Heap Leach Oxygen Delivery and Predictive Ore Routing
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Solution Overview
Problem
Current heap leaching operations face challenges in optimizing copper recovery due to factors like oxygen starvation within leach stockpiles, inefficient acid utilization, and variability in ore mineralogy, leading to suboptimal economic conditions.
Innovation Solution
A system that utilizes predictive modeling and leach analytics to optimize ore routing and processing by integrating historical data, mineralogy, irrigation, and chemical data to adjust parameters such as acid consumption, oxygen introduction, and ore placement, thereby enhancing copper recovery and reducing costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If ore is placed in heap leach stockpiles for copper recovery, then copper extraction is achieved, but oxygen starvation within the stockpile interior reduces recovery efficiency
Solution Approach 1:
The patent introduces an intermediary system (oxygen delivery infrastructure including pipes, pumps, and distribution networks) to transport oxygen from the surface to the interior of the stockpile, mediating the oxygen transfer process and eliminating the oxygen starvation condition that would otherwise occur in the confined interior space
Solution Approach 2:
The patent employs pneumatic and hydraulic systems to inject oxygen gas or oxygen-rich fluids into the stockpile interior through distributed injection points, using pressure-driven flow to deliver oxygen deep into the leaching mass where natural diffusion is insufficient
2Ease of manufacture
If gangue minerals are present in heap leach operations, then ore processing is simplified, but acid consumption increases without value recovery
Solution Approach 1:
The patent applies local quality by varying leach solution composition and application rates across different zones of the stockpile based on local mineralogy, delivering higher acid concentrations to copper-bearing zones while reducing or eliminating acid application to gangue-dominated zones, thereby optimizing acid utilization
Solution Approach 2:
The patent implements feedback control by continuously monitoring leach solution chemistry, flow rates, and stockpile conditions, then adjusting acid dosing and solution circulation in real-time to match actual copper mineralization zones, preventing excessive acid consumption in gangue areas
3Productivity
If ferric iron is used to oxidize copper sulfide minerals, then leaching efficiency improves, but ferrous iron accumulates and requires continuous re-oxidation
Solution Approach 1:
The patent establishes continuity of useful action by maintaining constant aeration and oxygen supply to the leach stockpile, enabling continuous re-oxidation of ferrous iron back to ferric iron, thereby sustaining the oxidative leaching cycle without interruption or accumulation of reduced iron species
Solution Approach 2:
The patent introduces strong oxidants (oxygen gas, oxygen-rich air, or oxygen-containing fluids) directly into the leach stockpile to accelerate the re-oxidation of ferrous iron to ferric iron, maintaining high oxidative potential and leaching efficiency without relying solely on slow atmospheric oxidation
4Quantity of substance
If chalcopyrite minerals are processed via leaching, then some copper recovery is achieved, but recovery rates remain low compared to oxide ores
Solution Approach 1:
The patent applies parameter changes by adjusting leach solution chemistry (acid concentration, redox potential, temperature) and physical conditions (aeration rate, particle size distribution, stockpile density) to optimize the leaching of refractory chalcopyrite minerals, transforming the leaching environment to enhance copper recovery from difficult-to-leach sulfide phases
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The system improves copper recovery rates by optimizing chemical and physical driving forces in leach operations, leading to increased profitability and extended mine life by making data-driven adjustments in real-time.
Implementation Method 1
When ferric iron oxidizes copper sulfide minerals, the ferric iron is converted to ferrous iron. The ferrous iron is converted back to ferric iron to further oxidize copper sulfide minerals.
Implementation Method 2
The top and sides of a heap leach stockpile are open and atmospheric oxygen is readily available
Implementation Method 3
Exposure to dilute sulfuric acid carries sufficient chemical energy to put the copper into solution
Data Source
AI summary
The method may comprise receiving historical data (e.g., mineralogy data, irrigation data, raffinate data, heat data, lift height data, geographic data on ore placement and/or blower data); training a predictive model using the historical data to create a trained predictive model; adding future assumption data to the trained predictive model; running the forecast engine for a plurality of parameters to obtain forecast data for a mining production target; comparing the forecast data for the mining production target to the actual data for the mining production target; determining deviations between the forecast data and the actual data, based on the comparing; and changing each of the plurality of parameters from the forecast data to the actual data to determine a contribution to the deviations for each of the plurality of parameters.