Modelling zinc heap bioleaching

A comprehensive modelling study of the HydroZinc™ heap bioleach process, using the HeapSim modelling tool, is described. The model was calibrated on the basis of a small number of column leach experiments and compared against pilot heap test results. The model calibration thus confirmed, a detailed sensitivity study was conducted in order to establish the key parameters that determine the overall rate of Zn extraction. In the present case these were found to be oxygen gas–liquid mass transfer, various factors affecting the delivery of acid into the heap, and factors affecting the temperature distribution within the heap. A set of improved design parameters are proposed that would almost double the zinc conversion rate measured in the pilot plant – from 83% in 740 days to 78% in 383 days – and increase zinc production rate from 1.77 to 4.35 kg/m2/day. However, this improvement must be evaluated in the context of various implications for the downstream process.