Documentos de Académico
Documentos de Profesional
Documentos de Cultura
Heaps
Luis Miguel Panduro Robles
Sociedad Minera Cerro Verde S.A.A.
Senior Metallurgist
lpanduro@phelpsd.com.pe
ABSTRACT
The purpose of using forced aeration in leaching operations is to increase the extraction kinetics of copper
contained in the ore, and this is achieved when oxygen from the air oxidizes the ferrous ions present in the
leach solutions forming ferric ions. The ferric ion formed oxidizes the copper (from chalcocite and
covellite) or sulphur (from primary or residual covellite), and it is reduced to ferrous ion. Under conditions
of suitable acid-supply, the ferrous ion is oxidized with oxygen again and the cycle continues until
sulphide leaching ceases due to copper metal precipitates formation or copper metal exhaustion.
This paper describes the work performed at the Cerro Verde copper mine in Peru with regards to
optimization of forced aeration.
INTRODUCTION
Column tests with injection of forced air to accelerate the extraction kinetics of the leach process have
been investigated at Cerro Verde during several years On the basis of these data and the experience of
other mining operations, tests were carried out at larger scales. Tests were carried out at industrial level at
the Cerro Verde Pad 4. The results confirmed previous observations at smaller scale and established forced
aeration as an industrial operative practice.
TEST DEVELOPMENT
This paper describes the evaluation of forced aeration at the industrial level in Cerro Verde by considering
factors such as:
Oxygen requirement.
Determination of the optimal hole diameter in aeration pipes.
Evolution of the aeration ratio and oxygen content.
Pregnant solution behaviour in terms of pH, mV, Fe 3+ , etc.
Selection of the most appropriate type of aeration pipe.
Chalcocite Oxidation:
Covellite Oxidation:
Chalcopyrite Oxidation:
Pyrite does not react, because historical data do not show a decrease in the iron content.
Copper in the test heaps comes mainly from chalcocite and covellite, and to a lesser extent from
chalcopyrite and enargite as determined by quantitative optical microscopy.
Reactions go through 100% completion.
The test cell used (Cell 801) contained 504.566 metric ton of sulphide ore, with a total copper grade of
0.653% giving a fine copper content of 3.297 metric ton. Table 1 shows the copper distribution observed
among the different sulphide species.
WT%*
TONNAGE (mt)
CHALCOSITE
0.529% Cc
2666.63
2129.35 Cu in Cc
COVELLITE
0.252% Cv
1273.02
846.06 Cu in Cv
CHALCOPYRITE
0.15% Cp
756.85
262.56 Cu in Cp
ENARGITE
0.024% En
121.10
58.62 Cu in En
OXYGEN (mt)
CHALCOSITE
1340
COVELLITE
852
CHALCOPYRITE
562
ENARGITE
86
TOTAL
2840
Metric Ton
89
In addition, by considering the copper content and the mass of ore in the test cell, and by assuming that
the average copper extraction in the first 30 days of continuous rinsing is 30%, the following theoretical
ratios of air requirement are obtained:
Ratio volume of air/ton ore per day:
0.28 m3air/ton.day
3
Ratio volume of air/kg of copper: 4.30 m air/kg of total copper
BLOWER
1
18" VENT SLEEVE
2
3
AERATION PIPES
HOLE DIAMETERS: 1.59 mm and 2.0 mm
Test Description
The test cell was divided into 10 sectors, 5 of them with 1.59-mm hole diameter pipe and the rest with 2.00
mm hole diameter pipe.
One PLS sampler and six gaseous oxygen monitors were installed in each of the ten sectors. Air pressure
was monitored at the beginning and at the end of the two-inch aeration pipes and along the vent sleeve.
Test Results
As the leach time progressed a drop in air pressure and flow was noticeable. The following figures show
the behaviour of air with time for the 2.0 mm and 1.59 mm hole perforated pipes. Later, it was found that
plugging by Cu-Fe salt precipitation caused the pressure loss of the pipe orifices. Graph 2 shows the
evolution of flow for the 2 mm holes, and Graph 3 the flow observed for 1.59 mm holes. As it is observed,
the flow decrease with time is more significant when the hole diameter in the aeration pipe is smaller,
probably due to a more severe plugging effect is such case.
FLOW (cfms )
120
61 DAYS
100
107 DAYS
183 DAYS
261 DAYS
80
60
40
20
0
0
200
400
Nro LINEA
800 AIREACION1000
600
1200
1400
TIME
Ev. 1
Ev. 5
Ev. 9
Ev. 13
Ev. 17
Ev. 21
1600
FLOW (cfms )
120
0 DIAS
33 DIAS
100
61 DIAS
107 DIAS
80
183 DIAS
261 DIAS
60
40
20
0
0
200
400
600
Ev. 5
Ev. 1
Ev. 9
1200
1400
Ev. 17
Ev. 13
1600
1800
Ev. 21
0.80
0.70
0.60
0.50
0.40
0.30
0.20
0.10
0.00
30
60
90
120
150
180
210
240
Leach Days
2.0 mm. Orifices
1.59 mm.Orifices
GGN
AVERAGE RECOVERY
AVERAGE RECOVERY
MODEL
0.0
0.0
0.0
30
40.0
30.0
40.2
60
56.6
50.6
54.2
90
64.2
57.8
60.5
120
69.6
64.2
64.3
150
72.7
66.4
67.1
180
75.0
70.3
69.2
260
77.2
73.5
73.2
Evaluation
Oper.(Days)
Fe3+/FeT
In-Out Balance
Production
Ratio
Fe+3 (kg/t)
P-801-1
Blanco
253
0.62
-2.00
0.32
0.26
-3.36
P-801-2
253
0.91
-3.00
1.63
0.12
0.61
P-801-3
253
0.69
-3.40
1.11
0.89
2.76
P-801-4
253
0.53
-0.20
-0.17
0.16
-0.12
P-801-5
253
0.72
-3.20
0.86
0.29
1.95
P-801-6
263
0.66
-2.20
0.47
0.18
0.70
P-801-7
199
0.94
-2.60
1.53
0.24
1.38
P-801-8
263
0.68
-2.00
0.62
0.26
-0.72
P-801-9
263
0.76
-2.20
1.06
0.34
2.18
P-801-10
259
0.77
-1.80
0.84
-0.01
0.13
Graph 5 shows the total iron balance. It is observed that after about 50 days of leaching an equilibrium
value is reached, where the mass of iron irrigated equals the effluent iron in the pregnant solution. Also, as
it is shown in Graph 6, the effluent solution pH tends to decrease continuously as the leach proceeds,
reaching about pH 1.8 after 200 days.
FeT (Out-In)
5.0
4.0
Blank
3.0
Orif. 1.59 mm
2.0
1.0
0.0
-1.0
-2.0
-3.0
0
50
100
150
Leach Days
200
250
300
Blank
2.6
Orif. 1.59 mm
2.4
Orif. 2.00 mm
pH
2.2
2.0
1.8
1.6
1.4
1.2
1.0
0
50
100
150
Leach Days
200
250
300
days. The first 30 days chemical leaching takes place, and then biochemical leach begins. Full bacterial
oxidation is seen much later with 1.59 mm holes, not earlier than 130 days of leaching.
Hole Diameter Evaluation in Aeration Pipes
Oxidation-Reduction Potential (mV)
600
1.0
0.9
550
0.8
ORP (mV)
Fe+3/FeT
0.7
0.6
0.5
0.4
0.3
300
0.0
50
100
150
200
250
Orif. 1.59 mm
Orif. 2.00 mm
Orif. 2.00 mm
400
350
Orif. 1.59 mm
0.1
450
Blank
Blank
0.2
500
300
50
100
Leach Days
150
Leach Days
200
250
300
GRAPH 8: Potencial Eh
Hole Size
(mm.)
Distance between
holes (cm.)
N
NCA
DSA
CICA
CISA
2
2
Variable (*)
2
2
50
50
150
50
50
Inner
Protecting
Corrugation
No
No
No
Yes
Yes
Ring
No
Yes
Yes
Yes
No
A Protecting Ring shown in Picture 1 is used to prevent plugging in aeration pipe holes. The ring has 8
orifices designed to distribute the air around the pipe, and therefore the chances of plugging decrease by
a factor of 8.
PICTURE 1: PROTECTING RING
The Graph 9 shows the test sectors in the test cell. Test pipes were distributed in 10 sectors, five of them
with 5 lines of each type of pipe and the other five with 4 different types of pipe. Each sectors had all 5 or 4
pipe types, with the purpose that the operating conditions (height, ore size, etc) are the same for all pipes.
75 m.
75 m.
75 m.
A: 5 sectors,
5 lInes of each type
125 m.
B: 5 sectors,
4 lines of each type
125 m.
0.45(m3/day.mT)
Air Ratio
0.40
0.35
0.30
0.25
0.20
0.15
0.10
0.05
0.00
0
20
40
60
80
100
120
140
160
180
200
220
DAYS
NCA
DSA
CICA
CISA
19
0.31
0.48
0.43
0.23
0.10
42
0.16
0.39
0.29
0.10
0.06
65
0.13
0.36
0.21
83
0.09
0.33
0.22
0.14
0.05
110
0.07
0.27
0.18
0.07
0.03
154
0.06
0.26
0.20
0.08
0.02
175
0.05
0.21
0.15
0.08
0.03
221
0.11
0.40
0.29
0.10
0.06
SOLUBILITY RATIO
% RECOVERY
8 DSA
0.87
75.8
0.19
1N
0.87
71.4
0.15
7 NCA
0.87
75.5
0.25
2 NCA
0.90
78.2
0.35
3 DSA
0.91
80.7
0.25
9 CICA
0.92
76.6
0.16
4 CICA
0.92
73.5
0.13
6N
0.93
83.3
0.19
5 CISA
0.93
80.6
0.06
10 CISA
0.95
78.6
0.12
The copper extraction shown in Table 7 for each sector corresponds to the average of 12 sampling points
per sector. It is observed that the extraction is higher in sectors having more air injected (sectors aerated
with DSA and CISA pipes). According to these results, the difference in copper recovery between well and
poorly aerated sectors is about 3 to 4 percent extraction.
86 m.
39 m.
1 m.
GRAPH 11: Pipes connected to the vent sleeve over the heap surface
The following graphs 12 and 13 show the results of the tests. The pipe designated as DSA (pipe with
variable hole diameters) resulted in smaller pressure drop and consequently supported a higher airflow
along the length of the pipe. The variable hole diameters helped to achieve a more uniform distribution.
40
GRAPH 12:
Pressure along 2 pipes
35
30
25
20
15
10
5
0
1 m.
39 m.
63 m.
87 m.
DISTANCE m.
NCA
DSA
CICA
CISA
TYPE
1 m.
39 m.
63 m.
87 m.
35.0
16.0
11.0
9.0
NCA
34.8
13.0
9.0
7.5
DSA
36.8
22.0
16.0
14.0
CICA
38.0
15.0
11.0
9.0
CISA
37.0
12.0
7.0
6.0
CAUDAL (cfm)
GRAPH 13:
Airflow along the 2 pipes
30
20
10
0
15-39 m.
39-63 m.
NCA
63-87 m.
DISTANCIA m.
DSA
CICA
87-111 m.
CISA
TYPE
15-39 m.
39-63 m.
63-87 m.
87-111 m.
27.2
24.8
21.8
20.0
NCA
24.5
27.0
21.6
20.0
DSA
6.3
11.1
21.9
22.7
CICA
18.4
8.7
17.1
12.4
CISA
21.6
14.2
15.4
15.6
TONNAGE
OPERATING
DAYS
AERATION
RATE
m3/(day-mt)
m3/(day-mt)
% GASEOUS
OXYGEN
INSIDE PILE
802
810503
28
84
93
162
208
0.40
0.25
0.23
0.21
END OF AERATION
18.0
12.9
9.1
6.4
803
804535
25
69
86
106
142
167
0.34
0.18
0.16
0.15
0.13
END OF AERATION
19.1
17.7
13.8
12.7
10.9
804
870495
25
84
117
155
170
0.35
0.15
0.10
0.10
END OF AERATION
14.3
6.5
8.5
8.0
805
750917
11
65
107
178
195
0.40
0.22
0.16
0.13
END OF AERATION
17.3
13.5
10.0
8.4
806
682629
1
20
76
142
180
210
0.35
0.44
0.25
0.15
0.15
END OF AERATION
18.7
15.8
9.5
8.4
0.60
0.50
0.40
0.30
0.20
0.10
0.00
0
20
40
60
80
100
120
140
160
180
200
Days
INTERMITTENT
CONTINUOS
GRAPH 14: Air rate evolution for continuous and intermittent air blowing
FLOW (cfm)
7000
6000
5000
4000
3000
2000
1000
0
0
10
20
30
40
50
60
70
80
90
100
DAYS
INJECTING WATER
MEAN
MEDIAN
StDev
MINIMUM
MAXIMUM
NORMALITY
0,82
0,83
0,06
0,69
0,91
0,25
6,23
6,13
0,38
5,61
6,91
0,03
p-Value
4,26
4,23
0,35
3,16
5,09
0,07
144,11
144,34
8,55
121,63
159,51
0,90
19,55
19,43
1,01
17,34
21,71
0,72
11,26
11,10
0,78
9,60
12,75
0,48
2,66
2,64
0,27
2,11
3,22
0,66
2,84
2,85
0,08
2,67
2,93
0,01
0,22
0,24
0,10
0,00
0,40
0,28
From the evaluation of the weight and significance of the variables described above on copper extraction,
the following equation was obtained with the aid of linear multiple regression:
FINAL Cu RECOVERY (%) = 22,4 + 127 SOLUBILITY RATIO - 18,6 Fe+3 (g/l) + 26,5 AIR RATE
(m3/mT-day) - 4,93 LEACH RATE (m3/mT)
Detailed results of the statistical analysis are presented below. As shown, the p-value for the variables air
rate and copper solubility are less than 0.05, indicating that both variables are significant on copper
extraction. The air ratio coefficient is also positive (+26.5) in the recovery equation.
Predictor
P
Coef
StDev
Constant
22,43
28,34
Solubility Ratio
126,79
11,68
Fe+3 (g/L)
-18,592
9,593
AIR RATE
26,492
7,487
Leach Ratio
-4,927
2,619
S = 3,569
R-Sq = 84,8% R-Sq(adj) = 82,1%
0,79
10,86
-1,94
3,54
-1,88
0,437
0,000
0,065
0,002
0,073
Analysis of Variance
Source
DF
Regression
4
Residual Error 23
Total
27
SS
1629,66
293,01
1922,67
MS
407,41
12,74
Source
DF
Seq SS
Solubility Ratio
Fe+3 (g/
AIR RATE
Leach Ratio
1
1
1
1
1440,30
9,46
134,82
45,08
F
31,98
P
0,000
COST ($)
ORE TONNAGE
BLOWER COST
2300
ORE GRADE:
6246
26218
OPEX
2" AERATION PIPES COST
5760
2 ", 60 DOLARS/PIPE
BLOWING COST
INSTALLATION COST
285
0.653 %CuT
71 %
73 %
2323 mt Cu
2388 mt Cu
PLUS IN COPPER
65 mt Cu
COPPER PRICE
0.74 $/p. Cu
0.19 $/p. Cu
501000 mt.
ACID
PRICE
1.0 kg/mt
38 $/mt
SAVING IN ACID
19038 US$
SUBTOTAL
10819
98375 US$
TOTAL
37037
61337 US$
CONCLUSIONS
The main conclusions of this work are as follows:
Under de conditions tested, the increase in copper recovery obtained with the use of forced
aeration was 2 points of percent.
Hole diameters of 2 mm in the pipes result in better air injection than that observed with smaller
holes (1.59 mm).
The most appropriate type of aeration pipe tested was type NCA, having 2 mm hole diameter,
protecting ring, and flat internal wall.
Applying intermittent blowing or injecting humidified air can reduce plugging in aeration pipes.
For the 501.000 ton test cell used and under the conditions tested, there is an economic
advantage in using forced aeration
REFERENCES
1.
2.
3.
4.
5.
Robert W. Bartlett, "Solution Mining, Leaching and Flows Recovery Material", Second Edition, 1998.
Severe Palacios C., "Leach Engineering".
Eduardo Patio - Geoffrey Hansford, "Biolixiviacin, Modelamiento de Biopilas de Lixiviacin".
Metallurgy Area Sociedad Minera Cerro verde S.A.A., "Report of Metallurgical Evaluations.
MINITAB Release 13.