heap leaching brochure

®

Heap LeachingSenninger mining solutions

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.

Call (407) 877-5655 • Web: www.senninger.com®

Providing Solutions To The Mining Industry

0.052"[1.32 mm]

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" – 1/8", of the mini-Wobbler® help minimize clogging without requiring expensive filtration.

Drip Lateral Lines(Emitters are placed every two feet within the line)

New DemandsModern 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.

ChallengesApplication 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.

Lateral line emittereffective discharge flow area

mini-Wobbler®

(on riser)

Uniform Solution Contact

Channeling occurs

Unleached area

(Actual size)

#77/64”

(2.78mm)

#81/8”

(3.17mm)

#63/32”

(2.38mm)

mini-Wobbler® nozzle orifice sizes

#81/8"

[3.17 mm]

#63/32"

[2.38 mm]

#77/64"

[2.78 mm]

(Actual sizes)

Low pressure leaching designs comparisonDrip: 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® andXcel-Wobblers are spaced20 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.


Providing Solutions To The Mining Industry

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.

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.

WinSIPP2 Densogram*

*Uniformity evaluation

ModelMINIWOBBLER

Layout: RectangularOffset Spacing 0 ft [0 m]

Average Precipitation0.0033 gpm/ft2 [8.2 L/hr/m2]

Base Pressure20 psi [1.38 bar]

Head Spacing20 ft [6 m]

0.05 [1.23 m]

Coefficient of Uniformity

Distribution Uniformity

Scheduling Coefficient 5%

0.42 [11.09 m]

92.88%

88.64%

1.24

Infinite

Row Spacing23 ft [7 m]

Nozzle7

Flow1.51 gpm [343 L/hr]

Available Tool to Help DesignWinSIPP2 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.

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.

mini-Wobblers® are often installed to salvage plugged or improperly

designed drip zones.

23 ft.

[7 m.]20 ft.[6 m.]

mini-Wobblers®

2 ft. [0.61 m.]

apart


Comparison Drip & SprinklerIrriMaker® design for 100 m x 100 m pad (328 ft. x 328ft.)

Drip Bill of material Sprinkler

54,000 linear ft.[16,459 linear m.]

16 mm PE lateral /[20 mm] PE lateral

4,700 linear ft.[1,433 linear m.]

328 Fittings 15

27,000 Emitters 255Drip Energy required Sprinkler

60 Pumps 60

10 Pipes 10

2 Fittings 2

15 Emitter operating pressure 15

8 Filtration 4

95 Total 91Drip 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

Drip [Material take-off]

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]

Sprinkler [mini-Wobbler®/Xcel Wobbler®]

Dust Control / Side Slope Leaching

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.

3123 & 4123Part-CircleImpact Sprinklers[Gold/Silver Mining]3/4" NPT male base, nozzle #9 (9/64")

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

NOTE: Pressure regulator recommended@ 40 psi [2.76 bar], Flow: 3.65 gpm [0.23 L/s]


Side slope recovery

Sprinklers

45 ft. [13.72 m]radius of throw

50 ft. [15.24 m]spacing

40 ft.[12.19 m]

Portable pipe

Reduces traffic dust on mining roads.


Xcel-Wobbler HA CMS

[Copper Mine Special®]• Recommended for high

sulfuric acid (0.5 to 3.0 pH) copper mining

solutions (Greater than 10/gpl H2SO4)

• Multi-level throw: approximately 24°

Xcel-Wobbler HA

[Gold/Silver Mining]• Recommended for pH

range 3.0 to 9.0 gold and silver mining solutions.


Xcel-Wobbler MA CMS[Copper Mine Special®]• Recommended for high

sulfuric acid (0.5 to 3.0 pH copper mining solutions (Greater than 10/gpl H2SO4)


• Smaller droplets than high-angle model for a more gentle application and WindFighterTM

ability.

Xcel-Wobbler MA

[Gold/Silver Mining]• Recommended for pH

range 3.0 to 9.0 gold and silver mining solutions.


• Smaller droplets than high-angle model for a more gentle application and WindFighterTM ability

Xcel-Wobbler®

(High-angle & mid-angle models)Senninger’s Mining Xcel-Wobblers utilize a uniqueoff-center rotary-action to provide extremely uniform coverage at low pressures with very low evaporative losses.

MS911

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.

Heap Leaching Applicators

Riser AdapterIs 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

temporary and portable systems.

NOTE: For [Copper or Gold/Silver]3 ft. [0.9m] tubing sizes:

0.270": I.D. and 0.345" I.D. Super Barb Plug also available

mini-Wobbler®

Employs the same unique off-center rotary-action as the Wobbler®. It provides extremely uniform coverage over a large diameter at low pressures. It produces a gentle application of solutions.

Gold/Silver Copper

10 HL 05

heap leaching brochure

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