Proceedings of Heap Leach Mining Solutions, 2016

October 18-20, 2016, Lima, Peru

Published by InfoMine, 2016 InfoMine, ISBN: 978-1-988185-03-3

Increasing Au extraction from the leach pad

Cesar Espejo, Metallurgy Head, MINSUR SA, Peru
Bryners Sarmiento, Leaching and Watering Engineer, MINSUR SA, Peru

Abstract
At the beginning of the Pucamarca Project, extraction rates for gold were estimated at 65 % at a P80 5
grain size. However, as the mine was developed, its metallurgical behavior was evaluated and evidence
pointed to the potential to increase extraction.

Table 1: Extraction by lithology: Pucamarca Project

Ore type % Au (125 mm)

Hybrid breccia 58%
Tuft breccia 60%
Fragmented tuft 80%
Tuffisite 70%
Quartz porphyry breccia 68%
Huilacollo volcanic 71%
Overall average 65%

To better characterize the Checocollo deposit, in coordination with the geology department we
processed 1,290 sample probes from previous campaigns drillings. The assays were made using the Quick
Leach Test (QLT); these are fine screen tests with a high cyanide concentration used to determine the
maximum expected extraction.
In the assays some samples showed outstanding extraction rates, but other samples had low extraction
rates in the same Checocollo pit (under 80 %), pointing to some refractability characteristics.

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Figure 1: QLT Assays, Checocollo

Parameter optimization
Lower grain size
To evaluate the influence of grain size on gold and silver extraction cyanidation, certain metallurgical tests
were performed in the pilot pads to demonstrate the advantages of leaching at lower grain sizes.

Column assays
The extraction degree for the same material was evaluated for various grain sizes from project 13C at the
Checocollo pit.
The parameters for the two columns were as follows:
Free cyanide concentration: 80 ppm
Irritation density: 10 L/h m2
Column circuit: Open
Column testing yielded a 3% higher gold extraction rate when compared to crushed (p80= 1.98) and
ROM material (p80= 2.12). Likewise, comparing the two columns shoed kinetics improved by three days
(Crushed ore: 45 days, ROM Material 48 days).
On average, silver extraction reaches 2.8%, probably influenced by its refractory characteristics and,
additionally by lower head grade. Meanwhile copper extraction rates are slightly higher in crushed
materials, because of higher release rate.

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Table 2

Figure 2: Extraction kinetics

Pilot assays
Metallurgical tests were performed on Pilot Pads using Checocollo ore, both ROM and crushed.
The ore head grade at the pads reached 0.80 g /t for gold and 9.2 g /t for silver.
Extraction from the ROM material reached 56.65 % for Au and 4.22 % for Ag; crushed mineral
resulted in 66.97 % gold extraction and 9.35 % silver extraction, thus demonstrating the advantage of
leaching at lower grain sizes that resulted in increased extraction of 10.32% for gold and 5.13% for silver.

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Test conditions
Table 3: Test conditions: ROM pilot pad Crushed pilot pad

Pilot Pad 1 Pilot Pad 2

P80
Grain size ROM 3.12
Grain size Crushed P80 2.43

Wet ore weight 19,750,000 Kg Wet ore weight 18,267,370 Kg

Humidity 1,7 % Humidity 2,2 %
Dry ore weight 19,419,583 Kg Dry ore weight 17,867,132 Kg
Irrigation density 11 L/h*m2 Irrigation density 11 L/h*m2
CN concentration - 60 Ppm CN concentration - 60 Ppm

Table 4: Leaching test sampling

Ratios Extraction (%)

Sample
NaCN (kg/t) CaO (kg/t) Au Ag
Pilot 1 cell - ROM
0.15 0.53 56.65 4.22
Material
Pilot 2 cell crushed
0.11 0.50 66.97 9.35
material

Figure 3: Extraction kinetics Pilot Pad N1 (ROM) Pilot Pad N2 (Crushed)

Obvious advantages can be had from using smaller grain sizes in Au and Ag extraction. At present,
the crushing plants conveyor belt is equipped with online grain size analysis devices.

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Figure 4: Grain size control during operation

On-off irrigation
The impact of ON-OFF leached mineral irrigation was evaluated after their leaching cycle. These results
were good. This technique increases gold extraction between 0.5 and 1.0 %.

Preliminary column tests

Irrigation of column samples where the irrigation cycle had concluded recently resumed two days later
resulting in a slight increase in rich percolates.

Figure 5: Irrigation of column samples

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These tests were repeated for several columns as they concluded irrigation with an obvious increase
in gold grades, which increased further as residence time increased. To obtain more information, non-
irrigated pilots were also monitored, confirming the advantages of the On/Off process.

Figure 6: The on-off effect

Figure 7: Au grade for pilot cell percolation

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Table 5: Additional extraction from Pilot Pad No. 3

% extraction Au

Before ON/OFF After ON/OFF Total

69.9 1.7 71.6

The advantage of the On-off method for irrigating leaching pad cells is obvious. However, its success
depends on residence time and the type of ore alteration.

Irrigation optimization
Pucamarca mine suffers from critical water scarcity. It is an extremely dry area. The irrigation operating
ratio was 1.0 m3/Tn; irrigation ratios (m3/Tn) were adjusted without a negative impact on extraction. The
impact of increasing cell lift was also evaluated, as well as the behavior of several column tests. Next the
corresponding kinetic curves were prepared (extraction vs. irrigation ratios).

Extraction vs. irrigation ratios

Figure 8: Kinetic curves for various column tests

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The kinetics curves show maximum extractions correspond to irrigation ratios above 0.8
m3/Ton. The curve becomes asymptotic above that rate. Monitoring of fresh pad cells also showed
irrigation ratios close to 0.8 m3/Ton. The percolation figures from one of those cells are shown below:
CELL L14-C06B-F2B
Tonnage 90,865 SMT

Au grade 0.504 gr/ton

Ounces Au 1,472 Oz

1,115 Oz
Estimated recoverable Au ounces

8m
Cell lift

3.43%
Ore humidity

1,105 m3
Humidity volume

Figure 9: Gold grade trends in percolation as a function of time

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Figure 10: Gold grade trend as a function of irrigation ratio

The irrigation ratio defined for a fresh cell is 0.8 m3/Ton. However, if there are old (irrigated) cells
underneath the fresh cell, an additional flow would be required to dissolve the gold ounces to the lower pad
section (Arrival point: PLS).
To identify this Additional Ratio other dilution tests were performed, with a resulting extra ratio for
every lower lift equivalent to 0.044 m3/Ton. The irrigation ratio for a fresh cell is expressed by the following
equation:
R irrigation = R ext. + (N R Transp.)
Where,
R: Irrigation ratio (m3/Ton)
R ext: Irrigation ratio for maximum extraction from a fresh cell (m3/Ton)
N: N of depleted lower cells are transported
R transp: Additional ratio required to transport dissolved ounces through the depleted cell (m3/Ton)
Example: For a cell heap on the tenth lift, the irrigation ratio would be as follows:

R irrigation = R ext. + (N R Transp.)

R irrigation = 0.8 + (0.044 9 gravel layers)

Final Ratio = 1,196 m3/ton

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Pad fines handling

Pucamarca reserves include materials with significant clay contents. This poses serious issues for pad
handling as the required permeability and percolation characteristics for heap leaching are not met.
Tests were performed to determine the appropriate proportions of this material to send it to the Pad
without a negative impact on recovery.

Sampling
Sampling took into account the moraines dip. The pit was divided into two sectors. In sector one, the pit
reached an approximate average of 70 meters whereas in sector 2 the average pit was about 30 meters. A
total 42 samples were collected, and subsequently laid down on a topographic plan.

Figure 11: Division of pit

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A representative approximately 3 ton sample was obtained from each probed sample.
Subsequently, the probes from each sector were composited in a single sample to accomplish
the best representation in terms of grain size and chemical analysis for each sector. The
sample from the Checocollo Pit was provided by the Geology Department. It was considered
the most representative pit to be used for blending. The final sample distribution included a
total seven columns as shown in the following table, including their respective weight
distribution. (See Table 6.)

Table 6: Blending rates for column tests

The column tests adhered to the following parameters for columns measuring 47 inches
diameter and 3 meters height.

Free cyanide concentration: 70 ppm

Irrigation density: 11 L/h m2
Column circuit: Closed
test pH: 10.5
Sample grain size: 80% <3.5

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Findings
Table 7: Results from extraction in column tests

Figure 12: Kinetics of extracted moraine mixes

Testing showed the best gold extractions rates come from blending Checocollo 2: moraine
1 from both sectors with yields of 71% and 66%, respectively. Tests from previous years in the
moraine deposits reported significant gold extraction fluctuations. (No geological pattern is
present.) Stability and permeability tests were carried out as well. Findings point to a mix with
at least 14% fines, mesh below 200, for a 120 m height. This percent of fines is appropriate to
ensure the pads stability and also for metallurgy.

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Moraine blending: Industrial level Checocollo (Pilot Pad)

Piloting design
For the test, stacking combined Checocollo ore and moraine material (with a maximum 14% value of fines
in the final mix). Materials (Checocollo / moraines) were mixed in the primary crushers dump pocket.
Using the results from grain size assays we define the weight share for each hauling cycle at 2 Checocollo:
1 moraine to ensure fines under 14%. Unloading from the loader trucks were controlled for weight to ensure
the right proportion in the mix. The mix in the crusher was performed on both sites. Additionally, the time
for each hauling cycle was recorded (2 Checocollo trucks and 1 moraine truck) which ranged between 11
and 15 minutes. Fluctuations resulted in moraine fines clumped in the crushers intake restricting the
continuous flow of mineral and requiring continually using the rock breaker.

Figure 13: Mixed minerals

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Test parameters

Grain size irrigation: 80% -3.4

Irrigation density: 1 l/h*m2
Free cyanide concentration: 60 ppm
Percolation solution control (composite) every 12 hours
Percolation solution sampling (point) every 3 hours
Irrigation solution dripping control every 3 hours
Dry tonnage, n 3 Pilot Pad: 17,782.4 Tn

Pilot findings

Extraccin por
Muestra Ley Cabeza Ratios Solucion Dias
3
Au (g/t) Ag (g/t) Cu(g/t) m /t NaCN (kg/t) Cal (kg/t) Au Ag

PAD PILOTO 03 0.82 4.7 37 1.30 0.091 1.280 69.91 5.02 83

During irrigation of the pilot pad (a Checocollo ore and moraine mix), no puddles were observed.
Irrigation was evenly spread, confirming the mix was appropriate.
Gold extraction from ores used for the pilot pad mix were as follows:

Checocollo ore, (polygon 17E-2):

Au grade: 0.615 g/t
% Extraction, column test: 75.84%
Moraine ore:
Au grade: 1.3 g/t
% extraction, BRT test: 64.78 %

Global pilot pad extraction reached 69.9% (in the first irrigation round). This result is similar (on a
weighted approach) to extractions from pure materials used for the mix. Consequently, it is convenient to
blend materials with a high fines content.

Geo-metallurgical model
Metallurgical tests for the same Checocollo pit show extraction fluctuations. To better characterize the pits
ores, a geo-metallurgical plan was prepared, consisting in defining geological Units based on pit alterations.
Next, samples were taken and metallurgical tests performed for each defined GU. The data was handled

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over to the Planning Department to prepare the corresponding blocks and estimate the recoverable Au
ounces. Initially 3,202 QLT tests were prepared using samples from drills at the Checocollo Pit, followed
by column tests.
Defining alterations: the Geology Department prepared a study to determine the best possible
classification of GUs as determined by the type of alteration.

Table 8: Distribution by Pit Alteration

TIPOS DE ALTERACIONES
Argilico Avanzado AAR
Argilico Intermedio AR
Silice Granular Si_GR
Silice Masiva Si_MA
Silice Pulverulenta Si_PU
Roca fresca UA
Silice Vuggy VUG

QLT tests revealed materials with low Au extraction potential, and falling extraction rates as head
grades fall. (See Graphic n 7.)

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Figure 14: Au extraction and head grade

Based on this data, extraction by alteration and grade ranges were estimated.

Table 9: Advanced argillic

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Table 10: Intermediate argillic

Table 11: Grain silica

Table 12: Massive silica

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Table 13: Vuggy silica

Based on QLT test results, extractions were initially classified by alteration and grade range.
% Au extraction by alteration
Au grade
range Si_GR Si_MA VUGGY SILICA AAR Si_PU
0.1 - 0.3 69.51 51.52 67.90
76.47 70.01
0.3 - 0.5 72.47 72.19
55.42
0.5 - 1.0 73.01 71.52
77.65 79.90
>1 76.14 59.27 74.49
Ag 3.52 2.99 3.98 3.63 2.94

Table 14: Au grade range % Au by alteration

These values were adjusted based on column tests results to then determine extractions for reserves
calculations. These tests also confirmed the influence of grain size on extraction.

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