110) and the orebody (100), and also due to the enhanced / improved / modified porosity and permeability of the fractured rock silo (120) and the orebody (100). It will be understood that it is due to this fluid communication between these wells (40, 50), that may be either inherent within the original formation (110) and / or enhanced / improved / modified within the fractured rock silo (120), that the injected fluid in the subsequent steps of the method is able to flow at a controlled fluid flow rate to dissolve and extract one or more metals from the orebody.

[0096] At step d) of the method, in one embodiment, the casing string (not illustrated) comprising at least one flow control device (10) may be run within each injection well (40). In another embodiment, a casing string (not illustrated) comprising at least one flow control device (10) may also be run within the or each production well (50). Within the wells (40, 50), the, or each flow control devices (10) are orientated to a first position, such that the fluid is injected in a desired direction, at a controlled fluid flow rate, through the orebody (100). This is particularly advantageous, as the, or each flow control device (10) is capable of efficient delivery of the fluid to the desired area within the formation (110), which is likely within the region of the orebody (100) therein, to avoid erroneously injecting the fluid to an undesirable section of the formation, and also to maximise delivery of the fluid to the desired area while ultimately maximising the contact between the fluid and the metal contained within the orebody (100), thereby optimally dissolving the metal from the orebody (100). Subsequently, the dissolved metal from the orebody (100) is extracted from the formation (110) via the production well (50).

[0097] One exemplary illustration of step d) is provided in Figure 18F, where two injection wells (40) and one production well (50) are illustrated within a fractured rock silo (120) of the formation (110). Within this Figure, although not illustrated, each of the wells (40, 50) comprise the flow control device (10), each orientated to a first position so as to direct flow of the fluid through a first mining section (130a). That is, in this example, the flow control devices (10) within each well (40, 50) is orientated such that the fluid flows in the direction of the illustrated arrows within Figure 18F, such that the injection wells (40) inject the fluid into the first mining section (130a), may also be considered a minable level, which comprises or is adjacent to the orebody (100), and subsequently the fluid, now comprising the solution comprising the fluid and the dissolved metal from the orebody (100), at least partially within or adjacent to the mining section (130a), is collected, or extracted / produced, via the production well (50) that may comprise a correspondingly orientated flow control device (10). It will be appreciated that theproduction well (50) may or may not comprise a flow control device (10), as in the case of this example, it is merely operating as a conduit for collecting / extracting / producing the solution comprising the fluid and the dissolved metal therein. It will be understood by those skilled in the art that the requirement of flow control devices (10) within wells (40, 50) will be contingent upon the designed, or modelled, fractured underground rock, within the formation (120) that comprises the orebody (100) of interest.

[0098] Subsequent to mining the first section (130a) as above, with reference to Figure 18G, the flow control devices (10) may subsequently be orientated to a second position so as to direct flow of the fluid through a second mining section (130b), or second mineable level. The flow control devices (10) may further be orientated to subsequent positions (e.g. third, fourth, fifth, etc.) so as to direct flow of the fluid through subsequent mining sections (130c, 130d, 130e, etc.), or mineable levels. In this embodiment, the method may comprise repeats of steps that orientate the flow control device (10) to subsequent positions, by rotating the tubular member (11) within sleeve members (12) to inject the fluid into subsequent mining sections / mineable levels, which are adjacent to, or proximal to, the orebody (100) to dissolve at least one metal therein, and in subsequent steps collect the solution containing the dissolved metal from the orebody (100) via the one or more production wells (50).

[0099] It will be appreciated that the number of mining sections (130a to 130e, for example) may be determined during the drilling of the wells (40, 50), when data or sampling techniques were performed. It will also be understood that knowledge of the formation (110) and the orebody (100) therein will aid in determining the number of mining sections (130a to 130e, for example). It will further be understood that the number of flow ports (13) and angled screens (14) of the flow control devices (10) utilised within the wells (40, 50) may be selected based on the data or sampling techniques performed.

[0100] It will be appreciated that the illustration of step d) in Figures 18F and 18G is exemplary only, and that other, alternate, arrangements of injection (40) and production (50) wells within the fractured rock silo (120) are envisaged, such as, but not limited to, number of wells (40, 50), placement of wells (40, 50) within the silo (120), etc.

[0101] The, or each, flow control device (10) may be orientated via several means located at the surface. In one example, where the casing string comprising the flow control device is run into the wells (40, 50) utilising drill pipe, or other pipe work, from the surface, an operator may manipulate the drill pipe using surface equipment to thereby orientate the down hole flow control device (10). In one example, the flow control device (10) may be orientated by surface tooling that is operable by an operator, such as a “J-latch”, or the like, that enables the operator, who may be a driller, to orientate the flow control device (10) from the surface, and utilise markings, or the orientation of the “J-latch”, at the surface that enables the operator to understand the orientation of the downhole, or subsurface, flow control device (10). In this embodiment, where the operator is using a “J-latch” at the surface to orientatethe downhole flow control device (10), the “J-latch” may be connected to drill pipe, or other similar pipework, that is ultimately connected to the tubular member (11) of the flow control device (10), such that manipulation / operation / tuming of the “J-latch” at the surface also turns the downhole tubular member (11) with respect to the sleeve member (12) to thereby orientate the flow control device (10). It will be appreciated that the sleeve member (12) itself may be orientated by one or more tools at the surface by the operator, and these one or more tools may themselves comprise markers at the surface that enable the operator to understand the orientation of the sleeve member (12), and its angled screens (14), downhole with respect to the tubular member (11).

[0102] It will be appreciated that the above example where a “J-latch” tooling is used at the surface to orientate the flow control device (10) is only one such example, and that other tools and methods are envisaged, beyond those disclosed herein, for orientating the flow control device (10), its tubular (11) and sleeve (12) members, downhole.

[0103] It will be appreciated by those skilled in the art that Figures 18A to 18G illustrate the method steps according to one embodiment of the present disclosure, in an exemplary way. These Figures are not to be considered to scale, or in any way limiting, however, they should be considered to aid in clarifying the method steps discussed herein.

[0104] Referring now to Figures 1 to 17C, according to one embodiment, there is illustrated a flow control device (10) for use within a method for in-situ recovery of metals from an orebody (100), such as embodiments of such a method already discussed. The device (10) comprises a tubular member (11) disposed within a sleeve member (12), wherein the tubular member (11) is rotatable within the sleeve member (12). The tubular member (11) comprises one or more flow ports (13) and one or more corresponding sealing elements (16), wherein each flow port (13) is positioned along a vertical axis of the tubular member (11) and are each offset from one another along a horizontal axis of the tubular member (11); the sleeve member (12) comprising one or more angled screens (14), wherein each angled screen (14) is positioned along a vertical axis of the sleeve member (12) and each corresponding to an associated flow port (13); wherein, in use, the tubular member (11) is rotated to a first position to align a first flow port (13) with a corresponding first angled screen (14) to provide fluid communication between an interior of the tubular member (11) and an exterior of the sleeve member (12).

[0105] Referring to Figure 12, one embodiment of the flow control device (10) is illustrated. In this Figure, the flow control device may be considered to be at an ‘initial position’, or an ‘installation position’, or a ‘running position’, such that the tubular member (11) within the sleeve member (12) is aligned at a desired position for when the device (10) is utilised within an ISR process, such as step (d) within any one of the embodiments of the method.

[0106] Next, referring to Figure 13, the flow control device (10) is illustrated with an indicative arrow for the rotation of the tubular member (11) within the sleeve member (12), such that the device (10) is in the first position, aligning the first flow port (13) with the corresponding first angled screen (14) to provide fluid communication between an interior of the tubular member (11) and an exterior of the sleeve member (12). This first position is denoted with (A) within this Figure. At this first position (A), the device (10) may be utilised within an ISR well (40, 50) to execute the ISR process by injecting a fluid into one or more of the wells (40, 50). Alternatively, at this first position (A), one or more of the devices(10) within one or more of the wells (40, 50), may collect the pregnant solution comprising the injected fluid with the dissolved metal from the orebody (100) within a solution. In this embodiment, where the device (10) is at the first position (A), the aligned first flow port (13) and angled screen (14) may be positioned downhole, within one of the wells (40, 50), for example, at the first mining section (130a), from which the orebody (100) is to be mined. That is, the first position (A) may be considered to provide the fluid for injection access to the first mining section (130a) to dissolve the metal from the orebody (100).

[0107] Referring to Figure 14, there is illustrated a cross section of the device (10) of Figure 13, where illustrative arrows indicate the flow of the fluid from the interior of the tubular member (11) to the exterior of the sleeve member (12), when the device is at the first position (A).

[0108] Next, referring to Figure 15, there is illustrated a second position (B) for the device (10), where a second flow port (13) is aligned with a corresponding second angled screen (14) to provide fluid communication between an interior of the tubular member (11) and an exterior of the sleeve member (12). Indicative arrows within this Figure indicate the flow of the fluid from the interior of the tubular member(11) to the exterior of the sleeve member (12). It will be appreciated that this second position (B) may be corresponding to a position downhole, within one of the wells (40, 50), for example, at a second mining section (130b), from which the orebody (100) is to be mined. That is, the second position (B) may be considered to provide the fluid for injection access to the second mining section (130b) to dissolve the metal from the orebody (100).

[0109] Although further Figures illustrating subsequent positions for the device (10) are not illustrated, those skilled in the art will appreciate that subsequent positions of the device (10) will correspond with subsequent positions downhole, within one of the wells (40, 50), to allow the device (10) to mine, interval / section by section, the orebody (100), allowing the device (10) to inject, or extract, or produce, the fluid for the purposes of the ISR process as described in any one of the embodiments of the method herein.

[0110] Referring now to Figure 16, there is illustrated, in a schematic form, an embodiment of the present disclosure, where an example of use of an injection flow control device (10’) within an injectionwell (40), and an extraction / production flow control device (10”) within an extraction / production well (50) is illustrated. In this embodiment, indicative arrows are provided to illustrate the flow of the fluid from the injection device (10’), via the injection well (40), such that the fluid is directed, or focused, into a first mining section (130a) of the orebody (100), to dissolve and extract one or more metal(s) therefrom. It will be apparent from this illustration that the device (10) is capable of delivering a directed, or focused, injection of the fluid without wastage of the fluid to undesirable, or unplanned sections within the formation. This is advantageous, as not only is the fluid more effective, or efficient, in mixing and dissolving the metal(s) within the orebody, the fluid is also not unintentionally lost to other sections within the formation (110) that may otherwise be harmful to the environment, or cause downhole problems.

[0111] Also, within Figure 16, indicative arrows illustrate that once the fluid flows through the orebody (100), it is collected, or received, by the production device (10”) within the production well (50). The collected, or received, fluid may be considered the pregnant solution that comprises the dissolved metal from the orebody (100), and is extracted via the production well (50) to be subsequently processed at a surface location.

[0112] Figures 17A to 17C illustrate a top view of the fluid control device (10), according to an embodiment, where the tubular member (11) is rotated from an initial position to a, for example, first position, to thereby align a first flow port (13) with a corresponding first angled screen (14), to permit fluid communication between an interior of the tubular member (11) and an exterior of the sleeve member (12). The indicative arrows within these Figures represent the turning of the tubular member (11) within the sleeve member (12), which may be operable by an operator at the surface via one or more of the ways previously described.

[0113] In this way, advantageously, the fluid control device (10) can deliver a directed, or focused, flow of the fluid into the formation (110) comprising the orebody (100) to dissolve metal therein and subsequently produce therefrom. It will be apparent that another advantage of the directed, or focused, delivery of the fluid by the device (10) for ISR purposes ensures that the fluid reaches the metals of interest and efficiently extracts the target metal(s) from the orebody (100), without wastage of the fluid, or loss of the fluid to other sections within the formation (110). It will also be apparent that yet another advantage of the device (10) is that the injected fluid is directly delivered into the fractured rock silo (120) of interest, where the fractured rock silo has an increased surface area, thus the surface area of contact between the injected fluid and the target metal(s) of interest within the orebody (100) therein is maximised.

[0114] In one embodiment, the sealing elements (16) of the fluid control device (10) are packing elements that restrict flow between a flow port (13) and its corresponding angled screen (14). That is, thepacking elements (16) reside on an outer surface of the tubular member (11) and restrict the fluid from being directed, or focused, through the other flow ports (13) and their corresponding angled screens (14).

[0115] In one embodiment, each flow port (13) comprises a corresponding upper and lower sealing element (16). Wherein, the sealing elements (16) prevent, or restrict, the flow of the fluid, from the interior of the tubular member (11) to the exterior of the sleeve member (12), through the incorrect, or undesired, flow port (13) or sleeve member (14).

[0116] In one embodiment, the sealing elements (16) may be packers, or inflatable packers, such as those that isolate particular zones within tubular products or wellbores. In the embodiments where the elements (16) are inflatable packers, these may be inflated to a ‘set’ position, where they are capable of isolating zones, by differential pressure. In another embodiment, where the sealing elements (16) are packers, they may be ‘set’, where they are capable of isolating zones, by manipulating the tubular member (11) within the sleeve member (12) by either rotation or ‘push / pull’ movements (i.e. manipulating the inner tubular member up and down within the wellbore relative to the sleeve member).

[0117] In one embodiment, the angle of the screens (14) is selected based on a controlled fluid flow rate to minimise a pressure drop at an interface between each angled screen (14) and its corresponding flow port (13). That is, advantageously, the angle of the screens (14) may be designed such that the pressure drop between each angled screen (14) of the sleeve member (12) and its corresponding flow port (13) of the tubular member (11) is minimised. Additionally, it will be appreciated that a further advantage of the angle of the screens (14) being selectable, is that the angle may be decided based on the controlled fluid flow rate, that the fluid is injected or extracted from the one or more devices (10), to minimise a pressure drop at an interface between each angled screen (14) and its corresponding flow port (13).

[0118] In one embodiment, the combination of the angled screens (14) and the controlled fluid flow rate minimise precipitation of gangue minerals, such as those that may be resultant from injecting the fluid and subsequently mixing with the contents of the orebody (100), at the interface between each angled screen (14) and its corresponding flow port (13).

[0119] In one embodiment, referring to any one of Figures 1 to 15, the sleeve member (12) further comprises an upper and lower thread (17) that enables several sleeve members (12) to be connected in series. It will be appreciated that, for example, in the instance that the flow control device (10) is used within a casing while drilling arrangement for drilling and producing from the wells (40, 50), the upper and / or lower threads (17) of the sleeve member (12) may be connected to casing members (not illustrated), above or below the sleeve member (12). Alternatively, it will also be appreciated that the upper and / or lower threads (17) of the sleeve member (12) may be connected to other casing or pipe for the purposes of drilling and / or producing from the wells in an ISR process.

[0120] In one embodiment, the tubular member (11) further comprises an upper and lower thread (18) that enables several tubular members (11) to be connected in series. It will be appreciated that, for example, in the instance that the flow control device (10) is used within a casing while drilling arrangement for drilling and producing from the wells (40, 50), the upper and / or lower threads (18) of the tubular member (11) may be connected to drill pipe (not illustrated), or other pipe, above or below the tubular member (11). Alternatively, it will also be appreciated that the upper and / or lower threads (18) of the tubular member (11) may be connected to other pipework for the purposes of drilling and / or producing from the wells in an ISR process.

[0121] In the above embodiments, it will be appreciated that the upper thread (18) enables the tubular member (11) to be connected to other tubulars that enable the tubular member (11) to be rotated within the sleeve member (12).

[0122] In one embodiment, where a casing string is run during the drilling of the wells (40, 50), the casing string comprises at least one flow control device (10) that is run within each of the production wells (50). In this embodiment, the fluid control devices (10) run within the production wells (50) are orientated to collect the solution containing the dissolved metal from the orebody (100).

[0123] The controlled fluid flow rate that the fluid is injected into the wells (40, 50) may be applied via surface equipment such as pumps commonly utilised in mining and / or oil and gas drilling. Those skilled in the art will appreciate that the surface pump may be any kind of surface pump that is capable of pumping the fluids discussed herein, for the purposes of injecting the fluid in a controlled manner down hole, through the fluid control device (10), and into the wells (40, 50) for the purposes of in-situ recovery of metals from the orebody (100).

[0124] In one embodiment, the blasting operation, the fluid, and the controlled fluid flow rate are selected to maximise pore volume exchanges as the fluid is injected through the orebody (100) to dissolve the at least one metal therein.

[0125] In one embodiment, the fractured rock silo (120), created by the blasting operation within the formation (110), increases porosity and surface area of the orebody (100), such that the controlled fluid flow rate is optimised to maximise contact between the fluid and the orebody to dissolve the at least one metal therein.

[0126] In one embodiment, the fluid is selected based on the properties of the formation (110) and the orebody (100) to enhance permeability and alleviate passivation issues with the recovery of metals from the orebody (100). It will be appreciated that the controlled fluid flow rate, that is ultimately delivered to the orebody (100) via the fluid control device (10), may be a pulsed injection rate that injects the fluidthrough the orebody (100) to dissolve the at least one metal therein. Advantageously, the pulsed injection rate of the fluid maximises contact between the fluid and the orebody (100) to dissolve the at least one metal therein. It will be appreciated that an advantage of controlling the rate at which the fluid is injected into the orebody (100) via the device (10) is that the residence time of the fluid within the orebody (100) is optimised.

[0127] In one example, the fluid that is injected into the orebody (100) to dissolve and produce the one or more metals there from, may comprise a first fluid and a second fluid, wherein the first fluid is a chemical leaching solution and the second fluid is a bacterial leaching solution, wherein, in use, the first and second fluids are sequentially injected through the orebody to enhance permeability and alleviate passivation issues with the recovery of metals from the orebody. In this example, where the fluid comprises a first and a second fluid, this may be considered a sequential chemical and / or bacterial leach process that advantageously enhances the permeability of the orebody (100), in order to better extract, or collect, the metal(s) therein, and alleviate passivation issues, and Electrokinetics, within the orebody (100) to therefore improve reaction rates.

[0128] In one example, one of the first, second, or the only fluid, injected via the fluid control device (10) is a lixiviant that is used for recovering copper from the orebody (100).

[0129] In one embodiment, where the fluid is a lixiviant, the fluid control device (10) is utilised to deliver the fluid into an injection well (40) via a pulsed injection, causing a better metal (within the orebody) to lixiviant interaction (or mix) within the orebody, to therefore increase, or improve, pore volume extraction rate from the orebody (100).

[0130] In the above embodiments, the pulsed injection rate may be created by sequential changes in the controlled fluid flow rate, which in turn, is created by one or more surface pumps. By sequentially making changes in the pumping process, advantageously an engineering-induced flow fluctuation is created, which leads to better fluid coverage and improved lixiviant (i.e. fluid) contact with the one or more metals within the orebody for subsequent extraction. It will be appreciated that these sequential changes in pumping, to create the pulsed injection rate, combined with the ability to orientate and direct the fluid via the flow control device (10), provides the present disclosure with a unique advantage when recovering metals from an orebody via in-situ recovery methods.

[0131] The inventors were surprised to note that by utilising pulsed injection, delivered by the fluid control device (10), or by switched pumping methods by surface equipment (i.e. rapidly changing the injection or extraction well combinations), there is increased contact between the injected fluid and the particles metal(s) within the orebody (100). The inventors provide the below notes, detailing their observations.• Where the injected fluid is a lixiviant, in the instance that the lixiviant is a dilute acid (such as sulphuric, acetic, methane sulphonic), halide systems (I / T, Cl / Cl ), or Glycine (used in neutral to alkaline environment) can be circulated through the orebody (100), or rock mass, to remove copper and / or other metals.• In the instance that sequential biological and / or chemical leaching is utilised, i.e. where the injected fluid may comprise a first and a second fluid, this leaching “flushes” the orebody (100) to thereby create increased access to metal(s) therein by dissolving gangue material. The inventors note that this advantageously increases the porosity and permeability of the area being leached via the injected lixiviant.• Passivation, or the development of a coating, on the metal that inhibits leaching is noted to be common in copper sulphides. This can significantly reduce the metal recoveries from the orebody (100); however the inventors note that by initially using biological agents to facilitate the removal of the coating, and subsequently using a chemical leach agent, increases access to the valuable metals within the orebody (100) by advantageously minimising the passivation effect. The coatings can be dissolved or fractured by bacterial leaching allowing solutions to penetrate the uncontacted zone of mineral crystal within the orebody (100) containing the target metal(s).

[0132] To recap, advantages of the present disclosure include: a. Provides a method and a fluid control device (10) that is capable of delivering a directed, or focused, fluid to a mining section within an orebody (100) within a formation (110) without wastage, or loss, of the fluid to sections within the formation that are not to be mined. b. The method and the fluid control device (10) increases the residence time of the fluid and the metals (i.e. the time in which the fluid spends within the orebody in contact with the metals therein). c. The method and the fluid control device (10) being capable of directing, or focusing, the fluid injection into the orebody (100) allows for the increase in the number of times the fluid (for example, lixiviant) circulates through the pores of the orebody (100) to extract the metal(s) therein (i.e. improved pore volume exchanges). d. The angled screens (14) of the sleeve member (12) can be selected to minimise the pressure drop at an interface between each angled screen and its corresponding flow port.The angled screens (14), combined with controlling a fluid flow rate of the injected fluid, via surface pumping equipment, also aid in minimising the pressure drop at the interface between each of the angled screens (14) and its corresponding flow port (13). e. The blasting operation, to create the fractures within the formation (110), increases fluid flow throughout the fractured rock silo (120), creates increased fluid access points, porosity, permeability, and pore volume of the formation (110) and / or the orebody (100) therein to aid in the recovery of metals. f. The blasting operation to create the fractured rock silo (120) also increases the surface area of contact available for the injected fluid to subsequently dissolve metal(s) from within the orebody (100). g. The creation of the fractured rock silo (120), and the section-by-section mining method enabled by the fluid control device (10), allow for the extraction of metal(s) from an orebody (100) that resides within “hard rock” formations that typically have poor porosity and permeability.

[0133] It will be understood that the terms “comprise” and “include” and any of their derivatives (e.g. comprises, comprising, includes, including) as used in this specification, and the claims that follow, is to be taken to be inclusive of features to which the term refers, and is not meant to exclude the presence of any additional features unless otherwise stated or implied.

[0134] In some cases, a single embodiment may, for succinctness and / or to assist in understanding the scope of the disclosure, combine multiple features. It is to be understood that in such a case, these multiple features may be provided separately (in separate embodiments), or in any other suitable combination. Alternatively, where separate features are described in separate embodiments, these separate features may be combined into a single embodiment unless otherwise stated or implied. This also applies to the claims which can be recombined in any combination. That is a claim may be amended to include a feature defined in any other claim. Further a phrase referring to “at least one of’ a list of items refers to any combination of those items, including single members. As an example, “at least one of: a, b, or c” is intended to cover: a, b, c, a-b, a-c, b-c, and a-b-c.

[0135] It will be appreciated by those skilled in the art that the disclosure is not restricted in its use to the particular application or applications described. Neither is the present disclosure restricted in its preferred embodiment with regard to the particular elements and / or features described or depicted herein. It will be appreciated that the disclosure is not limited to the embodiment or embodiments disclosed, butis capable of numerous rearrangements, modifications and substitutions without departing from the scope as set forth and defined by the following claims.

Claims

CLAIMS1. A method for in-situ recovery of metals from an orebody, the method comprising:(a) forming at least one vertical well and a plurality of lateral wells originating from the at least one vertical well within a formation comprising the orebody;(b) performing a blasting operation within the lateral wells to create a fractured rock silo;(c) forming at least one injection well and at least one production well within the fractured rock silo, wherein the injection and production wells are within or adjacent to the orebody;(d) running a casing string comprising at least one flow control device within each injection well, wherein the flow control devices are orientated to a first position to inject a fluid at a controlled fluid flow rate through the orebody to dissolve at least one metal therein, and subsequently collecting a solution containing the dissolved metal from the orebody via the production well.

2. The method of claim 1, wherein the fractured rock silo increases porosity and surface area of the orebody, such that the controlled fluid flow rate is optimised to maximise contact between the fluid and the orebody to dissolve the at least one metal therein.

3. The method of either one of claims 1 or 2, wherein the blasting operation, the fluid, and the controlled fluid flow rate are selected to maximise pore volume exchanges as the fluid is injected through the orebody to dissolve the at least one metal therein.

4. The method of any one of the preceding claims, wherein the fluid is selected based on the properties of the formation and the orebody to enhance permeability and alleviate passivation issues with the recovery of metals from the orebody.

5. The method of any one of the preceding claims, wherein the controlled fluid flow rate is a pulsed injection rate that injects the fluid through the orebody to dissolve the at least one metal therein.

6. The method of claim 5, wherein the pulsed injection rate of the fluid maximises contact between the fluid and the orebody to dissolve the at least one metal therein.

7. The method of any one of the preceding claims, wherein the controlled fluid flow rate optimises a residence time of the fluid within the orebody.

8. The method of any one of the preceding claims, wherein the fluid comprises a first fluid and a second fluid, wherein the first fluid is a chemical leaching solution and the second fluid is a bacterialleaching solution, wherein, in use, the first and second fluids are sequentially injected through the orebody to enhance permeability and alleviate passivation issues with the recovery of metals from the orebody.

9. The method of any one of the preceding claims, wherein the fluid is a lixiviant that is used for recovering copper from the orebody.

10. The method of any one of the preceding claims, wherein step (d) is repeated by orientating the fluid control device to subsequent positions to inject the fluid at a controlled fluid flow rate through subsequent sections of the orebody to dissolve at least one metal therein, and subsequently collecting a solution containing the dissolved metal from the orebody via the production well.

11. The method of any one of the preceding claims, wherein each flow control device comprises: a tubular member disposed within a sleeve member, wherein the tubular member is rotatable within the sleeve member; the tubular member comprising one or more flow ports and one or more corresponding sealing elements, wherein each flow port is positioned along a vertical axis of the tubular member and are each offset from one another along a horizontal axis of the tubular member; the sleeve member comprising one or more angled screens, wherein each angled screen is positioned along a vertical axis of the sleeve member and each corresponding to an associated flow port; wherein, in use, the tubular member is rotated to the first position to align a first flow port with a corresponding first angled screen to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member.

12. The method of claim 11, wherein the angle of the screens is selected based on the controlled fluid flow rate to minimise a pressure drop at an interface between each angled screen and its corresponding flow port.

13. The method of any one of the preceding claims, wherein a casing string comprising at least one flow control device is run within each of the production wells, and wherein the fluid control devices within the production wells are orientated to collect the solution containing the dissolved metal from the orebody.

14. The method of any one of the preceding claims, wherein the blasting operation within the lateral wells is performed by introducing an explosive into one or more of the lateral wells and detonating the explosive to create the fractured rock silo, wherein the blasting operation increases the pore volume within the formation and orebody to aid in the recovery of metals.

15. The method of claim 14, wherein the detonating of the explosive creates a shock wave through formation and the orebody therein to create fractures and the fractured rock silo, wherein the fractures increase fluid flow throughout the fractured rock silo.

16. The method of any one of the preceding claims, wherein the solution containing the dissolved metal from the orebody is collected via the production well and is processed at a surface location.

17. A flow control device for in-situ recovery of metals from an orebody, the device comprising: a tubular member disposed within a sleeve member, wherein the tubular member is rotatable within the sleeve member; the tubular member comprising one or more flow ports and one or more corresponding sealing elements, wherein each flow port is positioned along a vertical axis of the tubular member and are each offset from one another along a horizontal axis of the tubular member; the sleeve member comprising one or more angled screens, wherein each angled screen is positioned along a vertical axis of the sleeve member and each corresponding to an associated flow port; wherein, in use, the tubular member is rotated to a first position to align a first flow port with a corresponding first angled screen to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member.

18. The flow control device of claim 17, wherein the sealing elements are packing elements that restrict flow between a flow port and its corresponding angled screen.

19. The flow control device of either one of claims 17 or 18, wherein the angle of the screens is selected based on a controlled fluid flow rate to minimise a pressure drop at an interface between each angled screen and its corresponding flow port.

20. The flow control device of any one of claims 17 to 19, wherein, in use, subsequent rotations of the tubular member within the sleeve member are subsequent positions that align subsequent flow ports with corresponding angled screens to provide fluid communication between an interior of the tubular member and an exterior of the sleeve member.

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