Heap

Leaching
Senninger mining solutions

®
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.
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.
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.

Drip Lateral Lines mini-Wobbler®

(Emitters are placed (on riser)
every two feet within
the line)
Unleached
area

Channeling
occurs

Did you know? Uniform Solution

Contact
The effective flow area for most
leaching emitters are so small
they often require filtration of 150 Lateral line mini-Wobbler® nozzle orifice sizes
or finer mesh. The larger nozzle emitter
orifice sizes, 3/32" – 1/8", of the effective
mini-Wobbler® help minimize discharge
clogging without requiring flow area
expensive filtration. #6 #7 #8
#6 #7 #8
0.052" 3/32" 7/64" 1/8"
3/32” 7/64” 1/8”
[1.32 mm] [2.38 mm] [2.78 mm] [3.17 mm]
(2.38mm) (2.78mm) (3.17mm)
(Actual size) (Actual sizes)

®
Call (407) 877-5655 • Web: www.senninger.com
Available Tool to Help Design WinSIPP2 Densogram* Model
MINIWOBBLER
Nozzle
7

WinSIPP2 custom mining software was developed to Base Pressure

20 psi [1.38 bar]
Flow
1.51 gpm [343 L/hr]

help mining leaching installations achieve the required Layout: Rectangular

Offset Spacing 0 ft [0 m]
application rate and uniformity. It provides visual Head Spacing
20 ft [6 m]
Row Spacing
23 ft [7 m]
comparisons of various combinations of applicators, Average Precipitation
0.0033 gpm/ft2 [8.2 L/hr/m2]
flows, pressures, and spacing options. Analyzing these
combinations in advance helps assure optimal system design 0.05 [1.23 m] 0.42 [11.09 m]
Infinite
and operation. Coefficient of Uniformity 92.88%
mini-Wobblers®
Distribution Uniformity 88.64%

*Uniformity evaluation Scheduling Coefficient 5% 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
• 1/3-1/2 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.

ft.
2f

20 23 m.]
[6 ft.
t. [ part

m.] [ 7
0.6
a
1m

mini-Wobblers® are often installed

] .

to salvage plugged or improperly

designed drip zones.

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.

®
Call (407) 877-5655 • Web: www.senninger.com
 Comparison Drip & 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 mm PE lateral / 4,700 linear ft.
[16,459 linear m.] [20 mm] PE lateral [1,433 linear m.]
328 Fittings 15
27,000 Emitters 255
Drip Energy required Sprinkler
60 Pumps 60
10 Pipes 10
2 Fittings 2
15 Emitter operating pressure 15
8 Filtration 4
95 Total 91
Drip Versatility Sprinkler
No PE lateral recyclable? Yes
No Emitter recyclable? Yes
No Visual performance assessment Yes
No Can flow be changed? Yes
High Plugging potential? Low
Yes Filtration required? No
No Can orifice be cleaned? Yes

®
Call (407) 877-5655 • Web: www.senninger.com
Dust Control / Side Slope Leaching
Sprinklers
40
[12.1 ft.
9m
]

Portable
pipe

Reduces traffic dust on mining roads.

3123 & 4123
Part-Circle
Impact Sprinklers
[Gold/Silver Mining]
3/4" NPT male base, nozzle #9 (9/64") 45 ft. [13.72 m]
radius of throw
The 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
50 ft. [15.24 m]
NOTE: Pressure regulator recommended spacing
@ 40 psi [2.76 bar], Flow: 3.65 gpm [0.23 L/s]
Side slope recovery

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 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.

®
Call (407) 877-5655 • Web: www.senninger.com
Heap Leaching Applicators
Xcel-Wobbler®
(High-angle & mid-angle models) Xcel-Wobbler HA CMS
Senninger’s Mining Xcel-Wobblers utilize a unique [Copper Mine Special®]
off-center rotary-action to provide extremely • Recommended for high
uniform coverage at low pressures with very low sulfuric acid (0.5 to
evaporative losses. 3.0 pH) copper mining
solutions (Greater than
10/gpl H2SO4)
• Multi-level throw:
PRMP approximately 24°

[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 Xcel-Wobbler MA CMS
drip. [Copper Mine Special®]
NOTE: Other higher flow regulators • Recommended for high
are also available.
sulfuric acid (0.5 to
3.0 pH copper mining
solutions (Greater than
10/gpl H2SO4)
mini-Wobbler®
• Multi-level throw:
Employs the same unique
approximately 18°
off-center rotary-action as the
Wobbler®. It provides extremely • Smaller droplets than
uniform coverage over a large high-angle model for a
diameter at low pressures. It more gentle application
Gold/Silver Copper
produces a gentle application of and WindFighterTM
solutions. ability.

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°
Riser Adapter
Is now available in a new versatile
model. The new quick-connect and
disconnect design has a press-fit inlet
and outlet. This makes it easy to assemble
and disassemble and store the various
components – an ideal feature for both Xcel-Wobbler MA
temporary and portable systems. [Gold/Silver Mining]
NOTE: For [Copper or Gold/Silver] • Recommended for pH
3 ft. [0.9m] tubing sizes: range 3.0 to 9.0 gold and
0.270": I.D. and 0.345" I.D. silver mining solutions.
Super Barb Plug also available • Multi-level throw:
approximately 18°
• Smaller droplets than
high-angle model for a
more gentle application
and WindFighterTM ability

®
10 HL 05 Call (407) 877-5655 • Web: www.senninger.com MS911