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 environmentalprotection. Optimizingthe functionalityand economyof heapleachfacilities
with closure and reclamationplans is key to a successfulproject. Whenclosureand reclamationneedsare identified
atthe beginning of the designprocess,a balancebetweenoperation,expansion,andclosureand reclamationneedscan
beachieved. Currentpractice in the designof heapleachfacilities and currentclosureand reclamationare examined
and suggestionsfor an integratedapproachare 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 metallurgicalprocessof 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. Pregnantsolution 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 chemicallyreconstitutedfor re-useon the heap. This
processallows the recirculation of the solutionand maximizesefficiency. Oftenthe pregnantsolutionis recirculated
throughthe heapto "build up" it's assayand 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 presentan overview of heapleach designand closure/reclamationpractice in Nevada. It
presentsdiscussionsand practicalsolutions based on the authors' experienceand points out the advantagesof
incorporatingclosureand reclamationconsiderationsinto 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.
Geotechnicalissues.
Detenninationof designparameters.

Minimum designcriteria for facilities to be built in Nevadaare prescribedin the NevadaAdministrative Code (NAC)
Section445A. Theseregulationsarebasedon the performanceof the facility, so use of minimum designcriteria does
not releasethe 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

Severalmetallurgicalissuesare critical to the pad designand layout. Most of theseare dictatedby the type of ore and
the economicsof metalrecovery. Key issuesfor pad layout include:
.Ore PreI2arationand PadLoading -A successfulleachingprocessrequiresthat solution be in contactwith large
areasof the ore. Dependingon the hostrock porosity and run-of-mine size, crushing may be neededto increase
the surfaceareaavailablefor solutioncontact. For ores that containfine soil or rock particlesagglomerationwith
a binding agentcould be requiredto allow adequatesolutionflow. -
.Lift Height-Lift heightis a functionof the padareaandproposedloadingrate. An iterativeprocessis usuallyused
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 methodsare the mostsuccessful.The use of cells can help optimize solution
recoveryand 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 re-
vegetation. 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 reclamationplan will needto incorporatestability analyses,coverdesignand re-vegetationissues.Field and

geotechnicaltesting of foundationmaterialsand spentore may be requiredto provide input into slope stability models
suchas XSTABL and SLOPE/Wwhich can predictthe long termstaticandpseudo-staticstability of fmal slopes. Soil
cover designmay involve laboratorytesting of the proposedmaterialto 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 proposedvegetation.

3.2 Reclamation and Closure Plans

Closure and ReclamationPlansare two distinct documentsin the Stateof Nevadaand are reviewedby two separate
groups. The closure plan addressesthe 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. Paragraph3 of this regulationallows alternatemethodsof chemicalstabilizationto be used,if the operatorcan
demonstratethat 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,technologiesareavailablewhich provide a bio-reductionof metals
in the heap. Thereare currentlya numberof provenand developingtechnologiesthatareavailableto provide adequate
stabilization of spentheapore. As some of thesetechnologiescan be costly, with the tradeoff of reducingthe time
required to achieve closure,a detailed laboratorytesting programto evaluatevariousalternativesif recommended.

In order to provide a productive post-mining land use,the reclamationplan mustaddresslong term stability and re-
vegetation of the heap leachpad. Generallyspeaking,mostheap leachgrading plansare successfulwith slopesflat
enoughto preventerosion. The state may require a stability analysison slopesdependingon the site conditions. All
ore must remain on the pad unlessthe operatorcandemonstratethat contaminants will not bereleasedto 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 designedto be non-erosive.Generally.the industrystrivesto re-
vegetateto a level of productivity which existed prior to mining. The reclamationvegetationcan be comparedto a
referencearea at the mine. It is advisableto conductsite specific re-vegetationstudiesto evaluatedplantspeciesand
planting/seeding techniquesfor inclusion in the final reclamationplan. 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 reclamationguidelinesindicatesthat good, optimal designand efficient closure and
reclamationare often not completelycompatible. As mine operationsare typically sensitiveto up-front capital costs,
the tendencyis to designfacilities thatminimize up-frontcapitalinvestment. Thesefacilities may incur higher closure
and reclamationcostsat the end of the facility life. By identifying potentialclosure and reclamationneedsduring the
initial planningand design process,an integrateddesigncanbedevelopedthat will meetthe needsof project fmancing,
operation,and final closureand reclamation.
4.1 Initial Planning
In the initial planningstages,representatives
from all phasesof the leachfacility life shouldbe included. Typically, the
projectowner,operators,civil andprocessengineers,environmentalcoordinator,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 decommissioningof 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 post-
mining 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

,.--// ORE
MINE PIT

\
\, /
/

EXPANDING LEACH PAC

,
FUTURE' I
SEGMENT
I
I
~o~~ o~ A=vmI1S I
I
'WNE ORE J
.PREPARE ORE AND STACK ON PAD

.LEACH ORE

.RlNSE/TREAT If" NECESSARY

.ClOSE SPENT ORE PILE IN PlACE

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

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

FIGURE 2
PERMANENT EXPANDING PAD SCHEMATIC

~ 35
 WATER/REAGENT/pH

..LEACHING SOLUTION A _EN SOLUTION

\lINE PIT ,

~L- I ~
BARREN
SOLUTION PONO

I UE:TAl
RECOVERY

~O~CE OF l=v1Tll!S
ORE UFTS
-ulNE ORE

-PREPARE AND STACK IN VALLEY

-LEACH
r RETAINING STRUCTURE
-COVER WITH NEW ORE

-L.EACH

.REPEAT PROCESs

.RINSE/TREAT If' NECESSARY PREGNANT SOLUTION

CONTAINMENT
-L.EAVE IN PLACE (SATURATED ZONE)

.RECLAIM

FIGURE 3
VALLEY FILL PAD SCHEMA11C

A) SINGLE UNERS

ClAY

! / I ..C C a
," " " " " , , ...",
i a 7 ~ C a a 0 ASPHALT
{--: ;-: ;-: ;-: ;-:;~ CONCRETE $0. 7 ~ 0 " C 0 I
~,' ,",' ,",' ,"," ,"," ,","' ICoooo-
-",<-" ; f- .,,~,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 4
TYPICAL PAD UNING SYSTEMS

36
~