Heap Leach Systems
Heap Leach Systems for operational excellence: driving safety, throughput, recoveries and cost efficiencies
Key Facts
- Capacity
- Up to 18,000 t/h and more
- Leach types
- Dynamic (On/Off) leach pad stacking and reclaiming
- Commodities
- Copper, precious and other base metals
- Conveying and dumping
- Spent ore conveying and dumping
- Stacking
- Permanent leach pad stacking
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TAKRAF Heap Leach Systems
As one of the few global suppliers, TAKRAF delivers engineered solutions for both dynamic on/off and permanent leach pad applications. From stacking and reclaiming to conveying and spent ore (or “ripios”) dumping, we provide the complete value chain under one roof. This single point of contact is key for seamless engineering, reliable supply and successful construction of heap leach projects.
On/Off Leach Pad System
On/off leach pads typically involve four key steps:
- Stacking
- Reclaiming
- Conveying
- Dumping
Thorough equipment design and holistic dump planning are essential for smooth operations and long-term success.
Stacking at on/off leach pad systems
Stacking is typically achieved with a mobile stacking bridge (MSB) in a “racetrack” design pioneered by TAKRAF in the 1990’s. This approach provides an efficient, reliable and easy-to-operate material handling solution for transporting and stacking ore, while maximizing throughput to increase plant uptime. Where greater flexibility is required, the system can be configured with a series of mobile conveyor bridges (MCBs) combined with a stacker or spreader. Our advanced stacking technology ensures uniform and controlled placement of ore on the leach pad, supported by precision equipment and automated systems that deliver consistent performance and efficient leaching.
Reclaiming at on/off leach pad systems
Reclaiming is performed typically using a bucket-wheel reclaimer in combination with a mobile reclaiming bridge (MRB) for fast and safe removal of spent ore. Hybrid solutions with mobile conveyor bridges or mobile equipment are also possible. Our solutions are designed to handle high volumes with minimal downtime, ensuring continuous operation.
Conveying at on/off leach pad systems
Robust and flexible conveyor systems transport ore and/or spent ore to, from and across the leach pad with minimal energy consumption. TAKRAF’s mobile and relocatable conveyors adapt to changing pad layouts, reducing infrastructure costs and enhancing operational agility.
Dumping at on/off leach pad systems
Dumping (or the depositing) of spent ore (or “ripios”) is typically carried out with a spreader in combination with shiftable conveyors, whilst mobile stacking bridges (MSBs) provide an alternative. TAKRAF also offers a unique combination of extendable conveyors and mobile conveyor bridges (MCBs) with a spreader for dumping material into irregular shaped topographies delivering high flexibility and efficiency. Our approach ensures safe disposal, minimal dust generation and compatibility with future reclamation or rehabilitation plans.
Permanent Heap Leach Stacking
Permanent heap leach stacking is generally comprised of the following two steps:
- Conveying
- Stacking
Permanent heap leach conveying
Robust and flexible conveyor systems transport ore to and across the leach pad with minimal energy consumption. TAKRAF’s mobile and relocatable conveyors adapt to changing pad layouts, reducing infrastructure costs and enhancing operational agility.
Stacking for permanent leach pads
The optimal stacking solution depends heavily on the available topography and key project parameters such as lift height and throughput. When greater flexibility is required, a series of mobile conveyor bridges (MCBs) combined with a stacker or spreader can be deployed. In rough terrain, TAKRAF offers a unique combination of extendable conveyors and mobile conveyor bridges (MCBs) with a spreader, enabling material stacking into irregularly shaped topographies with high flexibility and efficiency. For evenly shaped terrain, shiftable conveyors and mobile stacking bridges (MSBs) are also an effective option. All solutions are designed to deliver consistent performance and place material for efficient leaching, providing an efficient, reliable and easy-to-operate material handling system.
TAKRAF Leach Pad Systems streamline the heap leaching process with reliable, high-performance solutions at every stage.
Using state-of-the-art 3D software and leveraging decades of heap leach experience, TAKRAF engineers and designs conveyor routings, dumps and leach pads that maximize heap leach performance and ensure you achieve more from your ore.
Benefits
Better long-term economics
- Lower cost per tonne stacked
- Improved recoveries extend mine life and boost project NPV
- Reliable automation reduces downtime and operator variability
Environmental and safety benefits
- Fewer haul trucks = lower emissions, dust, and noise
- Reduced traffic means improved worker safety
- More precise stacking helps protect liners and drainage systems
Lower capital and operating costs
- Reduced haulage costs: Conveyor-based stacking cuts down truck use
- Lower fuel and labor costs compared to traditional truck dumping
- Scalable: You can expand heap height and area gradually instead of building everything upfront
Improved metal recovery
- Uniform ore placement creates consistent permeability, so leach solution flows evenly
- Controlled lift heights reduce compaction, improving solution percolation
- Better solution distribution = higher recovery rates and faster leach cycles
Higher and safer heap construction
- Enables taller heaps with controlled lift stacking
- Reduces risk of slope failure by minimizing uncontrolled dumping
- More predictable heap geometry improves geotechnical stability
Operational Flexibility
- Handles a wide range of ore types and particle sizes
- Easy to adjust stacking rates, lift heights, and stacking patterns
- Integrates well with crushing, agglomeration, and conveying systems
