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Gold heap leach simulation and optimization using a multiphysics model

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 SPECIAL GOLD SECTION

Gold heap leach simulation

and optimization using a
multiphysics model
S. Garcia, C. Ramon and A. Esplin
Minera Yanacocha SRL, Lima, Peru

J.E. Gebhardt and A. Hernandez

Process Engineering Resources Inc., Salt Lake City, Utah

D. McBride and M. Cross

Swansea University, School of Engineering, Swansea, United Kingdom

Abstract
The Minera Yanacocha operation presents various operating challenges, due to the complex structure of several
heaps interconnected with ponds and gold recovery plants. A comprehensive process model has been developed
in order to better understand the effects of certain operating parameters on issues such as water usage and inven-
tory. An integral component of the water/mass balance of the process is a model of each heap that describes the
flow and chemical behavior based on the individual characteristics of the heap. A computational fluid dynamic
(CFD) software framework is used to model the individual heaps. The structure, calibration and validation of the
model are described. Several examples demonstrating application of the process heap model are presented for
the La Quinua heap. The effects of loss of solution flow to the heap (i.e., pump failure), increased cyanide levels
in applied solutions and higher copper head grades on the process operation and balance are investigated with
model simulations and compared to the baseline operating conditions. An example of estimating gold production
and inventory based on projected heap loading plans is provided.

Key words: Gold/ gold ores, Heap leaching, Modeling and simulation

Introduction from intermediate ponds can be directed back to the heaps,

Minera Yanacocha S.R.L. (MYSRL) is a large while flow from pregnant solution ponds is processed through
gold heap leach operation located about 48 km north Merrill Crowe or carbon column plants. At MYSRL, intercon-
of Cajamarca City in the northern Cajamarca district nected piping permits the pumping solution from one area
of Peru. It is one of the world’s largest gold mines, of the mine operation to another. This complicates operating
producing 80,860 kg (2.6 million oz) of gold in 2006 practices, since there are numerous opportunities for exchange
(Newmont Annual Report, 2006). Reserves were re- of solution from one process area to another.
ported at 952,000 kg (30.6 million ounces) (Newmont The location of the mine complex in a tropical climate
equity 15.6 million ounces). As illustrated in Fig. 1, zone causes water management to be a recurring issue, as the
MYSRL has five openpit mines, several leach pads annual precipitation cycle goes through wet and dry periods,
and three metal solution processing plants. It recently with occasional significant precipitation events. Water manage-
added a processing plant to mill and tank leach tran- ment procedures are necessary to ensure an adequate supply
sitional ore. The site is large in area (total land area of process water during the dry season, and timely startup of
of ~89 km2) and exhibits different microclimates water treatment facilities at the beginning of the wet season.
within the area of the property; for example, heavy The costs of solution pumping and treatment of process water
rain may fall in one section while only a light drizzle before discharge to the environment during the wet season adds
falls in another. expense to the process. Proper water management practice can
A section of the process flowsheet for the MYSRL optimize and reduce operating costs.
site is illustrated in Fig. 2. MYSRL has multiple mine In this paper, the structure of the heap leach model is de-
pits and heaps (see Fig. 1) and each heap has a set of scribed, as well as the calibration and validation of the model.
ponds associated with the heap. These ponds receive Several examples of the application of the model are presented
pregnant leach solution, intermediate solutions and for the La Quinua heap. The effect of loss of solution flow
stormwater flows. Solution applied to the heaps can to the heap (i.e., pump failure) is described and the effect of
be pumped from various ponds. Recycled solutions increased copper content in the ore on the process metallurgy
Paper number MMP-09-037. Original manuscript submitted October 2009. Revised manuscript accepted for publication
Jaunary 2010. Discussion of this peer-reviewed and approved paper is invited and must be submitted to SME Publications
Dept. prior to May 31, 2011. Copyright 2010, Society for Mining, Metallurgy, and Exploration, Inc.

November 2010 • Vol. 27 No. 4 196 MINERALS & METALLURGICAL PROCESSING

 Figure 1 — Schematic of the Minera Yanacocha S.R.L. property site near Cajamarca,
Peru.

Figure 2 — Partial flowsheet of the Minera Yanacocha S.R.L. heap leach operation.

is discussed. With an integrated database for historical and
future heap-loading plans, the model can be used to estimate
heap production and inventory.
Model background & structure
The heap leach model is a phenomenological model that is
based on the physics and chemistry of the process, designed
and implemented within a computational fluid dynamics
(CFD) package. PHYSICA is used as the multi-physics soft-
ware framework (Bailey et al., 1999). The model incorporates
the fundamental phenomena of the process, which has been
mostly detailed by Bartlett (1998), within the context of a
defined geometry. Thus, the utility of this type of model is
geared toward developing a better understanding of the process
through investigations of the effects of key variables within
the process, both chemical and physical. A similar multiphys-
ics model structure has been employed in a copper heap leach
model (Bennett et al., 2003a; 2003b; 2006; Cross et al., 2006).
A practical model of a heap leach system offers considerable
challenges, due to the wide range of physical phenomena pres-
ent. The applied solution can consist of a number of reactants
of varying concentrations, which are diluted by rain events.
Heaps internally are made up of different ores of varying texture
and particle size distributions, which results in considerable
heterogeneity and leads to widely varying flow conditions,
coupled with liquid-solid reactions and transport of the soluble
species throughout the heap. Other phenomena that can influ-
ence flow conditions include decrepitation of the substrate,
compaction, channeling of the liquid phase and transport of
fines. Compaction can to a certain extent be modeled through

MINERALS & METALLURGICAL PROCESSING 197 Vol. 27 No. 4 • November 2010


Figure 3 — Schematic of the shrinking core model.
permeability functions. Decrepitation would only be an issue
where large proportions of the solid phase are soluble, which
is not typical in heap leach systems. Flow channeling is as-
sociated with strong structural heterogeneity, which may occur
over time when preferential pathways develop. The influence
of channeling can be incorporated into the model by defining
regions where a proportion of the solution travels through
non-interacting pathways. Precipitation is easily modeled
and the behaviour of fines can be dealt with using appropriate
rules. The comprehensive flow algorithm has been coupled
with PHYSICA transport equations to track the convection
of soluble species throughout the heap. A reaction set has
been implemented to describe the basic chemical reactions,
consumption of CN and the extraction of Au, Ag and Cu from
ore during the leach process. A shrinking core model is used
to describe the chemical dissolution reactions, between solid
particles and liquids, for various particle sizes.
Solution flow. Flow through variably saturated porous media
is typically characterized by the Richards equation (Bear, 1972).
Under typical heap operating conditions, flow through the heap
is generally considered to be in the unsaturated flow regime;
however, areas of low permeability, compaction and poor
drainage can lead to moisture-saturated areas within the heap.
Various versions of the classical Richards equation have been
proposed in the past and used to provide the basis for specific
numerical solution procedures (Tindall and Kunkel, 1999). In
this model, a scheme has been developed to handle complex,
variably saturated flow conditions, such as infiltration into dry
soil, drainage, perched water tables, flow through heterogeneous
materials and channeling effects. The basic equations of the
flow model are given here and a comprehensive discussion of
the numerical schemes employed and validation can be found
in McBride et al., 2005a and McBride et al., 2005b.
The Richards equation is written in terms of the water
pressure head and the water moisture variables. It is defined
by coupling the flow continuity equation with the Darcy flux
equation. The main variables used to describe the movement
of moisture through variably saturated regions are:
The pressure head or capillary head (h) defined as
(1)
where P is the pressure and ρg is the specific weight of
water (density x gravity). In unsaturated regions, h will take
negative values due to capillary suction. In saturated regions
all voids are filled with moisture and h ≥ 0.
The total hydraulic head (H) is
November 2010 • Vol. 27 No. 4 198
H=h+z (2)
where z is the elevation head, the vertical distance upwards.
The moisture content (θ) takes the saturated value, θsat, in
saturated regions and in unsaturated regions is dependent upon
h, giving θres < θ(h) < θsat, where θres is the residual moisture
content of the material.
The Darcy equation describes the movement of moisture
in saturated porous flow,
(3)
where q is the flux in the xi direction and Ksat is the saturated
hydraulic conductivity.
For unsaturated porous flow, Eq. (3) is modified, giving
the hydraulic conductivity as a function of the pressure head.
(4)
To ensure mass conservation, the volumetric continuity
equation also needs to be satisfied.
(5)
Substituting (4) into (5) and rewriting the righthand side
in terms of the pressure head (h) gives the mixed form of the
Richards equation:
(6)
Rewriting the left hand side of Eq. (6) in terms of the pres-
sure head (h) gives the h-based form of the Richards equation;
(7)
where C(h) is the specific moisture capacity and is defined as
(8)
The choice of the primary variable to be solved allows the
Richards equations to be written in different forms. Both the
h-based and ‘mixed’ forms of the Richards equations can be
employed in the solution of variably saturated conditions,
but special care must be taken to ensure mass balance. The
h-based form can achieve good mass balance if the change in
h is small enough during a time step, whereas the mixed form
improves mass balance with a sharp-wetting front. Therefore,
a simple switching method is employed between the mixed
form and standard h-based scheme according to the local soil
water conditions.
To close the mathematical equation, models such as those
given by Brooks and Corey (1964) or Van Genuchten (1980)
are needed to specify constitutive relationships for pressure
head – moisture content – hydraulic conductivity. The most
commonly employed model, developed by Van Genuchten
MINERALS & METALLURGICAL PROCESSING
(1980) is:
(9)
(10)
where θres is the residual saturation after draindown, α and
n are material parameters and m = 1-1/n.
The unsaturated soil hydraulic properties θ(h) and K(h) are
in general highly nonlinear functions of the pressure head. It
is this highly nonlinear dependency of the hydraulic proper-
ties on the pressure head that makes solution of the Richards
equation problematic. Sophisticated numerical schemes and
transformations, such as the ones described by Celia et al.,
1990, Kirkland, et al., 1992, Pan and Wierenga, 1995, and Hao
et al., 2005, are required to enable solutions.
Reaction chemistry. The reactions module incorporates a
basic reaction set for the cyanide leaching of gold, silver and
copper. Since in many ores, high cyanide losses can occur
when other cyanicides are present, the model also allows for a
generic reaction that acts as a cyanide consumer. This generic
reaction can be specified for each ore type.
A shrinking core algorithm is employed for each metal to
model the extraction of the metal from an ore particle (Fig.
3). The ‘shrinking core’ concept, with instantaneous reactions,
assumes that the extraction process is controlled by diffusion of
the cyanide and cyanide complexes through the solution in the
ore particle pores. In fact, the reaction rate is not instantaneous
and in the model this fact is taken into account by having dif-
ferent reaction rates for each mineral species, according to the
following reactions for gold, silver and copper.
(11)
Mass relationship: 1 mole of Au reacted requires 1/4 mole
of oxygen and 2 moles of cyanide.
(12)
Mass relationship: 1 mole of Ag reacted requires 1/4 mole
of oxygen and 2 moles of cyanide.
(13)
Mass relationship: Since copper can form a variety of cya-
nide complexes, an average mass relationship is used based on
observation from operating data; that is, 1 mole of Cu dissolved
requires about 3.2 moles of cyanide.
The shrinking core models the chemical reactions between
a solid particle and liquid. Although for the purposes of the
model, the liquid does not ‘flow’ into the particle micropores,
cyanide as the reactant can diffuse into the micropores under
a concentration gradient. The metal is dissolved and metal-
cyanide complexes diffuse out into the bulk solution. Hence,
the reaction rate is limited by the rate of diffusion between
the particle surface and the reaction surface. Each reaction
is assumed to take place independently of all other reactions,
allowing the rate of reaction to differ for each mineral. In the
case where more cyanide is required for reactions within a time
step than is available, the cyanide is shared out proportionally,
based on the amount required by each reaction. The fraction of
particle reacted is then scaled back for each mineral. Multiple
MINERALS & METALLURGICAL PROCESSING 199
and varying particle properties can be specified for each ore
type. Small particles tend to react faster than large particles,
because the diffusion of reactants between the particle surface
and reaction surface is less significant.
Each particle size has an initial radius (r0). Each reacting
mineral has a characteristic radius (rm) for each particle size
to which the cyanide needs to diffuse for the reactions to take
place. It is assumed that the chemical reaction is instantaneous
and that the concentration of reacting mineral is uniformly
distributed in the particle.
The rate of change of the characteristic radius, rm, in an ore
particle of radius r0, is determined as
(14)
where B relates to the chemical leaching reaction rate and
is constant for all particle sizes, ρ is the particle density, Mi is
the molecular weight of the mineral and xi is the mass fraction
of the mineral.
Because of competing reactions from several minerals and
differing extraction rates for different ore types, the value of
the rate modifier, B, needs to be determined experimentally
for each ore and mineral.
The diffusion rate limiting, or resistance term Rdiff, is given by
(15)
where Deff is the effective rock diffusion coefficient and
dc/dr is the concentration gradient of the cyanide over the
radius of the particle.
Employing an explicit solution method, the characteristic
radius, rm, for a given particle for mineral i is obtained. If
there is insufficient cyanide available to meet the demands of
all the reactions, the available cyanide is shared out propor-
tionally to the reaction requirements and no mineral is given
preference over another. The particle fraction reacted, , and
characteristic radius, , are then scaled back accordingly.
Suite of software tools. There are several parts to the suite
of software simulation tools. The heap model can be run for
an individual heap and configured with data from operations,
mine planning and the chemical laboratory. The model simu-
lates expected heap performance under the given conditions.
Simulations of the heap can be performed using the fully
spatial three-dimensional heap model, but these simulations
require substantial computing time. With a typical ore loading
plan, simulation of a one-month leaching period with the 3D
model might require eight to 10 hours run time on a laptop,
depending on the number of actively leached cells. In order to
achieve a computational solution in run times that are practical
for a process engineer, a variation of the 3D model is used.
In this process heap model, all spatial information is ignored
and active regions of the heap are combined on an equivalent
elevation basis in order to speed up the computational time.
All operating parameters and material properties are col-
lected in a SQL database, where all records are maintained of
tonnage of ore placed on the heap, gold content in the ore, leach
schedules, application rates, ore characteristics, etc. Model input
parameters are available and can be derived from historical
values found in the database. Various simulation leach time
periods can be specified by the user. A base case simulation can
be performed with historical data. Then the user can modify
various input conditions and compare results from the heap
Vol. 27 No. 4 • November 2010

Figure 4 — Calibration of heap leach model (simulated)
against experimental data from column leach test (Garcia
et al., 2008).
leach simulations of the same time periods. With information
about the anticipated future heap loading plan and ore material
characteristics, the heap model can also be used to predict PLS
conditions, flow and concentrations, production and inventory.
In the examples presented here, the base case simulation
was performed with the historical data. Next, simulation
input parameters were modified on subsequent reruns of the
simulation in order to generate the results for the particular
process change.
Mass balance simulations of the entire process flow sheet
can also be performed. The information from the process heap
model is fed into a water and material balance model. The two
models are linked to enable data exchange and transportation
of results from the heap model, in order to resolve mass and
species concentrations. Resolution occurs in all streams around
the process on a daily basis. A description of the structure of
the process model tool was reported by Gebhardt et al. (2006).
Figure 5 — Comparison of the process heap leach model (simulated) flow and gold content against
measured data from plant operations.
November 2010 • Vol. 27 No. 4 200
Model validation
Validation is a critical phase of model implementation and
development. The phenomenological structure of the leach
model requires that certain physical and chemical relationships
and properties be calibrated to the actual system and ore type.
This mainly involves the mineral dissolution or reaction rates
and the ore hydraulic parameters. Kinetic reaction rates are
incorporated in the heap leach model through a shrinking-core
type reaction applied to each particle size class. The mineral
kinetic rate parameters are individually set, typically from
laboratory column leach test data, for gold, silver and copper.
An example of the calibrated reaction rates for gold and silver
for a column leach test is shown in Fig. 4. Cyanide consump-
tion rates can be matched to a specific ore type by defining
an alternative “other” or gangue-type mineral that consumes
cyanide at a particular rate.
Calibration and validation of the flow model was conducted
with data from the early stages of the La Quinua heap. With the
loading plan and leach schedule, the simulated flow and gold
production was compared to the historical values measured
during approximately the first 90 days, as shown in Fig. 5.
There is very good agreement between simulated flow recovered
and the volume as calculated from the measure pond levels.
There is also good agreement between simulated gold recovery
and that measured by the plant operations. Although cyanide
levels were not measured in the PLS, the cyanide content as
simulated by the model is also shown in Fig. 5.
Validation of the process heap model was performed with
data from operations for the large-scale La Quinua heap over
an extended time period; i.e., one year. A comparison of the
plant operating data and the results from the model simulation
of the same period is shown in Fig. 6. The simulated values
show excellent agreement with the plant daily production.
Model simulation – application and case
examples
The calibrated model is used to examine various operating
MINERALS & METALLURGICAL PROCESSING
Figure 6 — Validation of heap leach model simulation re-
sults compared to plant operating data (Garcia et al., 2008).
Figure 7 — Flow and gold concentrations in the PLS for
normal operating conditions and under loss of recycle
pump power (one-half of recycle flow) (Esplin et al., 2007).
scenarios. The heap leach model can be used to examine pre-
vious historical periods and the effects of alternative material
characteristics, different operating practices or other ‘what-if’
types of questions relating to any process variable or condi-
tion. A simulation of the base conditions for the heap and the
standard operating conditions is first performed. Then, a set of
simulations is conducted to examine the effects of the change.
A comparison with the base condition can then be evaluated
with various operating and economic factors considered.
Base case (normal operation) condition. The period from
November 1-16, 2005 was selected for the process water bal-
ance simulations. The process changes and upsets examined
in this paper were mainly directed at the La Quinua heap.
By November 2005, approximately 236 million metric tons
of ore had been placed on the La Quinua heap. The actively
leached surface area for the previous month was approximately
650,000 m2. Historical information from mine planning and
operation was used to construct the heap model. The results
from the heap simulation of the normal operating conditions for
the period are shown in Fig. 7. The heap model was initially
set up by simulating the entire lifetime leaching schedule for
the heap. A restart file was saved for the end of each month,
so that additional simulations could be performed from any
point in the heap life cycle (i.e., the beginning of any month).
Power loss to recycle pumps. In this simulation, the effect
of losing power to the recycle pumps was investigated. The
MINERALS & METALLURGICAL PROCESSING 201
Figure 8 — La Quinua pond volume for normal operating
conditions and under loss of recycle pump power (one-half
of recycle flow) (Esplin et al., 2007).
simulated flow of recycle solution to the La Quinua heap was
cut by one-half. The effect of power loss on the PLS discharge
flow from the heap is shown in Fig. 7. PLS flow decreases from
about 6,500 m3/h to ~5,000 m3/h, roughly a 20-25% reduction
in flow from the heap. The effect on gold concentration in the
PLS is the inverse, slightly higher gold grades in the PLS at
the reduced flow condition. Slower liquid velocity through the
heap allows the solution to reach higher gold concentrations.
The effect of power loss on the La Quinua pond volume
is shown in Fig. 8. If no other action is taken, the pond will
overflow 14 days after losing this pump capacity.
Increase in copper head grade. To investigate the effect
of an increase in the copper content of the ore being loaded
onto the La Quinua pad, a three-month period was selected
(January to March). The expected result of higher copper levels
in the ore is a reduction in metal recovery due to the cyanide
consumption by the copper minerals. The utility of the model
is to assist in gauging the magnitude of the effect due to an
expected change in copper content, by considering the gold
and silver recovery during this leach period.
The La Quinua heap had roughly 500,000 m2 of heap sur-
face area under leach during this period. The rate of solution
applied on a daily basis to the heap surface is shown in Fig. 9a
and varied between 8 to 12 L/m2/h. Solution was applied either
as barren or recycle flow to the areas under leach as shown
in Fig. 9b for barren and recycle, respectively. The baseline
simulation uses the normal or historical ore loading schedule
for the La Quinua heap. This data is retrieved and compiled
by the model user interface from a SQL database, along with
the relevant ore characteristics and properties prior to running
the heap simulation. Typically, several material types can
comprise a given cell or lift material. Using the reaction rate
parameters obtained from column tests (see Fig. 4, for example)
for a particular material, overall reaction rate parameters for
the composite ore are calculated on a cell-by-cell basis. The
average copper content for cells active during this leach period
was roughly 59 gpt for the baseline case. The copper content
was increased to 500 gpt for the simulated case.
The effect of increased copper head grade is shown in Fig.
10. Gold (Fig. 10a) and silver (Fig. 10b) in solution are reduced
by the presence of more copper in the system. Soluble copper
(Fig. 10c) in the PLS is increased. The levels shown in Fig.
10 were simulated with a copper reaction rate parameter and
Vol. 27 No. 4 • November 2010
 (a) (b)

Figure 9 — La Quinua heap conditions for (a) solution application rates and (b) area under leach
(Garcia et al., 2008).

lead to higher metal recovery from the ore. The role

of the model is to assist in gauging the magnitude
of the effect due to the change in cyanide content
by considering the gold, silver and copper recovery
during this leach period.
The heap area under leach was described previ-
ously for the increased copper head grade example.
The cyanide level in the barren and recycled solution
was 50 ppm for the baseline case. The cyanide level
was increased to 100 ppm for the simulated case.
The effect of an increased cyanide level is shown
in Fig. 11. Concentrations of all soluble metals
increased with a higher cyanide level. Gold concen-
trations in the PLS, shown in Fig. 11a, increased by
approximately 20%. Silver and copper concentra-
Figure 10 — Comparison of baseline and simulation results for increased
tions in the PLS also increased with higher cyanide
copper head grade (Garcia et al., 2008).
levels, as shown in Figs. 11b and 11c, respectively.
All soluble metal concentrations in the simulated PLS
track the baseline metal values, as the surface area
under leach and amount of solution applied did not
change. As would be expected, higher cyanide in the
applied solution results in higher cyanide levels in the
PLS. Cyanide concentrations in the PLS are shown
in Fig. 11d. Cyanide values in the PLS reach 20-30
ppm for the simulated case, with 100-ppm cyanide
in the applied solution. Baseline cyanide levels were
less than 15 ppm.

Estimating production. One of the challenges

in operations is production planning, integrated
with smooth and efficient metal recovery from solu-
tion. The variability of the ore, content of valuable
minerals and hydraulic characteristics, among other
parameters, coupled with the solution application
rate and chemistry, all contribute to the kinetic fac-
Figure 11 — Comparison of baseline and simulation results for increased tors of recovery. Also to be considered is where the
cyanide level (Garcia et al., 2008). ore is placed, elevation and height of lift. Using the
calibrated comprehensive model allows the opera-
maximum fraction extraction assumed to be equivalent for tor to evaluate various scenarios with multiple ore-loading
both the baseline and simulated cases. Under these conditions, schedules. In Fig. 12a, the simulated monthly gold production
there is not much effect on cyanide in the PLS discharge, as for the Carachugo heap is compared with historical physical
shown in Fig. 10d. production for the period January 2008 to July 2009 and then
simulated for production forecast with a particular ore loading
Increase in cyanide level. The effect of an increase in the plan through Dec 2009. The difference in the accumulated
cyanide level used in the barren and recycled solution applied to gold production value between the physical production and the
the heap was investigated for the La Quinua pad with the same simulated values was 4.2% at the end of July 2009, as shown
three-month period used for the previous example (January in Fig. 12b. This finding should be considered to be in excel-
to March). Higher cyanide levels in the applied solution could lent agreement between model and physical production and

November 2010 • Vol. 27 No. 4 202 MINERALS & METALLURGICAL PROCESSING

 Figure 12 — Comparison of production and simulated gold for the Carachugo heap
from Jan 2008 to Dec 2009 for (a) monthly gold production and (b) accumulated
production.
Figure 13 — Simulated species’ concentrations and flow volume for the PLS of the
Carachugo heap.
lends confidence to the simulated production values forecast
through the end of 2009.
Effect of increased irrigation rate & increased cop-
per head grades. With a similar loading plan for August to
December 2009 serving as the base condition, the effects of
increasing irrigation rate to active leach cells and higher copper
head grade in the ore were examined for the Carachugo heap.
At this point in the life of the heap, there were approximately
31 million metric tons loaded on the heap, with roughly 1.7
million tons added each month. The active surface area under
leach was approximately 210,000 m2. Average head grades
for the current ore were 0.6 g/t Au, 12.1 g/t Ag and 47.3 g/t
Cu. The typical irrigation rate was 10 l/h/m2 of barren solution
with a cyanide concentration of 50 ppm.
Irrigation rate was increased from 10 to 14 l/h/m2 during
a two-month period between August and October. Total flow
to the heap remained the same, except that the higher flow
rate was applied to new cells coming under leach. This newly
loaded ore was considered to be run-of-mine material, with a
particle size coarse enough not to affect the overall material
permeability.
The effect of increased copper head grades in the newly
placed material, from 47.3 to 1500 g/t, was simulated with
solution flow conditions similar to the base case. The results
and effects on gold, silver and copper concentrations in the PLS
are shown in Fig. 13, along with the PLS volume recovered
MINERALS & METALLURGICAL PROCESSING 203
during the simulated leach period. PLS volume flow, shown
in Fig. 13d, is identical for the base case and the case simulat-
ing increased copper head grade, as no change was made in
solution application rates. Increasing the irrigation rate to the
recently loaded cells has the effect of getting more gold into
the PLS in less time; i.e., there are higher gold concentrations
from August to November. However, the reverse is then ob-
served for the period November-December, when the PLS has
a lower gold grade. The effect of higher copper head grade is
a diminished capacity for gold dissolution, since more copper
will be solubilized by the cyanide, with, therefore, less cyanide
available to dissolve gold. The impact on silver recovery to
the PLS is expected to be similar to that for gold in these two
simulated cases. This is observed in Fig. 13b.
With a comprehensive heap leach model, it is possible to
monitor the concentration of gold dissolved into the liquid
phase over time. This allows the model to calculate the gold
inventory; that is, how much gold is remaining in the solid,
how much is in solution and what fraction of the soluble gold
reports to the PLS discharge over time. The effects of the two
simulated cases on the gold inventory are shown in Fig. 14.
The sharp rise in inventory at the beginning of each month is
an artifact of how the loading plan is recorded. There is little
effect on overall gold inventory from adjusting the irrigation
rate to the actively leached cells. However, the presence of
more copper in the ore results in lower gold recovery and, thus,
higher gold values in inventory.
Vol. 27 No. 4 • November 2010
 Figure 14 — Gold inventory for simulated cases with
increased copper heap grade and increased irrigation
rate for the Carachugo heap.
Summary
A comprehensive heap leach model based on multiphys-
ics software incorporating computation fluid dynamics has
been developed for modeling a gold heap leach operation.
The model is based on first principles and includes adequate
detail to model the solution flow and chemistry of the reactive
dissolution process that occurs within the gold heap. Gold,
silver and copper metal recovery is simulated, along with the
consumption and concentrations of the cyanide reactant.
The Minera Yanacocha operation has applied the process
simulation tool to evaluate and monitor a variety of operational
situations. In the examples reported here, the effects of several
process changes were described. The impact of leaching a ma-
terial containing more copper, i.e., higher copper head grade,
was investigated. For the specific time period in the heap life,
higher copper head grades had a detrimental effect on the
recovery of gold and silver. That is, more cyanide consumed
by the copper meant less cyanide available to react with gold
and silver. In the second example, the effect of higher cyanide
levels in the barren and recycled solution applied to the heap
was examined. Given that the area under leach and the solu-
tion application rates were unchanged, the model can be used
to estimate the cyanide levels in the PLS discharge. Cyanide
increased 10-15 ppm for the simulated case over the baseline
values. Using a specific leach period for the La Quinua heap,
the effect of a power loss was investigated by simulating a
reduction in the amount of recycle solution applied to the
heap. Pond volume increases steadily and reaches an overflow
condition after 14 days, if no other process changes are made.
The use of a comprehensive process heap model allows the
effects for a given ore under specific operating conditions to
be quantified. Finally, an example of estimating production
based on a specific loading plan was provided for the Cara-
chugo heap. Simulations indicated that gold in the inventory
increases when copper head grade increases, due to cyanide
consumption by the copper species.
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