HEAP AND DUMP LEACH PROCESS AT THE BUCHIM COPPER PROJECT-

METALLURGICAL TESTWORK

G. Savov, T. Angelov, V. Tsekov, I. Grigorova, I. Nishkov

Directior Recearch and Development, Iontech Engineering Ltd., 1113 Sofia, Bulgaria, phone: +359 2 8164431, fax:
+359 2 8164461, e-mail: savov@ionteching.com
Senior Technologist, Iontech Engineering Ltd., 1113 Sofia, Bulgaria, phone: +359 2 8164431, fax: +359 2 8164461, e-
mail: savov@ionteching.com
Chief Executive Officer, Iontech Engineering Ltd., 1113 Sofia, Bulgaria, phone: +359 2 8164431, fax: +359 2 8164461,
e-mail: savov@ionteching.com
Asst. Prof. Dr., University of Mining and Geology St.Ivan Rilski, Department of Mineral Processing and Recycling,
1700 Sofia, Bulgaria, phone: +359 02 8060253, e-mail: irena_mt@abv.bg
Vice Dean of Faculty of Mines, Professor, University of Mining and Geology St.Ivan Rilski, Department of Mineral
Processing and Recycling, 1700 Sofia, Bulgaria, phone: +359 02 8060253, e-mail: inishkov@gmail.com

ABSTRACT The Buchim Copper Project, now under construction, is located in eastern Macedonia, 95 km
from the Skopje capital and 170 kilometers from the nearest port Thessaloniki (Republic of Greece) at an
altitude of 620 m above sea level. The mineralization of Buchim ore deposit is porphyry.
Extensive metallurgical testwork was carried out to determine the effect on the projects feasibility and to
provide information needed for the plant design.
Ore body/reserve data, basic mineralogy and lithology are defined from representative sample for each
ore category prior to planning the metallurgical test program.
The metallurgical test program including detailed determination of physical and mechanical properties,
mineralogy, size distribution, total and acid soluble copper and conducting of elemental analysis (standard
ICP scan), acid consumption and acid cure tests as well as bottle-roll tests was performed.
A series of column leach tests represent the most important part of the testing program. Operating
parameters such as particle size, leach time, flow rate, heap height and acid addition are evaluated. Physical
tests and water tests are also was conducted to provide additional design information.
A dump leach-ion exchange-solvent extraction-electrowinning process was selected to treat the Buchim
ore to produce 2500 tpy of cathode copper.
The results obtained as well as the design criteria selected for the process are discussed in this paper.

Keywords: hydrometallurgy, copper ore, metallurgical test program, leaching, column tests.

1. INTRODUCTION test program, which involves a sequence of bottle

The Buchim Copper Project, scheduled for
construction and operation in 2011 is a leaching and
treatment facility at the Buchim mine site in
Macedonia. The facility is envisaged to organize
leaching of low grade ore from Bucim dump and
oxide heap of Vrsnik orebody and treat the pregnant
leach solutions via combination of Ion Exchange,
Solvent Extraction and Electrowinning to recover
copper into high grade copper cathodes (Jergensen,
1999).
To ensure the success of copper leaching
project, the metallurgical characteristics of the
subjected ores must be well defined. An extensive
roll tests and column tests, was carried out in the
early stages of development in order to determine
the effect on the projects feasibility, and to provide
information needed for the basic and detailed
design.
Subject of this paper is testwork on a
representative sample of ore from old dump.
The testwork is aimed at determining the
amenability of this ore to leaching, which depends
on the characteristic of the ore with respect to
porosity and permeability to leach liquor,
percolation, acid consumption, and metal recovery.
2. BUCHIM COPPER DEPOSIT
2.1. General
Buchim copper mine is situated near the village of
Buchim and in the south borders of Plachkovitsa
Mountain, in Republic of Macedonia. Dominating top
in the immediate surrounding is Versnik, on 720
meters above the sea level, while 620 meters is the
average above the sea altitude of the ore deposit.
Buchim mine territorially and administratively
belongs to the municipality of Radovis. It is 14
kilometers away from the city of Radovis, and 30
kilometers from Stip. The mine has good
communication lines. Asphalt road, about 3.5
kilometers long, is connecting the mine with Veles -
Stip - Radovis regional road.
The climate in the region is Mediterranean-
continental.
The specific geographical and topographical
situation of the region provides for its specific
landmark: long and warm summers with high
average daily temperatures and reduced
precipitation, low winter temperatures and
occurrence of winds from all directions.
2.2. Geology
Buchim mining field is occupying the northern parts
of Buchim-Damjan-Borov Dol mining region, created
between two major geotectonic units: the Serbian-
Macedonian massif and the Vardar zone. According
the positioning of the tectonic plate this is a place of
depositing i.e. place of contact of the two
geotectonic units, at which point the Vardar zone is
sinking under the Serbian-Macedonian massif. This
mining field is defined with lower rank fault planes,
alkaline fractions of the tertiary intermediary
magmatic and copper porphyry mineralization. The
geologic structure of this region is quite complex
with explicit tectonics. Buchim ore deposit occupies
the southern parts of Buchim mining field. The
geologic structure of Buchim ore deposit features
mainly Precambrian metamorphic rocks (gneisses,
micashists and amphibolites) and tertiary volcanic
rocks. The gneisses are the most frequent lithologic
members in the ore deposit, and they are at the
same time the most favorable lithologic environment
for disposal of ore mineralization. The mineralization
of Buchim ore deposit is porphyric. The copper
mineralization is connected with the process of
silification, and it occurs in the gneisses and the
amphibolites and biotitic schist, as well as at the
point of their contact with the andesites. In the rifts
of these rocks there are mineralized quartz ledges
with presence of fine impregnation at the same time.
The copper minerals are also present in the
andesites, but their content is considerably
decreasing proportionally with the increase of the
andesite distance from the contact with gneisses.
The kaolinization and the chloritization are
connected with the hydrothermal activity in the ore
deposit. Main mining phenomena occur in the
primary zones, where the chalcopyrite occurs as
basic copper mineral. Other minerals present are:
pyrite, hematite, magnetite, and seldom
molybdenite. The precious metals, gold and silver,
occur in smaller concentrations, but though enough
for their valorization. The zone of secondary
sulphide enrichment is insignificantly developed.
Besides the minerals from the primary zone,
chalcosine and small quantity of copper carbonates
occur.
Low grade ore stored on old dump is from mining
activities on the Central ore body of Bucim mine.
This orebody is characterized of primary copper
mineralization and it is created around the latitic
dike. The ore mineralization mainly occurs in the
gneisses, but as a ring around the latitic burst. The
ore body is in The Central ore body is a typical
representative of the primary copper mineralization
and it is created around the latitic dike. The ore
mineralization mainly occurs in the gneisses, but as
a ring around the latitic burst. The ore body is in
shape of upturned, cut cone and morphologically it
is following the shape of the volcanic body. Its mine
mineral is the chalcopyrite, accompanied by pyrite,
magnetite, hematite, cubanite, valerite, natural gold,
borite, etc. Bucim mine consist also of Bunardzik,
Vrsnik and Cukar ore bodies which are well
investigated and are of subject for further
exploration.
Figure 1. Bucim dump
3. EXPERIMENTAL
3.1. Sampling
For the metallurgical testwork, approximately 2 tons
of samples were taken from Bucim dump Figure 1,
according the following procedure: (1) determination
of ten pre-selected places spread across a large
areal extent of the mine area; (2) excavation of ten
different pits (5 meters deep) at each of the pre- The total quantity of ore is dumped carefully on a
selected places; (3) collection of 200 kg sample of clean, concrete surface so as not to break the larger
each pit, simply excavating a full sample at once. particles. A 200 kg representative sample is
Each pit sample is collected into separate steel prepared and then crushed to -20 mm. The
drum with the sample locations clearly identified on representative sample are coned and quartered in
the drums with sample identification numbers; (4) the classic fashion to produce a 15 kg head sample.
shipment of the 10 pit samples, to the laboratory for Part of it is further crushed to -2 mm, and another
further preparation, assay and characterization. part is ground to -150 (-0.15 mm). These
samples are designed to determine the physical and
3.2. Metallurgical Testwork Program mechanical properties and chemical composition of
The metallurgical testwork program typically the ore, as well as for conducting of phase and
involves a sequence of the following stages, namely mineralogical analysis, acid consumption and bottle-
mineralogical examinations, bottle roll tests and roll tests. From the remaining crushed ore, 60 kg
column tests, optionally followed by piloting on test are taken for the column leach tests.
heaps. Mineralogical examinations are fundamental
4.2. Sample Characterization
to the metallurgical behavior, and therefore to the
technical and economic amenability of an ore to In Tables 1, 2 and 3 are shown physical
exploitation. They are normally performed first, to and mechanical properties, analysis of ore sample
obtain information about mineralized zones within by elements and phase analysis.
the ore body and the potential recovery. By
additional examination of the ore samples, the type Table 1. Physical and mechanical tests results.
and location of valuable minerals in the ore can be
determined and the gangue minerals can be No Parameter Unit Value
characterized. Bottle roll tests are the second stage 1 Volume density, g/cm3 2.57
of the metallurgical program. In these tests on a 2 Specific density,s g/cm3 2.67
bottle roll apparatus all the material remains in 3 Water absorption, W % 1.21
continuous motion and a pulp air interface is created
for aeration of the pulp. The main variables to be
considered are pulp density, acid concentration, Table 2. AES-ICP results.
ferric concentration, retention time and temperature.
No Parameter Unit Value
Generally bottle roll tests give an indication of metal
1 Cr % 0.006
recovery and acid consumption.
2 Fe % 3.7
On the other hand the column leach tests
give much more accurate information about metal 3 Co % 0.0023
recovery and acid consumption in the trickle 4 Ni % 0.0026
bed conditions as well as an initial indication of the 5 Cu % 0.4
possible percolation problems (Miller and Newton, 6 Zn % 0.49
1999). 7 Ga % 0.0009
Metallurgical test work with the Buchim ore was 8 As % 0.0074
carried out at the Iontech laboratory, based in the 9 Mo % 0.0017
University of Mining and Geology "St. Ivan Rilski", 10 Cd % 0.0007
Sofia. Tests were done using bottle-rolling and 11 Sn % 0.0064
column leaching techniques. 12 Sb % 0.0006
13 Te % 0.0002
3.3. Laboratory Facility Description 14 Pb % 0.007
The laboratory facility consists of a leaching, ion 15 Bi % 0.0007
exchange, solvent extraction and electrowining
section. It also has a sample preparation and Table 3. Phase analysis results.
analytical laboratory. The leaching sections include
standard bottle roll apparatus and 4 leach columns, Fraction Cu %
each 10 diameter and 1m high. The laboratory Fraction I (Cu in oxidized minerals) 0.204
facility is closed with a ion exchange, solvent Fraction II (Cu in secondary sulphides) 0.069
extraction and electrowining sections. Fraction III (Cu in primary sulphides -
chalcopyrite) 0.124
TOTAL for ore sample 0.397
4. RESULTS AND DISCUSION
4.1. Sample Preparation As can be seen from the table above most of the
copper presented is in oxide form (0.204%), the
content of primary sulphides-chalcopyrite is also
relatively high (0.124%), while the content of
secondary sulphides is only 0.069%.
4.2.1. Mineralogy
Main minerals are limonite, cuprite,
tenorite, native copper, goethite, malachite,
azurite, but relicts from pyrite, chalcopyrite,
chalcocite, specularite, rutile, magnetite, etc also
occurs
According the complex X-ray thermal analysis the
sample is represented by Quartz-25%; Labradorit
25%; Mikrocline 22%; Ortho-chamosite 12%,
Muscovite 9%; Pyrite 3% and Calcite 2%.
From this analysis can be concluded the
following:
Column leach tests are the most important
part of the metallurgical testwork program. The two
key results which can be determinate from the
column tests are the maximum copper extraction
and acid consumption under percolation-contact
mode. Leach tests are carried out using four 1 m
columns (2 sets x 2 columns) in closed-cycle. Leach
cycle in the first columns set (columns 1-1 and 1-2)
is 103 days, and the leach cycle in second columns
set (columns 2-1 and 2-2) is 73 days.
The main conditions of the column tests are
given in the table below:
Table 4. Column tests conditions.

Acid concentration

Acid concentration

Application rate
(1) The main gangue minerals are silicates,

after14th day
solutions(g/l)

solutions(g/l)
Ore quantity

first 14 days
in the leach

in the leach
Column No
inorganic compounds with high chemical and

(l/h.m2)
structural complexity, which are the most significant

(kg)
acid consuming component. However, they react
incompletely with sulfuric acid and with most of
them the rate of chemical reaction acid-gangue is a
function of the acid strength in the leach solution.
The moderate reactivity to acid of these minerals 1-1 13 6-8 6-8 6
limits the acid consumption; 1-2 13 12-14 6-8 6
(2) The content of calcite, mineral which reacts 2-1 13 6-8 6-8 12
violently even with very dilute sulfuric acid solutions 2-2 13 12-14 6-8 12
is only 2%, that suggesting moderate levels of acid
consumption during leaching process;
The results after 103 days and 73 days of
(3) The content of the main acid generating mineral
leaching are summarized in Table 5.
pyrite is 3%,which means that effective leaching cou
ld be achieved only by adding of a sufficient amount
of sulfuric acid from the outside. Table 5. Column leach tests results.

4.3 Acid Consumption

consumption

Acid/Copper
recovery,%
Column No

Net acid
Copper

In general, acid consumption depends mainly on the

kg/kg
kg/t

occurrence of acid-consuming minerals and crush

size of the ore, but also from the increased
contact time lixiviant - ore and the acid strength of
the leach solution. Determined by The Acid
1-1 53.66 34.45 8.68
Consumption Procedure-Short method, the gross
acid consumption is 22.3 kg / ton ore, while the 1-2 44.29 32.34 8.15
2-1 49.65 35.93 9.05
net acid consumption is 21.7 kg / ton ore. In the
same time according to the standard methodology - 2-2 66.10 52.08 13.12
Typical Acid Consumption Procedure-the gross acid
consumption is 28.6 kg / ton ore, while the net Copper recovery and net acid consumption for both
acid consumption is 27.1 kg / ton ore. sets are presented in Figures 2 and 3.
Copper tenor in Pregnant Leach Solutions (PLS) of
4.4. Bottle Roll Tests the four columns is presented in Table 6.
Bottle roll tests are conducted on a bottle roll
apparatus under standard procedure and provide Table 6. PLS Copper tenor.
initial information for copper extraction and
acid consumption. The obtained copper recovery is Column No PLS Copper tenor g/l
low -31, 9%, while the acid consumption of 29.3 1-1 0.453
kg / ton (gross) and 27.4 kg / ton (net) is relatively 1-2 0.513
high, so these results should rather be treated as 2-1 0.398
semi-quantitative. 2-2 0.512
4.5. Column Leach Tests
 5. PROJECT DESIGN CRITERIA
The project designs criteria are selected based on
the metallurgical testwork carried out at the lab
facility, and are summarized in Table 7.

Table 7. Project design criteria.

Process Parameter,unit Value

LEACHI Design ore grade, 0.25
NG Application rate,l/h.m2 12
(L) Acid concentration in the 15
leach solution(first 2
weeks),g/l
Acid concentration in the 6-8
leach solution,g/l
PLS copper tenor,g/l 0.5
PLS pH 1.8-2.2
Process Parameter,unit Value
ION IX feed copper tenor,g/l 0.5
EXCHAN IX feed pH 1.8-2.2
GE Filtrate copper tenor,g/l 0.02
(IX) Filtrate acid concentration, 3
g/l
Regenerate copper 15.6
Figure 2. Copper recovery and net acid tenor,g/l
consumption for columns 1-1 (blue line) and 1-2 Regenerate acid 20
(red line) concentration,g/l
Process Parameter,unit Value
SOLVEN Configuration (Extr. x 3Ex2S
T Strip.)
EXTRAC SX feed copper tenor,g/l 10.4
-TION SX feed acid 14
(SX) concentraion,g/l
Raffinate copper tenor,g/l 1.04
Rafinate acid 29
concentration, g/l
Process Parameter,unit Value
ELECTR Strong electrolyte copper 44
O- tenor,g/l
WINNIN Strong electrolyte acid 160
G concentraion,g/l
(EW) Spent electrolyte copper 32
tenor,g/l
Spent electrolyte acid 180
concentraion,g/l
Current density,A/m2 280-300
Cathode quality LME
Grade A
Cathode production,t/y 2400

The block flow diagram for the Buchim Copper

project is given in Figure 4.

Figure 3. Copper recovery and net acid

consumption for columns 2-1 (green line) and 2-
2 (black line)

Figure 4. Process flowsheet
Figure 4 depicts the overall process whereas L-
leaching, IX-ionexchange, SX-solvent extraction,
EW electrowinning, O-ore, W-spent ore, PLS-
pregnant leach solution, F-filtrate, LR-loaded resin,
SR-regenerated resin, RF-raffinate, RS-regenerate,
LO-loaded organic, SO-stripped organic, PE-
pregnant electrolyte, SE-spent electrolyte, C-
charging, R-regeneration, E-extraction, S-stripping.
6. CONCLUSIONS
Extensive metallurgical testwork has been
conducted to define the process for the Buchim
Copper Project. Bottle roll tests and column tests
were carried out at laboratory scale during the
conceptual study and ion exchange, solvent
extraction and electrowinning tests were run at lab
facility. Effects of particle size, application rate and
acid strength of the leach solutions were evaluated
and basic parameters like application rate, acid
consumption and copper recovery were selected.
A new combined Leach-Ion Exchange-Solvent
Extraction-Electrowinnig (L-IX-SX-EW) process
(Tsekov et al., 2005) has been selected to treat the
Buchim ore and to produce 2400 tpy of copper
cathodes.
The Buchim Copper project is now under
construction and is scheduled to come on stream in
late 2011.
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