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Hydrodynamic Characterization and Optimization of the Chuquicamata Ripios

Mina Sur Aglomerados Heap Leach Project – Part 1

Conference Paper · August 2000

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 Hydrodynamic Characterization and Optimization
of the Chuquicamata Ripios Mina Sur Aglomerados
Heap Leach Project – Part 1
J. Chahbandour1, A. Guzman1, C. Filippone1, and I. Carrera2
1
Water Management Consultants, Inc.
1875 Lawrence Street, Suite 500, Denver, CO 80202
Phone: (303) 297-9005; Fax: (303) 297-9007
2
Codelco-Chile, Division Chuquicamata
Subgerencia Oxidos Mina Sur
Chuquicamata, Chile

INTRODUCTION

Project description
Beginning in 1992, Codelco's Chuquicamata Division
initiated a feasibility investigation to define the economic
viability of benefaction of Mina Sur batch leach tailing
material. Between 1992 and 1995 Chuquicamata evaluated
four distinct alternatives for exploitation of this resource.
The results of this alternatives evaluation indicated that a 1:1
agglomerated mixture of Ripios Antiguos de Mina Sur
(RAMS) and Ripios Frescos de Mina Sur (RFMS) leached in
heaps would be the most technically and economically
attractive option. Resource estimates indicate that there are
approximately 85 million tons of RAMS material and 69
million tons of RFMS tailings. Together the combined
resource is approximately 154 million tons at a grade of
0.45% CuT.
Based on the feasibility investigation the process, design
and operational parameters were defined for an industrial
scale test facility. RAMS and RFMS materials were
agglomerated at a 1:1 ratio (referred to as Ripios Mina Sur
Aglomerados (RMSA)) in parallel drums and transported by
conveyor to a RAHCO stacker. The RAHCO placed the
material to a thickness of 18m in a prograding manner.
Operation of the leach pad commenced on June 27,
1998. Approximately 43 days after irrigation was initiated,
the heap suffered a massive slope failure involving
approximately 100,000 tons of material.
Subsequently, the project was returned to a basic
engineering level. A multi-disciplinary project team was
formed to evaluate the cause of the failure and to define the
necessary construction and operational criteria for successful
performance of a new industrial scale test pad.
This is the first of two papers presenting the results of
hydrodynamic characterization and optimization completed
as part of the RMSA heap leach project. This paper focuses
on the characterization and definition of optimal operational
conditions of the initial RMSA industrial test facility
described above. The subsequent companion paper
(Hydrodynamic optimization of Chuquicamata's Ripios Mina
Sur Aglomerados Heap Leach Project – Part 2) summarizes
the hydrodynamic characterization, design and optimization
of the new RMSA2 facility currently in operation.
Objectives
As part of the multidisciplinary project team, Water
Management Consultants was retained to perform a
hydrodynamic evaluation of the initial RMSA leach pad
with the following objectives:
• Determine the hydrodynamic mechanisms
responsible for the failure of the RMSA
industrial heap.
• Identify the operational conditions that would
allow optimal economic leaching of the
industrial leach pad.

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HYDRODYNAMIC CHARACTERIZATION – PART 1
To achieve the objectives outlined above, a hydrodynamic
characterization program was designed to:
• Define the hydrodynamic parameters
responsible for the observed behavior and that
would control the performance under optimal
conditions.
• Define the spatial variability of hydrodynamic
properties of the agglomerated ore.
• Identify and compare the properties between
the leached and unleached areas.
The characterization of the initial RMSA leach pad
consisted of geophysical surveys, drilling and sampling, and
hydraulic testing.
Geophysical survey
Under the direction of Water Management Consultants,
Wellfield Services Ltda completed an electrical resistivity
tomographic survey on the industrial heap approximately six
months after irrigation was halted to define the solution
distribution within the profile. Both two- and three-
dimensional surveys were completed.
Figure 1
Two-Dimensional Electrical Resistivity Profiles
(1)
Wellfield Services Ltda , Juan Glasinovic 480, Galpon 39, Antofagasta, Chile.
-2-
WMCI – FEBRUARY 2001
The two-dimensional lines were oriented perpendicular
and parallel to the direction of advance that the RAHCO
stacker followed as the ore was placed.
Figure 1 presents the two-dimensional resistivity
profiles. Based on the resistivity structures illustrated in
these figures solution distribution patterns were established
that aided in development of the hydrodynamic conceptual
model. Because the survey was completed approximately
six months after irrigation was suspended, it was possible to
identify important hydrodynamic controls on solution
distribution and movement. The results indicated that
significant lateral migration of solution occurred during
operation inhibiting vertical solution flow. In addition, there
were distinct trends in vertical and horizontal solution
distribution that suggest that the heterogeneity in
hydrodynamic properties played an important role in
solution movement and retention. Solution accumulation in
the middle of the profile resulted from reductions in
hydraulic conductivity and vertical contrasts in
hydrodynamic properties.
HYDRODYNAMIC CHARACTERIZATION – PART 1(Continued)
Drilling and sampling
Drilling and sampling were completed in order to define
the vertical and horizontal variability in key hydrodynamic
parameters. Information was collected from both irrigated
and non-irrigated areas to identify changes in hydrodynamic
characteristics that resulted from irrigation. Boreholes were
completed along each of the two-dimensional geophysical
lines in order to correlate the geophysical data with
variations in the hydrodynamic characteristics of the
agglomerated ore.
The difference in physical properties between the
irrigated and non-irrigated areas was relatively small,
suggesting that the initial conditions established when the
material was placed determined, to a large extent, the
magnitude and heterogeneity of key hydrodynamic
parameters. Variations in hydrodynamic properties
correlated well with the geophysical data and showed
distinct horizontal and vertical trends.
Figure 2
Variations in Bulk Density and Degree of Saturation as a Function of Depth
Density vs Depth
RMSA-6
0 0
5 5
Depth (m)
10
15
20
1.40 1.50 1.60 1.70 1.80 1.90 2.00 2.10 2.20
Density (gr/cm 3)
Figure 2 illustrates typical variation in density and
degree of saturation as a function of depth. Variations such
as these were important in defining contrasts in material
properties that influenced solution distribution and leaching
efficiency. Master variables controlling the hydraulic and
hydrometallurgical performance were defined as a result of
the analysis of the drilling and sampling data.
-3-
WMCI – FEBRUARY 2001
These master variables were subsequently utilized
during the optimization runs to identify improved
operational conditions that would allow maximum copper
recovery.
Hydraulic testing
In-situ measurements of hydraulic parameters were
completed in both irrigated and non-irrigated areas of the
RMSA heap. The results indicate that the average saturated
hydraulic conductivity of the irrigated area was
approximately one order of magnitude lower than that of the
non irrigated area. The average saturated hydraulic
conductivity in the non-irrigated area was approximately 1.1
x 10-4 cm/s versus 6 x 10-5 cm/s in the irrigated area.
Therefore, the relatively small but significant
differences in key hydrodynamic parameters measured
between non-irrigated and irrigated areas had a strong
influence on saturated hydraulic conductivity. The behavior
of the industrial RMSA leach pad was particularly sensitive
Degree of Saturation vs Depth
RMSA-6
Depth (m)
10
15
20
10.00 30.00 50.00 70.00 90.00
Degree of Saturation (%v/v))
to these variations because the initial conditions were so
close to critical limits. As a result only small changes in
magnitude were required to severely limit the performance
of the facility. This was a major contributing factor to the
slope failure.
HYDRODYNAMIC CONCEPTUALIZATION
The hydrodynamic conceptualization was developed
based on an assessment of the performance of the test pad
during operation and the hydrodynamic characterization
results. The key points included in the conceptual model for
each of these components are summarized below.
Operational performance
Approximately 92% (110,000 m3) of the solution
applied during the 43-day operational period was retained as
storage resulting in phreatic levels of 15 m within the RMSA
heap. Even under these hydraulic head conditions, flow
from the drainage pipes was minor due to the retentive
capacity of the material. Significant lateral migration
resulted from the physical heterogeneity and strong retentive
capacity of the agglomerated material which ultimately lead
to loss of control of solution collection.
The hydrodynamic efficiency (a measure of changes in
inventory over time) of the RMSA pad is illustrated in
Figure 3 and shows an increase to approximately 7% during
operation. The low hydrodynamic efficiency resulted from
the significant amount of solution in storage early in the
leach cycle. The elevated inventory resulted from the lateral
movement of solution and high operational moisture content.
Figure 3
Measured Hydrodynamic Efficiency for the RMSA Industrial Pad
1 .0 0 0 0
0 .1 0 0 0
Hydrodynamic Efficiency
0 .0 1 0 0
0 .0 0 1 0
0 .0 0 0 1
0 10
The copper recovery reached a maximum of approximately
8%. The projected recovery was 60% based on the results of
metallurgical testing completed during the feasibility
evaluation. The significant amount of solution that
remained in inventory would have prevented the projected
recovery from being attained in the planned 180-day
operational cycle.
Based on the operational performance of the RMSA
leach pad, it is clear that the conditions imposed by a
WMCI – FEBRUARY 2001
constant irrigation rate of 8 l/hr/m2 were incompatible with
the hydrodynamic characteristics of the agglomerated
material. The high retentive capacity of the RMSA required
a significant hydraulic head to initiate and maintain solution
discharge, which compromised the geotechnical stability of
the heap.
Hydrodynamic characteristics
Similarities between leached and unleached areas
indicate that the initial conditions were a critical factor in the
performance of the RMSA leach pad. Due to the methods of
construction and quality of agglomeration, key
hydrodynamic parameters were at critical limits prior to start
up. The results of the physical characterization indicated
that there were important horizontal and vertical trends in
key hydrodynamic parameters that controlled solution
distribution and inventory. The results also indicate that
relatively small differences in magnitude were required to
create significant contrasts in hydraulic characteristics.
Three principal orientations to heterogeneity in
hydrodynamic characteristics resulted from the stacking
method. The two principal horizontal axes were related to
the direction of advance of the RAHCO stacker. Parallel to
the direction of advance the variability is characterized by a
20 30 40 50 60 70 80
T im e ( d a y s )
short correlation range ( 3 m) resulting from large changes
in material properties over relatively short distances.
Perpendicular to the direction of advance material properties
are relatively uniform and show less variability over longer
distances ( 10 m). Variability in the vertical direction
results from the influence of material segregation on
hydrodynamic properties and is characterized by a short
correlation range.
-4-
HYDRODYNAMIC CONCEPTUALIZATION (Continued) WMCI – FEBRUARY 2001
During operation the spatial heterogeneity in hydraulic
Figure 4 illustrates the results of the stochastically conductivity controlled the vertical and horizontal solution
simulated hydraulic conductivity field within the RMSA distribution within the leach pad. Local contrasts in material
leach pad. The hydraulic conductivity field was properties controlled flow segregation and a high degree of
characterized by the maximum values near the surface and a solution retention resulted from the significant fines content
clear reduction to the minimum values with depth. The and strong lateral movement of solution.
figure illustrates the rapid changes in hydraulic properties
along the axis parallel to the direction of advance.
Perpendicular to the direction of advance the lateral
variability in hydraulic conductivity was minimal as
indicated by the trends observed in the field.

Figure 4

Simulated Hydraulic Conductivity Field

Paralela a la
Parallel to thedireccion
direction de apilado
of advance

15

Z (m)
10

0
0 50 100 150 200 250 300 350
Y (m)

K (cm/s): 0.002 0.0035 0.005 0.0065 0.008 0.0095

Perpendicular
Perpendicular toa the
la direccion deadvance
direction of apilado

15
Z (m)

10

0
0 50 100 150 200 250 300
X (m)

K (cm/s): 0.002 0.0035 0.005 0.0065 0.008 0.0095

-5-
HYDRODYNAMIC OPTIMIZATION WMCI – FEBRUARY 2001

Approach
The operational and physical components of the
conceptual model were synthesized to construct a variably
saturated flow model. The model was calibrated against
observed phreatic levels in the leach pad and solution
discharge rates. The results of the calibration are illustrated
in Figure 5 and indicate that the model adequately
reproduced the observed behavior.
The hydrodynamic optimization of the RMSA leach pad
utilized the calibrated flow model and an optimization
routine that incorporated the site-specific criteria established
by Chuquicamata personnel. The criteria reflected
operational and geotechnical constraints required for
successful facility performance.
Figure 5
Results
The results of selected optimization runs are presented
in Figure 6. The results presented in this figure illustrate the
difference in predicted performance for distinct operational
conditions. The initial optimization runs indicate that while
geotechnical criteria could be satisfied the selected
operational conditions would result in excessive time to
reach maximum discharge rates. In addition, the results
showed that the requirements for stable flow through the
leach cycle could not be met.

Model Calibration Results

16000
Cumulative discharge (m )
3

14000
12000 Observed Discharge

10000 Predicted Discharge

8000
6000
4000 Loss of solution capture as
2000 critical head developed in pad

0
0 10 20 30 40 50 60
Days

The model successfully reproduced the solution

accumulation within the pad and the time of initial
discharge. The gradual deviation between observed and
predicted cumulative discharge is a result of imprecise
measurements of discharge. It is likely that the measured
values were underestimated as a result of partial solution
capture.

-6-
 HYDRODYNAMIC OPTIMIZATION (CONTINUED) WMCI – FEBRUARY 2001

Figure 6
Hydrodynamic Optimization Results

In itia l o p tim iz a tio n m o d e l

60,000 600

50,000 500
D eDischarge
s c a rg a (m 3)
(m3)
QQ (m(m3/dia)
Discharge (m 3)

40,000 3 / d ia ) 400

Q (m 3/day)
30,000 300

20,000 200

10,000 100

- 0
0 20 40 60 80 100 120 140 160 180
T i m e (D a y s)

F in a l o p tim iz a tio n m o d e l

60,000 600
D e s c a rg a(m3)
Discharge (m 3 )
50,000 Q (m3/dia) 500
Q (m 3 / d ia )
Discharge (m 3)

40,000 400

Q (m 3/day)
30,000 300

20,000 200

10,000 100

- 0
0 20 40 60 80 100 120 140 160 180
T i m e (d a y s)

-7-
 HYDRODYNAMIC OPTIMIZATION (CONTINUED) WMCI – FEBRUARY 2001

While these operational scenarios are able to meet the Implementation of this schedule would result in the
geotechnical stability criteria, they fail to create optimal following:
hydrodynamic performance. Figure 6 illustrates the • Increase of 520% in volume recovered relative to
results for the final optimization model. The the actual performance.
hydrodynamic performance that results from these
operational conditions meets all of the operational and
• Use 84% of the solution actually applied.
geotechnical criteria established by Chuquicamata • Increase hydrodynamic efficiency by a factor of
personnel. 3.4.
The optimal irrigation schedule consisted of the Increased copper recovery by 390% and achieve 75%
following components: of the target recovery.
• Initial wet up period using a constant irrigation
rate based on the hydrodynamic characteristics
of the ore.
• Intermittent irrigation cycles that were able to
sustain the desired hydrodynamic and
geotechnical performance. The rates and
duration of the intermittent cycle were matched
to the hydrometallurgical and hydraulic
characteristics of the ore.

SUMMARY

The initial feasibility investigation for the RMSA Heap Leach Dynamics Technology is based on well-
leach pad followed standard industry practices. However, established hydrologic tools that can be applied to
given the nature of the materials under investigation, the improve heap performance and reduce costs. Operations
lack of consideration for the hydrodynamic properties of with “difficult” material are excellent candidates to
the agglomerated ore during the design, construction, and benefit from optimization using Heap Leach Dynamics
operation of the RMSA resulted in significant technical Technology, although this technology has been applied to
and financial setbacks. Had the hydrodynamic less complicated leach operations resulting in significant
characteristics of the RMSA material been considered financial benefits to the operators.
during the initial feasibility investigation it is likely that
the facility would not have suffered the slope failure and
the projected operational targets would have been met.
The RMSA project clearly illustrates that design of heap
leach facilities can greatly benefit from Heap Leach
Dynamics TechnologyTM at a minimal cost relative to
normal feasibility expenditures.

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