HEAP LEACHING

SENNINGER MINING SOLUTIONS

Products for leach recovery of gold, silver and copper; Dust suppression; Solution evaporation; Rinsing and

com
SENNINGER.

www .

Providing Solutions To The Mining Industry

Founded in 1963, Senninger Irrigation Inc. has promoted the concept of Low Pressure High Performance efficient irrigation through the development of products that conserve energy and provide exceptional uniformity. Senninger products became popular in agricultural applications and, in 1970, grew to include the mining industry with the development of special acid-resistant sprinklers for the copper industry. Senninger sprinklers, spray nozzles and pressure regulators are used globally for minerals recovery, dust control, effluent dispersion, evaporation, side of slope leaching and other industrial applications. New Demands
Modern heap leaching practices include expanding technology that demands higher performance to meet strict industry requirements. In many cases, heap leach depths have increased to more than 500 ft of ore depth from only 50 to 65 ft a decade ago. This is a function of economic efficiency and surface area availability both driven by closure and reclamation costs and minimization of impact on agricultural land by mining. Leaching processes using drip methods depend on source point application of the solution, which promotes channeling. Because there is minimal lateral movement of the solution applied over the ore material, close spacing of the drippers and laterals is necessary to achieve the desired application rate. This increases the potential for clogged orifices and lines due to the small flow passages required. Low pressure, 10-20 psi (1.03-1.38 bar) spray nozzles like the mini-Wobbler evenly applies solution over large surface areas, much like a gentle rain, maximizing solution/ ore contact, while minimizing the potential for channeling or clogging. Uniformity of solution distribution is essential to maximizing metals recovery. Wobbler technology, with 90+% uniformity, is the most effective method for total solution contact with the aggregate surface. Channeling and plugging problems associated with drip systems make it difficult to achieve even solution/ore contact, especially in the upper section of a leach pad. Often, mini-Wobblers are installed directly into plugged dripper sites to complete the leach cycle or provide a final rinse.
mini-Wobbler (on riser) Drip Lateral Lines
(Emitters are placed every two feet within the line) Unleached area

Challenges
Application rates for leach solutions are designed to optimize metals recovery and minimize chemical consumption. Critical aspects of heap leach design are depth of ore, presence of water/solution, and local terrain conditions. Run of Mine (ROM) material or dump leach piles, segregate layers of coarse and fine textured material during material placement. Leaching solutions flow more readily in the more conductive layers, potentially leaving areas within the heap un-leached. As the trend of larger and deeper leach piles increases, this condition becomes more prevalent resulting in channeling within the piles.

Channeling occurs

Did you know?

The effective flow area for most leaching emitters are so small they often require filtration of 150 or finer mesh. The larger nozzle orifice sizes, 3/32" to 1/8", of the mini-Wobbler help minimize clogging without requiring expensive filtration.

Uniform Solution Contact

mini-Wobbler nozzle orifice sizes

Lateral line emitter effective discharge flow area

0.052" (1.32 mm)

#6 #6 3/32" 3/32 (2.38 mm)

(2.38mm)

(2.78mm)

#7 #7 7/64" 7/64 (2.78 mm)

(3.17mm)

#8 #8 1/8" 1/8 (3.17 mm)

Senninger.

com

www .

WinSIPP2 Densogram*

Available Tool to Help Design

WinSIPP2 custom mining software was developed to help mining leaching installations achieve the required application rate and uniformity. It provides visual comparisons of various combinations of applicators, flows, pressures, and spacing options. Analyzing these combinations in advance helps assure optimal system design and operation.
mini-Wobblers
*Uniformity evaluation

Model Nozzle MINIWOBBLER 7 Base Pressure Flow 20 psi (1.38 bar) 1.51 gpm (343 L/hr) Layout: Rectangular Offset Spacing 0 ft (0 m) Head Spacing Row Spacing 20 ft (6 m) 23 ft (7 m) Average Precipitation 2 0.0033 gpm/ft (8.2 L/hr/m2) 0.05 (1.23 m) Coefficient of Uniformity Distribution Uniformity Scheduling Coefficient 5% 0.42 (11.09 m) Infinite 92.88% 88.64% 1.24

Wobbler Technology Benefits

Operates at low pressures to save energy costs Provides 90+% uniformity of distribution in a full 360 area with a gentle application Offers the versatility of being moved and used repeatedly Provides visual confirmation of uniformity not afforded by surface drip application Easily adjusted flow and application rates Adapts to pad rinsing for reclamation 1/3 to 1/2 the cost of comparable drip systems Can be directly installed on existing drip systems Low pressure systems save energy and allow greater areas to be leached in less time. Many applicators are not designed to operate at low pressure. Senninger Wobblers have been engineered and designed to provide optimal performance at low pressures, in many cases as low as that used for drip emitters. At low pressure of 15 to 20 psi (1 to 1.38 bar), Wobblers provide a consistent droplet size throughout the entire wetted profile. The solution reaches the ore surface with a gentle even distribution.

Low pressure leaching designs comparison

Drip: To provide this application rate, drip irrigation systems would require spacing of laterals and emitters to be about 2 ft or (0.61 m) between drip lines and emitters. Wobblers: Mini-wobblers and Xcel-Wobblers are spaced 20 ft x 23 ft (6 m x 7 m) between sprinklers and lateral lines. Material and labor costs can vary significantly in these two systems.

20 (6 ft m)

ft 23 m) (7

m .61 t (0 t 2 f apar )

mini-Wobblers are often installed to salvage plugged or improperly designed drip zones.

com

www . Senninger.

NOTE: When a new layer of pad material is placed, drip irrigation lines cannot be re-used. mini-Wobblers and Xcel-Wobblers, however, are typically installed for easy relocation and re-use.

Comparison Drip and Sprinkler

IrriMaker design for 100 m x 100 m pad (328 ft x 328ft)
Drip (Material take-off) Sprinkler (mini-Wobbler/Xcel Wobbler)

Emitter spacing 2 ft (0.61 m) Lateral spacing 2 ft (0.61 m)

mini-Wobbler spacing 20 ft (6 m) Lateral spacing 23 ft (7 m)

Drip

Bill of material

Sprinkler

54,000 linear ft (16,459 linear m) 328 27,000

Drip

16 mm PE lateral / (20 mm) PE lateral Fittings Emitters

Energy required

4,700 linear ft (1,433 linear m) 15 255

Sprinkler

60 10 2 15 8 95
Drip

Pumps Pipes Fittings Emitter operating pressure Filtration Total

Versatility

60 10 2 15 4 91
Sprinkler

No No No No High Yes No

PE lateral recyclable? Emitter recyclable? Visual performance assessment Can flow be changed? Plugging potential? Filtration required? Can orifice be cleaned?

Yes Yes Yes Yes Low No Yes

Senninger.

com

www .

Side Slope Leaching Dust Control

Sprinklers

40 (12. ft 19 m

Portable pipe

Reduces traffic dust on mining roads

3123 & 4123 Part-Circle Impact Sprinklers

45 ft (13.72 m) radius of throw

(Gold/Silver Mining) 3/4" NPT male base, nozzle #9 (9/64") Senninger Part-Circle Impact Sprinklers, when coupled to a portable pipe system provide the best and most flexible option to leach side slopes or keep dust under control. Eliminates costly mobile watering Conserves water Increases coverage efficiency Allows dust control automation Side slope leaching option
NOTE: Pressure regulator recommended @ 40 psi (2.76 bar), Flow: 3.65 gpm (829 L/hr)

Side slope recovery

50 ft (15.24 m) spacing

Evaporation
(Gold/Silver/Copper Mining) Evaporation through a sprinkler nozzle is a function of nozzle size and pressure.Typically this requires high pressure which necessitates higher energy costs. Senninger Super Spray UP3TM with the evaporation pad can be used at pressures as low as 20 psi (1.5 bar) or as high as 80 psi (6.0 bar) with nozzle sizes from 5/32" (3.97 mm) and larger.

com

www . Senninger.

Quick-Connect Riser Adapter

Quick-Connect Riser Adapter RSAD2T (Available for 0.270" PE I.D. tubing only)

Installation recommendations
Quick-Connect Riser Adapter
1. Place the riser adapter in the desired location 2. Support it with either 1/2" or 3/4" PVC pipe or 5/16" plastic stake (PL/1000093) 3. Cut Polyethylene tubing to desired length 4. Insert Super Barb (with tapered end) into both ends of tubing 5. Press fit one tapered end into riser adapter

Riser Adapter
1. Place the riser adapter in the desired location 2. Support it with either 1/2" or 3/4" PCV pipe or 5/16" plastic stake (PL/1000093) 3. Cut Polyethylene tubing to desired length 4. Push one end of tubing approximately 1/2" into riser adapter 5. Insert Super Barb Fitting (with barbed end) into other end of tubing 6. Using the proper punch tool, cut hole in lateral where the tubing will attach 7. Insert barb into the hole
Riser Adapter RSAD270 0.270" I.D. Tubing 3 ft (0.9 m) TU1ST3 Riser Adapter RSAD345 0.345" I.D. Tubing 3 ft (0.9 m) TU15ST3

Super Barb Fitting FTSB2T

0.270" I.D. Tubing 3 ft (0.9 m) TU1ST3

Friction loss through the entire assembly (including 3 ft of 0.270" PE tubing) is 6.3 psi at 2.0 gpm (0.43 bar at 454 L/hr). * Consult factory for friction loss on flows greater than 2 gpm (454 L/hr) or tubing longer than 3 ft (0.9 m).

1/2" or 3/4" PVC pipe or 5/16" plastic stake Super Barb Fitting Fitting FTA15B15B Lateral Friction loss through the entire assembly (including 3 ft (0.9 m) of 0.345" PE tubing) is 1.6 psi at 2.0 gpm (0.11 bar at 454 L/hr). * Consult factory for friction loss on flows greater than 2 gpm (454 L/hr) or tubing longer than 3 ft (0.9 m).

Super Barb Fitting FTSB2T

Super Barb Fitting FTA1B1B

Super Barb Plug FTPLUG2T

6. Using the proper punch tool, cut hole in LDPH lateral where the tubing will attach 7. Insert bushing into the hole 8. Press fit the remaining tapered end into the bushing

6. Using a 7/16" drill and tap to bore a 1/4" hole in HDPE lateral where the bushing will fit 7. Insert the threaded bushing into the tapped hole 8. Press fit the tapered end into the threaded bushing

Lateral Friction loss through the entire assembly (including 3 ft (0.9 m) of 0.270" PE tubing) is 6.1 psi at 2.0 gpm (0.42 bar at 454 L/hr). * Consult factory for friction loss on flows greater than 2 gpm (454 L/hr) or tubing longer than 3 ft (0.9 m).

Bushing FTHS2T

Tubing punch tools sold separately: TUPTAP51 for 0.345" barb fitting and press-fit bushing (red handle). TUPTAP41 for 0.270" barb fitting (green handle).

Lateral Bushing (Threaded) FT1M2T

Senninger.

com

www .

Heap Leaching Applicators

mini-Wobbler
Senninger mini-Wobblers employ unique off-center rotary-action. They provide extremely uniform coverage over a large diameter at low pressure producing a gentle application of solutions.
Gold/Silver Copper

Senningers Xcel-Wobblers utilize a unique off-center rotary-action to provide extremely uniform coverage at low pressures with very low evaporative losses.

Xcel-Wobbler HA CMS
Recommended for high sulfuric acid (0.5 to 3.0 pH) copper mining solutions (Greater than 10/gpl H2SO4) Multi-level throw: approximately 24

(Copper Mine Special)

Xcel-Wobbler MA CMS
Recommended for high sulfuric acid (0.5 to 3.0 pH copper mining solutions (Greater than 10/gpl H2SO4) Multi-level throw: approximately 18 Smaller droplets than high-angle model for a more gentle application and WindFighterTM ability.

(Copper Mine Special)

Xcel-Wobbler HA

(Gold/Silver Mining) Recommended for pH range 3.0 to 9.0 gold and silver mining solutions. Multi-level throw: approximately 24

Xcel-Wobbler MA

(Gold/Silver Mining) Recommended for pH range 3.0 to 9.0 gold and silver mining solutions. Multi-level throw: approximately 18 Smaller droplets than high-angle model for a more gentle application and WindFighterTM ability

PRMP

(Mining ProspectorTM Pressure Regulator) Is ideal for copper or gold/silver mining installations requiring lower flows (0.1 - 7.0 gpm) including side slope leaching and drip.
NOTE: Other higher flow regulators are also available.

com

www . Senninger.

16220 E. Highway 50, Clermont, FL 34711 Phone (407) 877-5655 Fax (407) 905-8249 International Fax (407) 905-8239 Website: www.senninger.com E-mail: info@senninger.com

11 HL 01

MS911