Modeling of Agglomerate Size Distribution for Heap Leaching

"Agglomeration has become common pre-treatment step to improve heap leach percolation thereby recovery, the fundamental understanding of the agglomeration process for crushed ores is still lacking. Agglomeration is required for ores which either contain excessive amounts of clay or an excessive quantity of fines generated during mining and crushing. Numerous experiments have been carried out in laboratory scale batch drums using different ores. It has been found out that experimental agglomerate size distributions exhibit self-preserving spectra. The self-preserving/ similarity distribution of the agglomerates is found to be independent of operating conditions and is uniquely determined by the size enlargement mechanism. An empirical model based on the absolute difference between moisture applied and optimum moisture was developed. This model uses self-preserving spectra in the form of a Rosin-Rammler distribution function to predict size distribution at different operating conditions. The empirical model was considerably easier to work with plant scale agglomeration drums. Also, a test known as dip test is developed which improves fundamental understanding of the agglomerate formation and growth mechanisms. This test also provides the progeny size distribution of each agglomerate size. The progeny size distribution was analyzed with a model that partitions the particles into a host and guest category. The ensuing partition coefficient identifies the behaviour of a particle as a host for other particles or a guest layering on other particles. This concept helps in identifying the type of agglomerate that would result for a specific feed size distribution. INTRODUCTIONHeap leaching is one of the hydrometallurgical processes that have served as a green and economically viable process for the treatment of low grade complex ores of copper, uranium, nickel, silver and gold (Dhawan et al., 2013). Heap leaching appears to be a favorable candidate for the least energy consuming process for low grade ores. In heap leach operations nowadays a pretreatment step known as crushed ore agglomeration has been implemented (Dhawan et al., 2013). A bed of agglomerates improves the uniform percolation of solution through the heaps of ore. Therefore, it was possible to treat wastes and mill tailings via agglomeration and heap leaching. Agglomeration pretreatment is required for ores which either contain excessive amounts of clay or an excessive quantity of fines generated during mining and crushing (Bouffard, 2005; Dhawan et al., 2013).While agglomeration has become common practice pretreatment step in heap leach operations, the fundamental understanding of the crushed ore agglomeration process is still lacking. The author reviewed publications up to 2012 on the crushed ore agglomeration process and did not come up with modeling studies on the topic (Dhawan et al., 2013). Some of the possible reasons can be the stochastic nature of the process, experimental difficulties, and lack of instrumentation for fundamental studies."