Closure, Remediation & Management of Precious Metals Heap Leach Facilities edited by Dorothy Kosich and Glenn Miller.

January 14-15. 1999

PRECIOUS METALS HEAP LEACH FACILITIES DESIGN, CLOSURE AND RECLAMATION

by Carl J. Burkhalter, P.E., Richard H. Allison, P.E., and Brett F. Flint, P.E. of Knight Piesold LLC, Denver Colorado and Elko Nevada

ABSTRACT
Modem mining and heap leachingpracticesincorporatestate of the art designto provide functionality, economy, expansioncapability,and environmental protection. Optimizingthe functionalityand economyof heapleachfacilities with closure and reclamationplans is key to a successful project. Whenclosureand reclamation needsare identified atthe beginning of the designprocess, a balancebetween operation, expansion, andclosureand reclamation needscan beachieved. Currentpractice in the designof heapleachfacilities and currentclosureand reclamation are examined and suggestionsfor an integratedapproach are developed.

1.0 INTRODUCTION
Chemical solutions have been used to extract metals for hundreds of years in mining history. Modem heap leaching started in the copper industry in the early part of this centtJry mainly in the form of ,'Dump Leaching." Heap leaching to recover precious metals became wide spread in the 1960's with Nevada gold producers leading the way. In recent years several of these pioneer facilities have reached the end of their useful life and have been successfully closed and reclaimed. As higher grade ore bodies are depleted, and heap leach technology improves, the use of heap leaching to recover precious metals will become more prevalent. As with other aspectsof mining, heap leaching inevitably involves some necessary and unavoidable environmental impacts. Responsible mining practices and environmental legislation dictate that mining operations be planned, and completed in a manner to minimize impacts to the local environment. With proper planning and design, many of the environmental impacts due to mining, and heap leach facilities can be mitigated and reclaimed, while still allowing the development of an economic resource. Modem mining design must consider existing environmental conditions and long term closure and reclamation needs from the beginning of the planning process.

1.1 Definition of Heap Leaching HeapLeaching is the tenDused for describingthe hydro metallurgicalprocess of removingmetalsfrom lower grade ores by advancing solution at a relatively slow rate through a pile or "heap" of ore. The solution is chemically formulated to reactwith the ore at a microscopic levelto dissolveandmobilize economicmetals,thereby"leaching" the desiredmetalfrom the ore. The heapis placedon a gentlysloping"pad" or within a naturalvalleyto allow gravity drainageat the baseof the facility and the collection of the resulting"pregnant"solution. Pregnant solution may be stored within the heapbehind a containmentberm or in an outsideholding pond from which it is pumpedto a metal recoveryplant. In the plant,the metalsare chemicallyremovedfrom the solution,leavinga "barren" solution,which is usually stored in an outside holding pond or tank where it is chemicallyreconstituted for re-useon the heap. This process allows the recirculation of the solutionand maximizesefficiency. Oftenthe pregnantsolutionis recirculated throughthe heapto "build up" it's assay and maximizethe recoveryof metal.

29

1.2 Definition of Closure and Reclamation After economical leaching of the ore is completed, the heap leach facility must be closed and reclaimed to either an external (regulatory) or internal (corporate) standard. Closure of the facility is defined as the chemical and physical stabilization of the material within the heap, such that the fate and transport of solutions from the heap are conn-oIled or mitigated to prevent the contamination of the local water resources or other environmental degradation. The chemical stabilization usually involves rinsing the heap with fresh water and/or detoxifying agentsto remove any residual metals and/or chemicals to environmentally safe standards. This process usually involves the replacement of several pore volumes of solution. The physical stabilization of the heap may involve regrading the side slopes for seismic stability and redirecting the outflow from the base to an infiltration or evaporation facility. Closure may also involve placing some type of cover over the heap to minimize infiln-ation of precipitation, reduce erosion, and prepare the facility for reclamation. Reclamation of a heap leach facility is generally defined as those processestaken to rettlm the area to a post mining land use that is considered to be equivalent to, or more productive than, the pre-mining conditions. This process addresses long term physical stability of the facility, surface water drainage and re-vegetation. Reclamation of a heap is similar to that used for other mine facilities such as uneconomical mine rock storage areas (waste dumps). The goal of closure and reclamation is to address the visual, physical, and hydrological impacts of the leach process, and to provide a permanent system that will remove, minimize or mitigate long term impacts.

1.3 Scope This paperis intendedto present an overview of heapleach designand closure/reclamation practice in Nevada. It presentsdiscussionsand practicalsolutions based on the authors' experienceand points out the advantagesof incorporatingclosureand reclamation considerations into the initial stagesof planning and design. Detailed design methods,conclusions,and/orrecommendations arebeyondthe intendedscope. 2.0 CURRENT HEAP LEACH DESIGN PRACTICE
Current heap leachdesign practice, which has developed in the past few decades,involves several key factors including:

Site selection. Selectionof the heaptype andconfiguration. Metallurgicalissues. Hydrologicalissues. Geotechnical issues. Detenninationof designparameters. Minimum design criteria for facilities to be built in Nevadaare prescribedin the NevadaAdministrative Code (NAC) Section 445A. Theseregulations arebased on the performanceof the facility, so use of minimum designcriteria does not release the operatorfrom responsibilityfor protectingthe environmentaland waterresourcesin the area.
2.1 Site Selection The selection of the site will depend on severalfactors and will influence other key components of the design process. In turn. the key components will aid the designer in evaluating each potential site and in developing an economical facility that will meet the needs of the mining operation and have desirable features from an environmental point of view. Information obtained during pre-feasibility, and feasibility level, studies is used to evaluate alternatives and develop a system to select the optimal site. Basic information needed will be site topography, ownership/access boundaries, deposit location, mining plan and adjacent land use, along with available geotechnical, geological and hydro geological information. Using this information a desk study can be completed and several site alternatives evaluated. Factorsto be considered include haul distance from the pit, location of the process plant, regrading required to obtain favorable topography, depth to groundwater, presenceof surface water (springs) and potential environmental impacts. Once an optimal site (or sites) is located, the other components discussed below are examined and the site either accepted or rejected. The process is an iterative one, taking into account the variables discussed below and the relationship with other mine components. It is always good practice to have at least one alternative site in case of unforseen events (such as discovery of economical ore beneath the facility during condemnation drilling.)

2.2 Heap Type/Configuration

Although each heap leach project is as unique as the ore it is designed to leach, there are three basic types of facilities currently used: .Reusable (On/Off) Pads -A relatively small pad area is loaded with one lift of ore which is leached, rinsed and removed. The pad is then reused again for another lift of ore. The spent ore is usually placed in a waste pile similar to uneconomical mine rock. The pad area is usually flat and graded to drain to the opposite side from which the ore is loaded and unloaded. Pad lining materials must be durable and able to withstand the constant traffic of loading equipment. It is common to incorporate a substantial "cover" or "overliner" in any lining system that includes geomembranes. Pregnant solution is generally stored in a holding pond outside of the heap to avoid unloading problems. Figure I depicts a typical schematic of a reusable pad layout and basic sequence of activities. .Permanent Ex~anding Pad -A relatively large area is graded and loaded with several lifts of ore which remains permanently on the pad. To save on initial capital costs, the pad is usually constt1lcted in stages, that may expand both horizontally and vertically. Pad lining materials can be a number of options, with geomembranes being the most common. Depending on the loading method for the first lift, the lining systems may include an overliner or protective cover. Pregnant solution is generally stored outside of the heap in a holding pond. Figure 2 illustrates a typical schematic layout for an expandable pad and the basic sequence of activities. .Vallej: Fill Pad -A natural valley is used to form the leach pad. A retaining stt1lcture, usually an earthen embankment, is used to contain the ore and solution at the down gradient toe. Pad lining options can vary with geomembranesthe most common. In the area with permanent solution storage, regulations may require a double liner with leak detection capability. Figure 3 shows a typical schematic layout for a valley-fill leach pad and basic sequence of activities.

2.3 Metallurgical Issues Several metallurgical issues are critical to the pad designand layout. Most of theseare dictatedby the type of ore and the economicsof metalrecovery. Key issuesfor pad layout include: .Ore PreI2aration and PadLoading -A successful leachingprocessrequiresthat solution be in contactwith large areasof the ore. Dependingon the hostrock porosity and run-of-mine size, crushing may be needed to increase the surfaceareaavailablefor solutioncontact. For ores that containfine soil or rock particlesagglomeration with a binding agentcould be requiredto allow adequatesolutionflow. .Lift Height-Lift heightis a functionof the padareaandproposed loadingrate. An iterativeprocess is usually used to optimizeeconomicsof the liner areaversusexpectedrecoveryand pumping requirements. Typical lift heights rangefrom 20 to 50 feet. .Leach Cycle and ApplicationRate-These are detenninedfrom laboratorycolumn leachtesting. The leachcycle is basedon the time and amountof solutionrequiredto optimize the metalrecovery.Leach Cells-Sometimesthe leachareais physicallydivided into cells to provide the heapoperatorwith a method of accountingfor which areasand methods are the mostsuccessful.The use of cells can help optimize solution recovery and recycle. The size of the cell will be baseduponthe leachcycle, solution applicationand ore loading rates.
2.4 Hydrological Issues A water balance for the facility is developed using the natural water and leach cycles. The natural water cycle includes precipitation and evaporation for the site, and is detennined from meteorological data collected at the site or at regional weather stations. Data for the natural water cycle are used to evaluate operational conditions during nonnal, wet, and dry cycles. This infonnation is used with the elements of the leach cycle (application rate, cycle time and ore adsorption) to create a water balance summary that indicates solution storage, make-up water and stonn water containment needs. The key to a successful water balance is the inclusion of all possible variables and sufficient time related meteorological data to be "statistically significant" (at least 3 to 5 times the expected heap life). Infonnation from the water balance is used to design the collection system beneath the heap, size the solution holding ponds. and to predict process water supply needs. The heap collection system usually consists of a network of perforated piping (corrugated polyethylene tubing) placed within a drainage layer at the base of the ore heap. These pipes direct solution flow to larger pipes or open channels, which carry processsolutions to the holding (pregnant) pond located either inside or outside the heap. The ponds are sized to provide operating solution volume, emergency heap draindown and a design stonn event runoff. In areas such as Nevada, where evaporation exceeds precipitation, the goal

31

is to have a "zero discharge facility" that maintains processsolutions in a closed circuit. In areas of high precipitation, covers or skirts may be used on the heap leach facility to limit the amount of precipitation that entersthe process circuit. It is also common to use a series of ponds to improve solution management. It is often economical to size operational ponds for "normal' operating conditions and to provide an "events' pond to handle solutions from storm events or other abnonnal operating conditions. This events pond may have a single lining on the premise that solutions entering the pond will be removed in a short period of time, once operations have returned to nonnal. 2.5 Geotechnical Issues Geotechnical issues for leach pad design involve the stability of embankmentsand the ore heap,seepage,and settlement within the facility foundation. It is beyond the scope of this paper to provide a detailed discussion of slope stability, and foundation issues. Briefmention is made of key issuesbased on heap leach design experience and analysis of heap leach facilities which have experienced slope or foundation movement: Foundation StTeng!h-lnfonnation on the stTength of foundation materials, especially at the "downhill" toe of the facility, is critical to a successfuldesign. Soft foundation material may present an unsuitable condition leading to slope and liner failures. A well planned, and adequately detailed geotechnical investigation is a must. Liner Interface Shear StTeng!h-Most heaps are designed with geomembrane and/or clay lining systems. The heap geometry almost always leads to conditions conducive to block failures with principle sliding planes along the liner surface. When analyzing these failure planes it is important that good shear strength data, from the materials to be used in the facility, is evaluated and used in the design. First Lift Anal~ses -In addition to analyzing the overall slope of the heap in a block failure mode, it is important to analyze the first lift at the down gradient toe of the facility. StTictrecommendations on lift height and loading direction may be required (downhill loading of the first lift should be avoided). Seepageand settlement issuesneed to be considered when selecting a lining system. If the system includes a synthetic geomembrane,a liner integrity test (puncture test), using the proposed materials, liner section and anticipated loads is recommended. Settlement analyses should focus on the evaluation of differential settlements which may lead to liner failure. 2.6 Design Parameters Based on the above analyses, several key design parametersshould be developed for the leach pad site. These include but are not limited to: .Liner Cross-section -Typical liners sections for heap leach facilities include single, composite and double liner systems (Figure 4). Most leach pads use the composite system that consists of a geomembrane overlaying a compacted, fme-grained soil liner. Solution ponds are generally designed with double liners with a leak detection system incorporated betweenthe primary and secondary liners. In valley fill leach pads the in-heap solution storage area will typically require a double lined system as well. .Loading Plan -Using the proposed mining rates and the metallurgical information discussed in Section 2.3, a loading plan for the facility is developed. The loading plan is based on the available facility area and the leach cycle to allow sufficient time for each lift of ore to be leached and rinsed if needed, before the next lift of ore is placed, or the ore is removed. Preliminary loading plans are prepared early in the design process to help size the leach pad area. .Slopes. Setbacksand Containment Berms -The geotechnical study will provide recommendations on the maximum overall slope and first lift setback so that heap material and solutions are contained during the design seismic event, or other emergency. The containment berms also prevent surface runoff from outside the pad from entering the system. Depending on the topographic layout and design storm event, engineered channels may also be required to divert surface flows away from the facility.

3.0 CURRENT HEAP LEACH RECLAMA TION/CLOSURE PRACTICE IN NEVADA

3.1 General Guidelines The Nevada regulations for heap leach pads require a final closure plan to be prepared and submitted two years prior to the estimated time of permanent facility closure (NAC445A.447). Regulations for heap leach pad reclamation are found in NAC519A.345. The regulations for reclamation address requirements for stable slopes land use and revegetation. while the closure regulations are written to protect ground water. The final closure and reclamation plans

must be written to specifically addresses the requirements of the regulations. These plans need to contain sufficient technical data to demonstrate that the requirements of the regulations will be met. As has been noted, the Nevada regulations are performance based; if the work an operator performs for a closure plan will not meet the criteria for bond release,the operator must continue to revise the plan and perform modifications on the heap until these criteria are met. Since the burden of proof is on the operator, technical data must be provided in the [mal closure and reclamation plans to substantiate that methods proposed will meet the requirements of the regulations for stability, re-vegetation and protection of water resources. The final closure plan should include data on rinsing and/or detoxification process for the spent ore. Such infonnation can be obtained from column testing. A 4 to 12 inch diameter column is loaded with samples of ore taken from the pit and rinsed with freshwater, or subjected to a proposed chemical or biological detoxification process. The column test will provide information on the number of pore volumes of rinse water required to meet effluent standards and on the effectiveness of any detoxification procedures. Often a series of tests are completed to evaluate the effectiveness of various rinse/detoxification processes. If effluent is to be disposed of in an attenuation/infiltration site, laboratory analysis of the attenuation capacity of the soils and the percolation rate at the proposed site will be required for the final closure plan.

The final reclamation plan will needto incorporatestability analyses, coverdesignand re-vegetation issues.Field and geotechnical testing of foundationmaterialsand spentore may be requiredto provide input into slope stability models suchas XSTABL and SLOPE/Wwhich can predictthe long termstaticandpseudo-static stability of fmal slopes. Soil cover designmay involve laboratory testing of the proposed material to provide informationon permeability,porosity, wilting point, field capacity,and soil particle distribution of the proposedcovermaterials. This informationcan then be used in computermodeling programssuchas SoilCover,HELP, OPUS,and UNSATII to predict how runoff and infiltration processwill function in the reclaimed facility and how it may effect the proposed vegetation. 3.2 Reclamation and Closure Plans Closure and ReclamationPlansare two distinct documentsin the Stateof Nevadaand are reviewedby two separate groups. The closure plan addresses the fate and transportof the effluent from the heapand how it will affect ground and surfacewater. Whereasthe reclamationplan addresses convertingthe landto anapprovedpost-mininglanduse. Closure regulations,asstated in NAC 445A43, require rinsing of the heapuntil the WAD cyanide level is reducedto 0.2 mg/l or less, pH is in the rangeof 6 to 9, and othercontaminates are at levelswhich will not degradeWatersof the State. Paragraph 3 of this regulationallows alternatemethodsof chemicalstabilizationto be used,if the operatorcan demonstrate that the resulting effluent will not degradeWatersof the State. Therefore,detoxificationwith chemicals suchas hypochlorite or hydrogenperoxide may be approved. Biological detoxificationis also beingapprovedwith the use of cyanideconsumingbacteria. In addition,technologies areavailablewhich provide a bio-reductionof metals in the heap. Thereare currentlya numberof provenand developing technologies thatareavailable to provide adequate stabilization of spentheapore. As some of thesetechnologies can be costly, with the tradeoff of reducingthe time required to achieve closure,a detailed laboratorytesting programto evaluate variousalternatives if recommended. In order to provide a productive post-mining land use,the reclamation plan mustaddress long term stability and revegetation of the heap leachpad. Generallyspeaking,mostheap leachgrading plansare successful with slopesflat enoughto preventerosion. The state may require a stability analysison slopesdependingon the site conditions. All ore must remain on the pad unlessthe operator candemonstrate that contaminants will not bereleased to Watersof the State.The MeteoricWaterMobility Testprocedureis oftenusedasa basisfor this determination. Ideally. the final grading plan for the heap leachpad will produceoverlandflow. Any ditchesor channelsthat are required for long termsurfacewatercontrol mustbe designed to be non-erosive.Generally.the industrystrivesto revegetateto a level of productivity which existed prior to mining. The reclamationvegetation can be comparedto a reference area at the mine. It is advisableto conductsite specific re-vegetation studiesto evaluatedplantspecies and planting/seeding techniquesfor inclusion in the final reclamation plan. Erosionwhich occurson the site must be repaired and areas with high plant mortality will require replantingbefore the reclamationbond will be released. Therefore.a well engineeredreclamationplan is generallya good investment.

3.3 Heap Leach Pad Reclamation and Closure Design Features Typical design feanlres of a modern closure design may include one or more of the following: clay or geomembrane caps. in-heap passive treatment, out of heap treatments, infiltration/soil attenuation fields, grading which maximizes sun exposure and groWth media covers. Clay or geomembranecaps reduce infiltration, capillary breaks and growth media are used to stimulate vegetation. Typical clay caps have an infiltration rate of IxIO-6cm/sec or less. In-heap passive treatments include bio-oxidation and bio-reduction treatments. The bio-oxidation treatments cultivate bacteria which will consume cyanide. However, thesetypes of treatmentshave the potential to produce acid rock drainage if there are significant amounts of sulfides present in the ore. A bio-reduction treatment fills the heap with carbon dioxide and produces bacteria which reduce the metals and cyanide in the heap by bio-reduction without the potential for creating acid rock drainage. The effluent in the heap may be conveyed to an infiltration field where the metals in the effluent may be attenuated by the soils.

4.0 PRACTICAL SUGGESTIONS FOR AN INTEGRATED APPROACH Examination of the designand reclamation guidelinesindicatesthat good, optimal designand efficient closure and reclamation are often not completelycompatible. As mine operations are typically sensitiveto up-front capital costs, the tendencyis to designfacilities thatminimize up-frontcapitalinvestment. Thesefacilities may incur higher closure and reclamation costsat the end of the facility life. By identifying potentialclosure and reclamationneedsduring the initial planningand design process, an integrated designcanbedeveloped that will meetthe needsof project fmancing, operation,and final closureand reclamation. 4.1 Initial Planning In the initial planningstages, representatives from all phases of the leachfacility life shouldbe included. Typically, the projectowner,operators, civil andprocess engineers, environmental coordinator,closureand reclamationsspecialists, and national or state regulatorsshould all be involved in the initial planning stagesof heap leachfacility. Early involvement of all thesegroups will help to identify relevantissuesthat will need to be consideredthroughout the design,operationand decommissioning of the facility.
The planning processshould include an identification of post-mining land use goals. Identification of post-mining land use can then be used to develop feasible closure and reclamation alternatives that can be considered during the design process. It should be noted that reclamation does not imply restoration. Generally, there is no requirement to restore the area to the same configuration and land use as existed prior to mining activities. In some cases, the resulting land forms from mining may be a beneficial addition to the area. For example, the surface of a reclaimed valley fill leach facility may provide a relatively level area conducive to agriculture in an area of high relief. In other cases, it may be desirable to have the reclaimed facility blend into the surrounding terrain. In either case, identification of the postmining needs will allow the designerto incorporate elements into the initial layout and operation of the facility that may reduce the time and cost requirements for closure and reclamation. Involving appropriate regulatory agencies in this process, or at a minimum, a thorough investigation of the regulatory requirements for closure and reclamation can also allow initial designs to address future needs. 4.2 Design Considerations Design issues that may impact final closure and reclamation include site selection and facility configuration. Placing a square leach pad in a flat plain may prove to be economical for design and operation, but will be difficult to blend into the surrounding topography at the end of mine life. It may be possible to site the leach facility close to existing hills, or other mine facilities such as uneconomical mine rock storage areas so that the rmal, reclaimed configuration has a natural appearance. The use of a round pad may be as economical from an operational standpoint as a square pad and will blend with natUral fonDs. Undulating side slopes may also blend in better. The metallurgical process used should be evaluated from the stand point of detoxification of the leached ore, and final fate of the leach solutions. Surface water design elements should consider the needs of reclamation, including the serviceability and durability of any diversion structures that will be required as part of the fmal reclaimed configuration. Mined ore may be stable at steepslopes for the operational life of the facility, but require extensive regrading to achieve slopes that are stable for the long term and amenable to re-vegetation. Perhaps a flatter heap slope can be used. Consideration of these requirementsduring the initial design phase may allow for practical, cost effective solutions that will allow for economical construction, operation. closure and reclamation.

FIGURE 1
REUSABLE lON/Om PAD SCHEMATIC

MINE PIT

,.--//
/

ORE

\,

/
EXPANDING LEACH PAC

,
FUTURE' I SEGMENT
I I

~o~~
'WNE ORE .PREPARE .LEACH

o~ A=vmI1S
J
ORE AND STACK ON PAD

I I

ORE If" NECESSARY

.RlNSE/TREAT .ClOSE

SPENT ORE PILE IN PlACE

qj':~
-"~
WATER/RfAGENT/ pH

~~=::::Y=~~=~~=~
PREGNANT RECOVERY SownoN POND

BARREN SOlunDN POND

FIGURE 2
PERMANENT EXPANDING PAD SCHEMATIC

35

WATER/REAGENT/pH ..LEACHING \lINE PIT SOLUTION A _EN SOLUTION

~L-

I
BARREN
SOLUTION PONO

~
I
UE:TAl

RECOVERY

~O~CE -ulNE ORE

OF l=v1Tll!S ORE UFTS

-PREPARE AND STACK IN VALLEY -LEACH -COVER

-L.EACH

r WITH NEW ORE

RETAINING STRUCTURE

.REPEAT PROCESs .RINSE/TREAT If' NECESSARY -L.EAVE IN PLACE .RECLAIM PREGNANT SOLUTION CONTAINMENT (SATURATED ZONE)

FIGURE
VALLEY FILL

PAD SCHEMA11C

A) SINGLE

UNERS

ClAY

,"

"

"

"

"

...",

..C a 7 7 ~ ~ 0 C " a

C a C

a 0 0 I ASPHALT

{--: ;-: ;-: ;-: ;-:;~

~,' ,",' ,",'

CONCRETE
;

i $0.

-",<-"

,"," ,"," ,","'

f-

ICoooo-

.,,~,v"

-;

B) COMPOSITE LINERS

CEOMe:1A8RANE ClAY

C) DOUBLE LINERS

GEOU~B~E
~N LAYER (G~UlAR SOIL OR GEONEr)

CLAY (OR
GEOMo.BRANE)

FIGURE

TYPICAL PAD UNING SYSTEMS

36 ~