Subsurface Heap Leaching Pressure Control for Occluded Ore Zones
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Solution Overview
Problem
Conventional surface and subsurface leaching methods for metal recovery face inefficiencies due to occlusion of leaching solution distribution systems, non-uniform percolation, and inability to regulate flow conditions, leading to suboptimal metal recovery and increased energy and solution wastage.
Innovation Solution
A subsurface leaching system with pressure and flow control, combined with residual metal mapping, delivers targeted leaching solutions at specific locations and depths within leach heaps, optimizing recovery by adjusting operational conditions based on minerology, chemistry, and permeability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If conventional surface and subsurface leaching methods are used, then metal recovery is achieved, but solution wastage increases and leaching uniformity deteriorates due to occlusion and non-uniform percolation
Solution Approach 1:
The patent applies parameter changes by regulating pressure and flow rates of the leaching solution to achieve target operational conditions. This controls the percolation process to maintain uniformity while preventing occlusion, thereby reducing solution wastage and improving leaching reliability simultaneously.
Solution Approach 2:
The patent implements feedback mechanisms through real-time monitoring and regulation of pressure and flow rates. This allows the system to adjust operational parameters dynamically to maintain optimal leaching conditions, preventing both solution wastage and non-uniform percolation.
2Productivity
If conventional leaching distribution systems are used, then leaching solution is delivered, but flow conditions cannot be regulated leading to suboptimal metal recovery
Solution Approach 1:
The patent applies dynamics by making the leaching solution delivery system adjustable and controllable. Pressure and flow rate regulation capabilities are integrated into the distribution system, allowing dynamic optimization of metal recovery efficiency while managing system complexity through controlled adaptability.
Solution Approach 2:
The patent changes operational parameters (pressure and flow rates) to optimize metal recovery. By regulating these parameters to achieve target operational conditions, the system improves productivity while the complexity is managed through focused parameter control rather than comprehensive system redesign.
3Loss of energy
If leaching solution is delivered without pressure and flow control, then solution is distributed, but energy use increases and recovery is suboptimal
Solution Approach 1:
The patent regulates pressure and flow rates as key parameters to optimize both energy efficiency and metal recovery. By controlling these parameters to achieve target operational conditions, the system reduces energy wastage while simultaneously improving recovery productivity, resolving the contradiction between energy loss and productivity.
Solution Approach 2:
The patent implements feedback control to monitor and adjust pressure and flow rates in real-time. This ensures optimal energy utilization while maintaining high metal recovery rates, preventing both energy wastage and suboptimal recovery by continuously adapting to operational conditions.
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
Enhances metal recovery efficiency by minimizing solution wastage, optimizing energy use, and improving leaching uniformity through real-time regulation of pressure and flow rates, thereby maximizing economic returns.
Implementation Method 1
Leaching solution may comprise any liquid capable of liberating a metal value from ore. In various embodiments, leaching solution may be acidic and may comprise sulfuric acid.
Implementation Method 2
The resultant process stream—the pregnant leach solution—is recovered, and a processing step such as solution extraction is used to form a highly concentrated and relatively pure metal value containing aqueous phase.
Implementation Method 3
Leaching solution is distributed on top of the heap and, by force of gravity, travels down towards the pad.
Implementation Method 4
regulating at least one of a pressure, a mass flow rate, or a volumetric flow rate of the leaching solution to achieve a first target operational condition
Implementation Method 5
delivering the leaching solution at the first target operational condition from the leaching solution regulating system to a subsurface leaching distribution system
Data Source
AI summary
The present disclosure provides a method comprising determining an ore map for a heap to identify a location of a recoverable metal value in the heap, delivering a leaching solution from a leaching solution source to a leaching solution regulating system, regulating at least one of a pressure, a mass flow rate, or a volumetric flow rate of the leaching solution to achieve a first target operational condition, wherein the first target operational condition is selected to optimize a set of operational parameters to maximize recovery of the recoverable metal value, delivering the leaching solution at the first target operational condition from the leaching solution regulating system to a subsurface leaching distribution system, and delivering the leaching solution at the first target operational condition from the subsurface leaching distribution system to the location of the recoverable metal value under a surface of the heap to leach and recover at least one metal value.