WO2024259540A1 - Methods and systems for in-situ leach mining - Google Patents
Methods and systems for in-situ leach mining Download PDFInfo
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- WO2024259540A1 WO2024259540A1 PCT/CA2024/050843 CA2024050843W WO2024259540A1 WO 2024259540 A1 WO2024259540 A1 WO 2024259540A1 CA 2024050843 W CA2024050843 W CA 2024050843W WO 2024259540 A1 WO2024259540 A1 WO 2024259540A1
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- orebody
- leachate
- lixiviant
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/28—Dissolving minerals other than hydrocarbons, e.g. by an alkaline or acid leaching agent
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/28—Dissolving minerals other than hydrocarbons, e.g. by an alkaline or acid leaching agent
- E21B43/283—Dissolving minerals other than hydrocarbons, e.g. by an alkaline or acid leaching agent in association with a fracturing process
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- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B2200/00—Special features related to earth drilling for obtaining oil, gas or water
- E21B2200/20—Computer models or simulations, e.g. for reservoirs under production, drill bits
Definitions
- Heap leaching is an extraction approach wherein a leachate is dripped on to heaps of crushed low-grade ores stacked at the surface of a mining operation, thereby dissolving the metals, and the pregnant liquor is collected and processed to recover the metals.
- Uranium may have been precipitated within the sandstone long after it was originally deposited.
- the sandstone comprises essentially pure quartz and feldspar, and the Uranium is present as a grain coating in an oxide form.
- An acidic leaching solution is created and injected under matrix flow conditions, usually in such a way as to make a sweep front in the sandstone, if possible.
- the leaching solution is treated at the surface to remove the dissolved Uranium, recharged, and recirculated.
- Contributing to the success of conventional leach mining of Uranium is that sandstones have inherent permeability, are relatively flat-lying in aspect, and are shallow (less than 1-2 km), thereby making the sandstone easier to access.
- DLM seeks to chemically leach the mineral values of commercial interest through the process of lixiviation, leaving behind the gangue.
- Surface impacts are small, compared to conventional mining approaches, as nonvaluable minerals (gangue) such as quartz, feldspar and hornblende remain in-situ.
- gangue nonvaluable minerals
- Continued development drilling can take place while preliminary chemical leaching is occurring, reducing initial outlay of capital.
- DLM involves a rock mechanics approach where the orebody, usually in an igneous or metamorphic geological environment, is essentially impermeable and may be ameliorated before a circulation pattern is implemented. There is no inherent limitation to the geometry of the orebody, from vertical to horizontal, and of any thickness or shape.
- the geometry of the orebody dictates in part the wellbore array design and the rock mass stimulation strategy. In principle, there are no limitations to depth, provided that the borehole array can be successfully emplaced to access the orebody. Circulation of leachate may be vertical, horizontal, or inclined, depending on the nature of the orebody and the rock mechanics properties of the host rock.
- the DLM method can also be used for mining minerals containing rare earth metals/elements and deposits of metallic minerals that contain values such as lithium, nickel, cobalt, and copper.
- the empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral values comprises at least one of: a flow rate of the leachate; a concentration of the leachate; or a mass of the recovered first amount of dissolved mineral values.
- applying the modification to the injection and production strategy of the leachate process comprises: modifying a restimulation strategy for restimulating the first portion of the orebody or other portions of the orebody.
- applying the modification to the injection and production strategy of the leachate process comprises: modifying a well configuration design of the plurality of wells.
- applying the modification to the injection and production strategy of the leachate process comprises: adjusting a volume, flow rate, and/or pressure of lixiviant flowing through the lixiviant flow network.
- applying the modification to the injection and production strategy of the leachate process comprises: modifying a lixiviant composition.
- applying the modification to the injection and production strategy of the leachate process comprises: drilling a plurality of new wells using directional drilling to intersect a second portion of the orebody, based on the updated model; and generating an expanded lixiviant flow network in communication with the plurality of new wells by stimulating and/or restimulating at least the second portion of the orebody using a third stimulation process.
- the first stimulation process and the second stimulation process is a hydraulic fracturing stimulation process
- the hydraulic fracturing stimulation process is conducted via the plurality of wells.
- the plurality of wells includes at least one injection well and at least one production well.
- the method further comprising: receiving the leachate at the at least one production well disposed at the target depth in the subterranean orebody and extending to the surface level, the production well for transporting the leachate to the surface level.
- the plurality of wells may have at least one well that is both and injection and production well.
- the present disclosure describes a system for extracting mineral values from a subterranean orebody using a cyclic leaching process including: one or more processor devices; and one or more memories storing machine-executable instructions, which when executed by the one or more processor devices, cause the system to: generate a lixiviant flow network of the subterranean orebody by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody; receive a lixiviant flow into the lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate is produced; update a model corresponding to the cyclic leaching process,
- FIG. IB is a schematic block diagram of an in-situ leach mining system suitable for implementation of examples described herein.
- FIG. 2 is a block diagram of an example computing system suitable for implementation of examples described herein.
- FIG. 3 is a block diagram of an example cyclic deep leach mining optimization system, in accordance with example implementations described herein.
- FIG. 4 is a flowchart showing operations of a method for extracting a mineral value from a subterranean orebody, in accordance with example implementations described herein.
- a model is updated based on empirical process monitoring data obtained during the extraction of mineral values and the first portion of the orebody is restimulated using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network.
- the cyclic leaching process is repeated to progressively develop other portions of the orebody.
- a "lixiviant flow network” or a “lixiviant circulation pattern” can mean: an induced network of flow pathways in a target orebody through which a lixiviant can flow.
- flow pathways in the orebody may be generated by stimulation of the orebody for creating in situ conductivity in the orebody .
- the lixiviant flow network can include an injection well, disposed at the earth's surface, extending into the subterranean orebody and in fluid communication with the flow pathways, for receiving a lixiviant, and a production well, disposed at the earth's surface, extending from the subterranean orebody and in fluid communication with the flow pathways, for the production of recovered leachate flow at the surface.
- fracturing fluid e.g., slurry
- a network of multiple fractures may be induced around the injection well, for example, defining a stimulated reservoir volume (SRV), where the near-wellbore hydraulic fracture development occurs in multiple directions (azimuth, orientations).
- RSV stimulated reservoir volume
- proppant may or may not be added to the slurry for emplacement in the generated fractures, for propping the fractures open and maintaining developed conductivity, for example, after the stimulation is complete.
- the liner or sections of the liner can have fluid flow openings (e.g. slots in a slotted liner, or another fluid flow communication structure) through which fluid can be exchanged between the wellbore string and the subterranean orebody 102 or sections of the liner can be solid.
- the liner can be made of metal, plastic or a composite material.
- sections of the wellbores can be open-hole. For example, if the rock mass is extremely competent, fully casing the injection well 112 and/or the production well 114 may not be necessary, and only the upper 100- 200 m need be cased and cemented in competent rock.
- steel tubing may be inappropriate due to leachate reactivity (e.g., highly acidic), and a low-chemical-reactivity carbon fibre-epoxy casing may be installed, or a polymeric tubing string (e.g., PVC tubing) used to circulate fluids.
- a wellhead 116 can be fixed to the injection well 112 and a wellhead 118 can be fixed to the production well 114.
- development of an induced fracture network within the orebody 102 may create in situ conductivity and surface area exposure to better access the mineral values via a leachate, thereby promoting inter-well communication and providing effective fluid flow and/or circulation pathways for the leachate within the orebody.
- various stimulation and formation conditioning methods may be used for generating flow pathways (enhanced fluid conductivity) or for achieving a desired level of internal surface area exposure for leaching.
- production tubing may transport the pregnant leachate from the subterranean orebody 102 to the surface level 104, where the mineral value can then be recovered, for example, the mineral value may be extracted chemically at a production facility 132, before the lixiviating fluid is reconstituted and re-injected or circulated in a continuous process.
- the pregnant leachate can be produced by artificial lift, for example, using an electrical submersible pump (ESP) assembly (not shown) disposed at a subsurface intake location near the heel of the production well 114.
- ESP electrical submersible pump
- FIG. IB shows an in-situ leach mining system 100b for extracting a target mineral or "value" from a subterranean orebody 102, in accordance with example implementations described herein.
- the in-situ leach mining system 100b is an illustrative example of a system to which the systems, methods, and processor- readable media described herein can be applied, in accordance with examples of the present disclosure.
- the in-situ leach mining system 100b comprises a multiwell configuration (e.g., multi-well array) including at least one parent well pair 110 and one or more child wells 122 (or infill wells) for optimized extraction of the target ore.
- a well pad on the surface 104 provides access to the child wells 122 through respective wellheads 126 of the child wells 122.
- the parent well pair 110 in FIG. IB is shown as a horizontal well pair and the child wells 122 in FIG. IB are shown as deviated wells (e.g., S-shaped), is it understood that the parent well pair 110 and the child wells 122 can be in any configuration, such as horizontal, vertical, or deviated.
- the child wells 122 may be configured to intersect a portion of the orebody 102 corresponding to a height 124 of the orebody 102.
- the parent well pair 110 and the one or more child wells 122 may represent either injection wells or production wells, for example, in various combinations according to the multi-well configuration design, and that the injection wells and production wells may be interchangeable, for example, by reversing the flow direction in the well, for example, as directed by an injection-production strategy.
- the multi-well array configuration includes a plurality of injection wells 112 for receiving a lixiviant flow 128 and a plurality of production wells 114 for receiving a recovered leachate 130 and transporting the recovered leachate 130 to the surface for processing.
- the injection wells 112 may be stimulated to generate induced fractures 120, for example, forming a fracture network within the orebody 102.
- the lixiviant flow may be directed through the fracture network, causing leaching of the mineral values to produce the leachate 130.
- the leachate 130 may propagate toward one of the production wells 114 and may be received through openings of the production 114 for transportation to the surface 104.
- FIG. ID shows a perspective view of an example multi-well array configuration for developing an inclined (dipping) orebody 102, in accordance with example implementations described herein.
- the design of the wellbore array depends on the geometric disposition of the mineral values in the orebody 102, the existence and nature of natural fracture systems, the orientations of the compressive stresses in the orebody, and the outcomes of the formation stimulation undertaken to create surface area and interconnectivity, among other possibilities.
- FIG. ID shows an inclined orebody 102 with a dip 154 measured from a horizontal plane, for example, where a dip angle 150 is measured with respect to a dip direction 152.
- the inclined orebody may be developed by a series of vertical (or substantially vertical) wellbores 140, or the inclined orebody may be developed by a series of horizontal (or substantially horizontal) wellbores 142 placed within the inclined orebody at different depths, or a combination of wellbore orientations may be used.
- a multi-well array configuration including horizontal wellbores for example, where horizontal production wells are positioned below injection wells, may present advantages for leachate production, for example, associated with a higher density of pregnant leachate compared to lixiviant.
- higher density leachate may flow preferentially downwards in the lixiviant flow network, for recovery via production wells positioned deep in the multi-well array configuration.
- the local stress state in a near-wellbore region may be altered in response to a stimulation or restimulation process, for example, causing fracture rotations as the stress system changes.
- a changing local stress state responsive to multiple stimulation processes may contribute to the generation of different fracture orientations and/or induced fracture network complexity.
- the shape and/or geometry of the stimulation zone as well as regional and/or local stress orientations may impact the desired wellbore placement (e.g., spacing, orientation, length etc.) in the wellbore array.
- placement of wells in zones of good connectivity that have been established by the stimulation process may enable a wider well spacing (e.g., with interwell spacing of up to several hundred meters between the wellbores, or more conservatively, with interwell spacing of 30-100 metres), where closer well spacing may enable better control of fluid flow in the stimulation zone over the extraction life.
- wellbores that are oriented along less favorable stress orientations may require a closer wellbore spacing, for example, to account for the poorer fluid flow interconnectivity between wells in that direction.
- FIG. 2 is a block diagram of an example hardware structure of a computing system 200 that is suitable for implementing example embodiments.
- computing system 200 can be an electronic computing device, such as a networked server.
- the computing system 200 can be a distributed computing system including multiple devices (such as a cloud computing platform) or a virtual machine running on one or more devices in mutual communication over a network.
- devices such as a cloud computing platform
- FIG. 2 shows a single instance of each component, there can be multiple instances of each component in the computing system 200.
- the computing system 200 includes at least one processor 202, such as a central processing unit, a microprocessor, a digital signal processor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a dedicated logic circuitry, a dedicated artificial intelligence processor unit, a graphics processing unit (GPU), a tensor processing unit (TPU), a neural processing unit (NPU), a hardware accelerator, or combinations thereof.
- processor 202 such as a central processing unit, a microprocessor, a digital signal processor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a dedicated logic circuitry, a dedicated artificial intelligence processor unit, a graphics processing unit (GPU), a tensor processing unit (TPU), a neural processing unit (NPU), a hardware accelerator, or combinations thereof.
- processor 202 such as a central processing unit, a microprocessor, a digital signal processor, an application-specific integrated circuit (ASIC), a field-programmable gate array (F
- the computing system 200 can include one or more network interfaces (collectively referred to as network interface 206) for wired or wireless communication over a network.
- the network interface 206 can include wired links (e.g., Ethernet cable) and/or wireless links (e.g., one or more antennas).
- the computing system 200 can communicate with one or more user devices (such as user workstation computers) via the network interface 206.
- the computing system 200 can also communicate with various sensors or other data sources to obtain data used in monitoring the resource extraction system 100.
- the sensors can include sensors located within the in-situ leach mining system 100a, 100b. For example, monitoring of various rates, concentrations, locations, flow paths, and other variables may be carried out continuously to understand how the orebody 102 is responding to the DLM process and to maximize the return rate of dissolved mineral value.
- the computing system 200 may include one or more memories 204 (individually or collectively referred to as "memory 204"), which may include a volatile or non-volatile memory (e.g., a flash memory, a random access memory (RAM), and/or a read-only memory (ROM)).
- the non-transitory memory 204 may store instructions for execution by the processor 202, such as to carry out example embodiments.
- the memory 204 may store instructions for implementing any of the methods of the examples and example embodiments.
- the memory 204 may include other software instructions, such as for implementing an operating system (OS) and other applications/functions.
- OS operating system
- the computing system 200 may also include one or more electronic storage units (not shown), such as a solid state drive, a hard disk drive, a magnetic disk drive and/or an optical disk drive.
- one or more data sets and/or modules may be provided by an external memory (e.g., an external drive in wired or wireless communication with the computing system 200) or may be provided by a transitory or non-transitory computer-readable medium. Examples of non-transitory computer readable media include a RAM, a ROM, an erasable programmable ROM (EPROM), an electrically erasable programmable ROM (EEPROM), a flash memory, a CD-ROM, or other portable memory storage.
- EPROM erasable programmable ROM
- EEPROM electrically erasable programmable ROM
- the memory 204 can also store information or data used in executing the cyclic deep leach mining optimization system 300, for example, a numerical model 320 and a leachate flow simulator 340.
- the components of the computing system 200 may communicate with each other via a bus, for example.
- FIG. 3 is a block diagram of an example cyclic deep leach mining optimization system 300 of the present disclosure.
- the cyclic deep leach mining optimization system 300 can be a software that is implemented in the computing system 200 of FIG. 2, in which the processor 202 is configured to execute instructions of the cyclic deep leach mining optimization system 300 stored in the memory 204.
- the cyclic deep leach mining optimization system 300 in this example includes a numerical model 320, a leachate flow simulator 340 and a DLM process evaluator 360.
- different functions of the cyclic deep leach mining optimization system 300 can be performed on different devices other than the computing system 200. For example, computationally intensive functions such as building a 3D numerical model (e.g., numerical model 320) and executing the numerical model 320 or the flow simulator 340 can be performed on a cloud computing platform in communication with a local computing system 200.
- computationally intensive functions such as building a 3D numerical model (e.g., numerical model 320) and executing the numerical model 320
- the cyclic deep leach mining optimization system 300 can receive as inputs 301, numerical model inputs 310, flow simulator inputs 312 and empirical process monitoring data 314 and can output a proposed DLM process modification 370.
- Analytical or numerical models are commonly employed in resource extraction operations for predicting rock behavior and for designing efficient and safe operations.
- Flow simulators are often used in resource extraction operations (e.g., hydrocarbon extraction, among others) to model fluid flow and predict recovery volumes.
- these models can be complex, and they are dependent on the quality and resolution of input data.
- wellbore monitoring or well and formation testing methods may be applied prior to development of the orebody and continually throughout development of the orebody 102, to gather and/or refine inputs for analytical or numerical models or flow simulators.
- the continuous monitoring may provide feedback regarding the orebody response to lixiviation and may inform future modifications to the cyclic DLM process, for example, the drilling of child offset (or infill) wells in appropriate locations, for example, to reduce the well spacing and achieve higher recovery factors, among other modifications.
- the numerical model inputs 310 may include information associated with well configuration, geology (e.g., mapped orebody geometry, richness etc.), drilling information obtained during the drilling of wells during exploration or pre-production phases, such as exploration wells, a parent well pair 110, or any injection wells 112, production wells 114 or monitoring wells, geophysical measurements (e.g., seismic data, geophysical logs etc.), rock mechanics information (e.g., elastic properties, permeability, porosity, conductivity, in-situ stress etc.), well completions data (e.g., pressures, flow rates, volumes, concentrations etc.) or production data (e.g., flow rates, volumes, concentrations etc.) among other data.
- geology e.g., mapped orebody geometry, richness etc.
- drilling information obtained during the drilling of wells during exploration or pre-production phases, such as exploration wells, a parent well pair 110, or any injection wells 112, production wells 114 or monitoring wells
- geophysical measurements
- determining an in-situ stress state during the delineation of the orebody is important for optimal wellbore array design.
- mathematical (e.g., numerical) modeling may be used to evaluate potential stimulation strategies for optimizing the orebody leaching.
- the numerical model 320 (e.g., such as continuum models, among other possibilities) may first be generated, based on the numerical model inputs 310.
- the numerical model 320 can be a software that is implemented in the computing system 200 of FIG. 2, in which the processor device 202 is configured to execute instructions of the numerical model 320 stored in the memory 204.
- the numerical model 320 may be generated for a geological environment, including the orebody or a portion of the orebody, for example, based on lithology, geological structures etc., and associated material properties and in-situ stress conditions.
- the leachate flow simulator 340 may also first be generated, based on flow simulator inputs 312 and information provided by the numerical model 320, for example, corresponding to wellbore configurations and induced fracture networks, among other data, to model the lixiviant flow network.
- the flow simulator inputs 312 may include information associated with well testing (e.g., for assessing the degree of interwell interconnectivity and preferred spatial flow directions), including pressure migration testing, tracer tests, and formation testing (e.g. injectivity testing and analysis, step-rate flow tests) or other methods to delineate the nature of the flow patterns created with respect to the orebody geometrical and mineral value distribution information.
- the flow simulator inputs 312 may also include other information, such as the wellbore configuration, orebody parameters (e.g., mapped orebody geometry, richness etc.), drilling information obtained during the drilling of wells during exploration or pre-production phases, such as exploration wells, parent well pair 110, or any injection wells 112, production wells 114 or monitoring wells, geophysical measurements (e.g., seismic data, geophysical logs etc.), rock mechanics information (e.g., elastic properties, permeability, porosity, conductivity, in-situ stress etc.), well completions data (e.g., pressures, flow rates, volumes, concentrations etc.) or production data (e.g., flow rates, volumes, concentrations etc.) among other data.
- the wellbore configuration e.g., mapped orebody geometry, richness etc.
- drilling information obtained during the drilling of wells during exploration or pre-production phases, such as exploration wells, parent well pair 110, or any injection wells 112, production wells 114 or monitoring
- the leachate flow simulator 340 may model the lixiviant flow network (e.g., fluid flow or circulation pattern of lixiviant and/or leachate through the induced fracture network) between a plurality of wells, for example, between one or more injection wells 112 and one or more production wells 114.
- continual data collection, analysis and interpretation may inform updates to either the numerical model 320 or the leachate flow simulator 340, for example, empirical process monitoring data 314 may include concentrations of the exiting leachate may be continually measured, along with the distribution of input and outflow, reflecting changes in fluid circulation pattern(s) as they develop in-situ, among other data associated with the cyclic DLM process that is measured during the process, for example, through experimentation or observation.
- periodic mapping of the disposition of the process in the orebody may be undertaken to determine the shape and position of leached zones, in order to continue to develop and optimize the deep leach mining process.
- these activities may include seismic methods (3D surface seismic, cross-hole seismic tomography, vertical seismic profiling, and others), resistivity mapping, interwell hydraulic tests, wellbore logging (temperature logs, tracer logs, etc.) and mathematical modeling of the leaching process in the subsurface.
- seismic methods (3D surface seismic, cross-hole seismic tomography, vertical seismic profiling, and others)
- resistivity mapping 3D surface seismic, cross-hole seismic tomography, vertical seismic profiling, and others
- interwell hydraulic tests 3D surface seismic, cross-hole seismic tomography, vertical seismic profiling, and others
- wellbore logging temperature logs, tracer logs, etc.
- mathematical modeling of the leaching process in the subsurface may be continually acquired and fed into the numerical model 320 or the leachate flow simulator 340 during cyclic DLM process operations, for updating the numerical model 320 and the leachate flow simulator 340.
- the numerical model 320 and the leachate flow simulator 340 may interact, for example, in an iterative process, to evaluate the effect of potential modifications to the cyclic CLM process, for example, including modifications to well configuration, wellbore stimulation and/or restimulation, slurry composition, injection-production strategy etc. on the predicted recovery of mineral values.
- the numerical model 320 may output a simulated DLM process modification 330 (e.g., where the simulated DLM process modification 330 may include a stimulation and/or a restimulation of an existing well in the in-situ deep leach mining system lOOa/lOOb, such as an injection well 112 or a production well 114, or the drilling of a new well, such as a child offset well 122, among other modifications) and the leachate flow simulator 340 may generate a predicted recovery 350 associated with the simulated DLM process modification 330.
- a simulated DLM process modification 330 e.g., where the simulated DLM process modification 330 may include a stimulation and/or a restimulation of an existing well in the in-situ deep leach mining system lOOa/lOOb, such as an injection well 112 or a production well 114, or the drilling of a new well, such as a child offset well 122, among other modifications
- the leachate flow simulator 340 may generate a
- the leachate flow simulator 340 may perform a flow simulation for a well configuration that incorporates the simulated DLM process modification 330, to evaluate the effect of the modification on the predicted flow dynamics for the lixiviant flow network (e.g. predicted rate of lixiviant flow, predicted leaching rate, predicted recovery of leachate, etc.) on the predicted recovery 350.
- the leachate flow simulator 340 may feed information back to the numerical model 320 to inform future simulated DLM process modifications 330.
- simulated DLM process modifications 330 can be iteratively provided to the leachate flow simulator 340 and evaluated until a predicted recovery meets a predetermined threshold value, among other criteria.
- a DLM process evaluator 360 may receive the predicted recovery 350 associated with the simulated DLM process modification 330 and may compare the predicted recovery 350 to empirical process monitoring data 314, for example, including a measured recovery, among other information, to determine a DLM process modification 370.
- the DLM process modification 370 may be implemented within the in-situ leach mining system lOOa/lOOb, for example, by stimulating or restimulating a portion of the orebody 102 (e.g., performing a hydraulic fracture stimulation on an injection well 112 and/or a production well 114), by drilling one or more new wells for targeting additional portions of the orebody (e.g., drilling a new offset or infill well using directional drilling to intersect a second portion of the orebody, such as adjacent portions of the orebody) for expanding the lixiviant flow network, by optimizing a slurry (e.g., lixiviant) design, by adjusting flow rates and/or pressures through the lixiviant flow network or altering flow paths in the lixiviant flow network (e.g., by adjusting injection rates and/or pressures and/or production rates and/or pressures), according to an injection-production strategy, among other possibilities.
- a slurry e.g., lixiviant
- DLM process modifications may occur repeatedly through the life of the orebody development, for example, in a cyclic manner until the orebody is exploited.
- an example process modification can be to adjust a valve of the production well 114 to reduce the production rate from the wellbore.
- reducing a production rate may cause the lixiviant flowing through the lixiviant flow network to flow in an alternate path, for example, toward other production wells 114, for increasing the amount of dissolved mineral values in the produced leachate and maximizing recovery.
- a modification can be to adjust a slurry design, for example, a concentration or composition of the injected lixiviant for increasing the amount of dissolved mineral values in the produced leachate and maximizing recovery.
- process modifications may be made at each wellhead individually.
- the DLM process may be guided by empirical data analyses and mathematical modeling to interpret what is happening at depth.
- the numerical model and 320 and leachate flow simulator 340 may be repeatedly recalibrated, for example, based on empirical process monitoring data to optimize the DLM process.
- Example implementations of methods for extracting mineral values from a subterranean orebody will now be described, with reference to the cyclic deep leach mining optimization system 300 executed by the example computing system 200 in co-operation with the in-situ leach mining system 100a or 100b.
- Method 400 begins at step 402 in which a lixiviant flow network of the subterranean orebody is generated by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody.
- the first stimulation process may cause an increase in the surface area within a stimulated volume of a near-wellbore region.
- the first stimulation process may generate interconnectivity between adjacent wellbores to enable fluid circulation in the lixiviant flow network (e.g., generating enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody).
- the stimulation process may involve some combination of hydraulic fracturing, hydroshearing, blast detonations, rocket propellant stimulation, acid stimulation, or other techniques.
- a lixiviant flow is received into a lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate 130 is produced.
- mineral "values" may leached from the subterranean orebody 102 into the leachate 130.
- the well may be a production well 114 and the leachate 130 is received at the production well 114, where the production well 114 is disposed at the target depth 106 in the subterranean orebody 102 and extending to the surface level 104, the production well 114 for transporting the leachate 130 to the surface level 104.
- a model corresponding to the cyclic DLM process may be updated based on empirical process monitoring data 314.
- empirical process monitoring data 314 corresponding to the leachate 130 or the recovered first amount of dissolved mineral value, among other sources of empirical data associated with the DLM process.
- measurements may include flow rate of the leachate, concentration of the leachate or a mass of the recovered first amount of mineral value, among other possibilities.
- the DLM process represents a cyclic process or iterative process, where monitored data is used to optimize and improve the DLM process using an engineered and/or data-driven approach.
- a DLM process modification 370 may be applied to the cyclic DLM process, for example, the first portion of the orebody may be restimulated using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant network.
- the second stimulation process may be performed based on the updated numerical model 320 and/or the updated leachate flow simulator 340.
- the cyclic DLM leaching process may be repeated to progressively develop other portions of the orebody.
- the second stimulation process may be repeated and/or performed multiple times on the first portion of the orebody or on other portions of the orebody, among other possibilities.
- DLM process modifications 370 may be implemented or repeated in a progressive manner within the in-situ leach mining system lOOa/lOOb, for example, by drilling one or more new wells for targeting additional portions of the orebody (e.g., drilling a new offset or infill well using directional drilling to intersect a second portion of the orebody, such as adjacent portions of the orebody) for expanding the lixiviant flow network, by optimizing a slurry (e.g., lixiviant) design, by adjusting flow rates and/or pressures through the lixiviant flow network or altering flow paths in the lixiviant flow network (e.g., by adjusting injection rates and/or pressures and/or production rates and/or pressures), according to an injection-production strategy, by stimulating or restimulating another portion of the orebody 102 using a stimulation process or a restimulation process, among other possibilities.
- a slurry e.g., lixiviant
- continuous monitoring of the cyclic DLM process regarding the orebody response to lixiviation may inform repeated future modifications to the cyclic DLM process and DLM process modifications may occur repeatedly through the life of the orebody development, for example, in a cyclic manner until the orebody is exploited.
- the present disclosure is described, at least in part, in terms of methods, a person of ordinary skill in the art will understand that the present disclosure is also directed to the various components for performing at least some of the aspects and features of the described methods, either by way of hardware components, software or any combination of the two. Accordingly, the technical solution of the present disclosure can be embodied in the form of a software product.
- a suitable software product can be stored in a pre-recorded storage device or other similar non-volatile or non-transitory computer readable medium, including DVDs, CD-ROMs, USB flash disk, a removable hard disk, or other storage media, for example.
- the software product includes instructions tangibly stored thereon that enable a processing device (e.g., a personal computer, a server, or a network device) to execute examples of the methods disclosed herein.
- a processing device e.g., a personal computer, a server, or a network device
- the software improves the operation of the hardware in one or more ways.
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Abstract
Methods and systems are provided for extracting mineral values from a subterranean orebody using a cyclic leaching process. A lixiviant flow network of the subterranean orebody is generated by stimulating a first portion of the orebody using a first stimulation process, causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody. A lixiviant flow is received into the lixiviant flow network via at least one well of the plurality of wells, with effect that a leachate is produced. A model is updated based on empirical process monitoring data obtained during the extraction of mineral values and the first portion of the orebody is restimulated using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network. The cyclic leaching process is repeated to progressively develop other portions of the orebody.
Description
METHODS AND SYSTEMS FOR IN-SITU LEACH MINING
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefits of priority to United States
Provisional Patent Application No. 63/509,681, filed June 22, 2023, titled DEEP LEACH MINING: ACCESSING RICH, SMALL OREBODIES, the contents of which are hereby expressly incorporated into the present application by reference in their entirety.
FIELD
[0002] The present disclosure relates to mining processes, more specifically to in-situ leaching processes, and in particular, to methods and systems for in-situ leach mining.
BACKGROUND
[0003] Mining of rare earth metals and/or elements such as lithium, nickel, cobalt, and copper from geological formations is essential for the advancement of technological and clean energy applications, such as battery development for electric vehicles. As discovery of large-volume, high-grade ore deposits has decreased, operators are increasingly required to extract metals from technologically challenging and/or high-cost environments. As such, many known deposits await development for higher commodity prices to compensate for limited ore volumes or lower-grade deposits, or mitigation of the high costs and technological limitations of conventional mining approaches to access deeper ore bodies. Furthermore, many deposits exist in remote locations, posing further challenges due to a lack of local infrastructure, opposition by local stakeholders, environmental concerns and complicated permitting processes.
[0004] Leaching may be used to extract valuable metals using chemical processes. Heap leaching is an extraction approach wherein a leachate is dripped on to heaps of crushed low-grade ores stacked at the surface of a mining operation, thereby dissolving the metals, and the pregnant liquor is collected and processed to recover the metals.
[0005] Solution mining, also known as in-situ leaching or in-situ recovery, is a mineral extraction method where a wellbore is drilled into a subsurface formation to recover minerals such as salts, (e.g. halite, potash), phosphorus, uranium, copper and lithium. Ores or other mineral deposits can be dissolved in-situ and the pregnant liquor is produced, for example, by pumping to the surface for collection and processing of the minerals. Often, these deposits are present in shallow sedimentary deposits that have inherent permeability and are relatively flat-lying in aspect.
[0006] Accordingly, it would be useful to provide improved techniques for in- situ leaching of metallic minerals that are more commonly found in crystalline rocks of inherently low permeability. Examples of such minerals include many sulphides (e.g., galena, sphalerite, nickel), oxides, and even carbonates or complex silicates.
SUMMARY
[0007] In some embodiments, the methods and systems described herein can be used to extract ore from a subterranean orebody by in-situ leach mining, where the orebody has been sufficiently stimulated to increase the surface area of mineral exposure and create flow pathways for a circulating lixiviant. Advantageously, the methods and systems described herein enable the extraction of valuable minerals from impermeable, deep or inclined orebodies, without relying on conventional underground mining methods. In this regard, previously inaccessible minerals may be recovered in a more efficient and environmentally conscious way. In addition, by using a multi-well array configuration, a large portion of a target subsurface mineral
deposit (an orebody) can be accessed from a single surface location, contributing to a smaller surface footprint and associated reduced surface resources.
[0008] Previous success in the extraction of metals by in-situ leaching is demonstrated by the recovery of Uranium from porous sandstone (sedimentary) deposits. Through deep formation water movement and geochemical reactions, Uranium may have been precipitated within the sandstone long after it was originally deposited. Ideally, the sandstone comprises essentially pure quartz and feldspar, and the Uranium is present as a grain coating in an oxide form. An acidic leaching solution is created and injected under matrix flow conditions, usually in such a way as to make a sweep front in the sandstone, if possible. The leaching solution is treated at the surface to remove the dissolved Uranium, recharged, and recirculated. Contributing to the success of conventional leach mining of Uranium is that sandstones have inherent permeability, are relatively flat-lying in aspect, and are shallow (less than 1-2 km), thereby making the sandstone easier to access.
[0009] Leaching can be applied directly in the subsurface providing that the orebody can be developed with a large internal surface area to allow dissolution of the target ore mineral or 'value', typically while leaving the no-value minerals behind (referred to as 'gangue'). Deep leach mining (DLM) requires properly located and designed wellbores in an array that accesses the orebody in an effective manner, rock mass stimulation to increase surface area of mineral exposure and enhance or create rock mass fluid conductivity, and optimized leaching chemical circulation programs to achieve appropriate value concentrations in the "pregnant" fluids returned to surface for value extraction, reconstitution, and recirculation to depth. In this regard, DLM seeks to chemically leach the mineral values of commercial interest through the process of lixiviation, leaving behind the gangue. Surface impacts are small, compared to conventional mining approaches, as nonvaluable minerals (gangue) such as quartz, feldspar and hornblende remain in-situ. Continued development drilling can take place while preliminary chemical leaching is occurring, reducing initial outlay of capital.
[0010] DLM involves a rock mechanics approach where the orebody, usually in an igneous or metamorphic geological environment, is essentially impermeable and may be ameliorated before a circulation pattern is implemented. There is no inherent limitation to the geometry of the orebody, from vertical to horizontal, and of any thickness or shape. The geometry of the orebody dictates in part the wellbore array design and the rock mass stimulation strategy. In principle, there are no limitations to depth, provided that the borehole array can be successfully emplaced to access the orebody. Circulation of leachate may be vertical, horizontal, or inclined, depending on the nature of the orebody and the rock mechanics properties of the host rock. In another example, the DLM method can also be used for mining minerals containing rare earth metals/elements and deposits of metallic minerals that contain values such as lithium, nickel, cobalt, and copper.
[0011] In some aspects, the present disclosure describes a method to extract mineral values from a subterranean orebody using a cyclic leaching process. The method includes a number of steps, including: generating a lixiviant flow network of the subterranean orebody by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody; receiving a lixiviant flow into the lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate is produced; updating a model corresponding to the cyclic leaching process, based on empirical process monitoring data obtained during the extraction of mineral values, the model for optimizing an injection and production strategy of the cyclic leaching process; restimulating the first portion of the orebody using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network; and repeating the cyclic leaching process to progressively develop other portions of the orebody.
[0012] In an example of the preceding example aspect of the method, the further comprising: in response to recovering a first amount of dissolved mineral value from the leachate at the surface level, updating the model based on empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral value; applying one or more modifications to the cyclic leaching process for extracting additional mineral values from the subterranean orebody, based on the updated model; and recovering a second amount of dissolved mineral value, based on the modified injection and production strategy.
[0013] In an example of any of the preceding example aspects of the method, further comprising: applying further one or more modifications to the cyclic leaching process modifications in a cyclic manner until the orebody is exploited.
[0014] In an example of any of the preceding example aspects of the method, wherein the empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral values comprises at least one of: a flow rate of the leachate; a concentration of the leachate; or a mass of the recovered first amount of dissolved mineral values.
[0015] In an example of any of the preceding example aspects of the method, wherein applying the modification to the injection and production strategy of the leachate process comprises: modifying a restimulation strategy for restimulating the first portion of the orebody or other portions of the orebody.
[0016] In an example of any of the preceding example aspects of the method, wherein applying the modification to the injection and production strategy of the leachate process comprises: modifying a well configuration design of the plurality of wells.
[0017] In an example of any of the preceding example aspects of the method, wherein applying the modification to the injection and production strategy of the leachate process comprises: adjusting a volume, flow rate, and/or pressure of lixiviant flowing through the lixiviant flow network.
[0018] In an example of any of the preceding example aspects of the method, wherein applying the modification to the injection and production strategy of the leachate process comprises: modifying a lixiviant composition.
[0019] In an example of any of the preceding example aspects of the method, wherein applying the modification to the injection and production strategy of the leachate process comprises: drilling a plurality of new wells using directional drilling to intersect a second portion of the orebody, based on the updated model; and generating an expanded lixiviant flow network in communication with the plurality of new wells by stimulating and/or restimulating at least the second portion of the orebody using a third stimulation process.
[0020] In an example of the preceding example aspect of the method, further comprising: receiving drilling information during the drilling of the plurality of new wells; and updating the model based on the drilling information.
[0021] In an example of any of the preceding example aspects of the method, wherein the first stimulation process and the second stimulation process is a hydraulic fracturing stimulation process, and the hydraulic fracturing stimulation process is conducted via the plurality of wells.
[0022] In an example of the preceding example aspect of the method, further comprising: updating the model based on one or more empirical process measurements corresponding to the hydraulic fracturing stimulation process.
[0023] In an example of any of the preceding example aspects of the method, wherein the plurality of wells includes at least one injection well and at least one production well.
[0024] In an example of the preceding example aspect of the method, further comprising: receiving the leachate at the at least one production well disposed at the target depth in the subterranean orebody and extending to the surface level, the production well for transporting the leachate to the surface level.
[0025] In an example of a preceding example aspect of the method, wherein the plurality of wells may have at least one well that is both and injection and production well.
[0026] In some examples, the present disclosure describes a system for extracting mineral values from a subterranean orebody using a cyclic leaching process including: one or more processor devices; and one or more memories storing machine-executable instructions, which when executed by the one or more processor devices, cause the system to: generate a lixiviant flow network of the subterranean orebody by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody; receive a lixiviant flow into the lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate is produced; update a model corresponding to the cyclic leaching process, based on empirical process monitoring data obtained during the extraction of mineral values, the model for optimizing an injection and production strategy of the cyclic leaching process; restimulate the first portion of the orebody using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network; and repeat the cyclic leaching process to progressively develop other portions of the orebody.
[0027] In some example aspects, the present disclosure describes a non- transitory computer readable medium storing instructions thereon. The instructions, when executed by a processor, cause the processor to: perform any of the preceding example aspects of the method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] Reference will now be made, by way of example, to the accompanying drawings which show example implementations of the present application, and in which:
[0029] FIG. 1A is a schematic block diagram of an in-situ leach mining system suitable for implementation of examples described herein.
[0030] FIG. IB is a schematic block diagram of an in-situ leach mining system suitable for implementation of examples described herein.
[0031] FIG. 10 is a perspective view of an example multi-well array configuration for implementing the in-situ leach mining system of FIG. IB, in accordance with example implementations described herein.
[0032] FIG. ID is a perspective view of an example multi-well array configuration for developing an inclined orebody, in accordance with example implementations described herein.
[0033] FIG. 2 is a block diagram of an example computing system suitable for implementation of examples described herein.
[0034] FIG. 3 is a block diagram of an example cyclic deep leach mining optimization system, in accordance with example implementations described herein.
[0035] FIG. 4 is a flowchart showing operations of a method for extracting a mineral value from a subterranean orebody, in accordance with example implementations described herein.
[0036] Similar reference numerals have been used in different figures to denote similar components.
DESCRIPTION OF EXAMPLE IMPLEMENTATIONS
[0037] The following describes example technical solutions of this disclosure with reference to accompanying figures. Similar reference numerals may have been used in different figures to denote similar components.
[0038] Methods and systems are provided for extracting mineral values from a subterranean orebody using a cyclic leaching process. A lixiviant flow network of the subterranean orebody is generated by stimulating a first portion of the orebody using a first stimulation process, causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody. A lixiviant flow is received into the lixiviant flow network via at least one well of the plurality of wells, with effect that a leachate is produced. A model is updated based on empirical process monitoring data obtained during the extraction of mineral values and the first portion of the orebody is restimulated using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network. The cyclic leaching process is repeated to progressively develop other portions of the orebody.
[0039] To assist in understanding the present disclosure, the following describes some concepts relevant to leach mining processes for producing a mineral "value" from a target orebody, along with some relevant terminology that may be related to examples disclosed herein.
[0040] In the present disclosure, an "orebody" can mean: a body of rock that contains a mineral that has commercial value. Part of this rock mass that contains mineral values is called "ore". Ore also contains minerals that have no commercial value, such as quartz and feldspar, referred to as "gangue". In this regard, an orebody contains ore comprised of one or more valuable minerals plus gangue. In the present disclosure, "mineral value" can mean: the minerals of interest to be mined/recovered within a rock ore, with the process described herein. In many operations, an orebody may only contain a small fraction of one percent of the
mineral value. For example, lead-zinc sulphide deposits in igneous rock masses contain the major mineral values of galena (lead sulphide - PbS) and sphalerite (zinc sulphide - ZnS). The concentration of these two mineral values in the orebody varies geographically, depending on many factors. Furthermore, in many mining operations, there are additional mineral values associated with the major minerals, such as silver or rare metals such as gallium, indium and germanium. These additional mineral values are found as small amounts of various minerals or even as small concentrations within the major minerals themselves, and they can be extracted from the ore as well as the lead and the zinc.
[0041] In the present disclosure, "in-situ recovery", "in-situ leaching", "in-situ leach mining" or "solution mining" can mean: a mineral extraction method where a mineral in a subterranean deposit is dissolved in a fluid (e.g., a chemical lixiviation agent or a lixiviant) to form a solution or leached from the subterranean formation, and the leachate is produced, for example, by pumping the leachate to the surface, where the mineral values can be recovered. Examples of minerals which are commonly extracted by in-situ recovery include evaporitic salts (e.g., halite, sylvite, glauberite), phosphorus, uranium, copper and lithium.
[0042] In the present disclosure, "heap leaching" can mean: A method for processing and extracting metallic mineral values from crushed low-grade ores stacked in heaps at the surface of a mining operation, wherein a lixiviant is dripped on to the heaps of crushed ore, thereby dissolving the mineral values, and a resulting pregnant liquor (e.g., leachate) containing the dissolved ore is collected and processed to extract the valuable metals.
[0043] In the present disclosure, a "parent well" can mean: an initial well to be drilled into a target subterranean formation, for example, before any other wells are drilled. In examples, parent wells can include parent well pairs, in which one well of the well pair is an injection well and the other well of the well pair is a production well.
[0044] In the present disclosure, a "child well" can mean: a well that is drilled after an initial parent well pair has been drilled into a subterranean orebody, and
possibly after a parent well pair has been on production. Child wells can also be called infill wells and can be designed to target a region of a subterranean orebody that cannot be accessed by a parent well pair. In examples, child wells can serve as injection wells or production wells and may be drilled in a range of configurations, for example, horizontal, vertical or deviated wells.
[0045] In the present disclosure, a "lixiviant flow network" or a "lixiviant circulation pattern" can mean: an induced network of flow pathways in a target orebody through which a lixiviant can flow. In examples, flow pathways in the orebody may be generated by stimulation of the orebody for creating in situ conductivity in the orebody . The lixiviant flow network can include an injection well, disposed at the earth's surface, extending into the subterranean orebody and in fluid communication with the flow pathways, for receiving a lixiviant, and a production well, disposed at the earth's surface, extending from the subterranean orebody and in fluid communication with the flow pathways, for the production of recovered leachate flow at the surface.
[0046] In the present disclosure, a "stimulation" can mean: a process of generating cracks or fractures in a rock mass through which fluid may flow more freely, for example, including hydraulic fracturing, hydroshearing, rocket-propellant stimulation, or explosive stimulation, among other stimulation approaches. In examples, hydraulic fracturing may include a "slickwater" hydraulic fracturing process, where one or more of a group of appropriate polymers is added to the water to reduce its frictional resistance as it moves through small aperture fractures, or other injection fluids may be used. In typical slickwater fracturing, extremely fluid high injection rates and/or pressures are employed for generating the fractures and extending the fracture length by carrying the fracturing fluid (e.g., slurry) far from the injection point. In examples, a network of multiple fractures may be induced around the injection well, for example, defining a stimulated reservoir volume (SRV), where the near-wellbore hydraulic fracture development occurs in multiple directions (azimuth, orientations). In examples, proppant may or may not be added to the slurry for emplacement in the generated
fractures, for propping the fractures open and maintaining developed conductivity, for example, after the stimulation is complete.
[0047] In the present disclosure, a "restimulation" can mean: a process of stimulating (e.g., by hydraulic fracturing, or using another stimulation approach) a well after an initial stimulation has occurred. In examples, a restimulation may take place after a period of operation and production from the previously stimulated well, for example, for enhancing a previously generated complex fracture network or for generating new fractures in a rock mass.
[0048] FIG. 1A shows an in-situ leach mining system 100a for extracting a target mineral or "value" from a subterranean orebody 102. The in-situ leach mining system 100a is an illustrative example of a system to which the systems, methods, and processor-readable media described herein can be applied, in accordance with examples of the present disclosure.
[0049] In some embodiments, for example, the in-situ leach mining system 100a comprises a parent well-pair 110. In examples, the parent well pair 110 may be a vertical well pair, a horizontal well pair or a deviated well pair, for example, based on the orientation of the orebody 102. Although the well pair 110 in FIG. 1A is shown as a horizontal well pair, this is exemplary and not intended to be limiting. In some embodiments, for example, the parent well pair 110 may include an injection well 112 and a production well 114 extending vertically from the surface 104 to a target depth 106 corresponding to the subterranean orebody 102.
Although wells of the parent well pair 110 are indicated as including an injection well 112 and a production well 114, it is understood that injection well 112 and production wells 114 may be interchangeable, for example, by reversing the flow direction in the well. In other embodiments, for example, a single well may be used instead of a well pair 110, for example, where the single well may represent an injection well 112 when fluid is flowing in one direction, for example, directed into the orebody 102, and may represent a production well 114 by reversing the flow direction in the well. In some embodiments, for example, the orebody 102 may be considered a shallow orebody, for example, located at a depth 106 less than 500 m
from the surface level 104, or in other embodiments, the orebody may considered a deep orebody located at a depth 106 between 500 m and 5 km from the surface level 104, among other possibilities. In some examples, during drilling, the trajectory of the injection well 112 and/or the production well 114 can change direction, for example, at the heel of the well, and extend laterally toward a toe of the well, for example, horizontally or in a deviated direction to access the subterranean orebody 102. In some embodiments, for example, the lateral extents of the injection well 112 and production well 114 may be substantially parallel.
[0050] In some embodiments, for example, the injection well 112 and the production well 114 may each comprise a tubing string (e.g. a coiled tubing or a production tubing, such as a packer-isolated production tubing) extending within a wellbore string from a surface level 104 and to the subsurface depth 106 corresponding to the subterranean orebody 102. In some embodiments, for example, the wellbore string can comprise a casing and optionally, a liner. In some embodiments, for example, the casing or sections of the casing may be perforated to generate fluid flow openings in the casing, through which fluid can be exchanged between the wellbore string and the subterranean orebody 102. In some embodiments, for example, the liner or sections of the liner can have fluid flow openings (e.g. slots in a slotted liner, or another fluid flow communication structure) through which fluid can be exchanged between the wellbore string and the subterranean orebody 102 or sections of the liner can be solid. In examples, the liner can be made of metal, plastic or a composite material. In other embodiments, for example, sections of the wellbores can be open-hole. For example, if the rock mass is extremely competent, fully casing the injection well 112 and/or the production well 114 may not be necessary, and only the upper 100- 200 m need be cased and cemented in competent rock. In some embodiments, for example, steel tubing may be inappropriate due to leachate reactivity (e.g., highly acidic), and a low-chemical-reactivity carbon fibre-epoxy casing may be installed, or a polymeric tubing string (e.g., PVC tubing) used to circulate fluids. At the surface level 104, a wellhead 116 can be fixed to the injection well 112 and a wellhead 118 can be fixed to the production well 114.
[0051] In some examples, the subterranean orebody 102 can include a minable source of ore, for example, a deposit of minerals containing rare earth metals such as praseodymium and gallium, or strategic minerals that contain values such as lithium, nickel, cobalt, and copper, among other minerals. In some examples, the orebody may be heterogenous, for example, comprising zones of higher-grade ore 108 or veins containing mineral values which may be targeted or prioritized for earlier development. In examples, the orebody 102 may represent an igneous or metamorphic rock environment, for example, exhibiting low permeability. In some embodiments, for example, the low permeability orebody 102 may be stimulated, for example, by hydraulic fracturing or another stimulation approach, to induce fractures 120 within the orebody.
[0052] In examples, development of an induced fracture network within the orebody 102 may create in situ conductivity and surface area exposure to better access the mineral values via a leachate, thereby promoting inter-well communication and providing effective fluid flow and/or circulation pathways for the leachate within the orebody. In examples, various stimulation and formation conditioning methods may be used for generating flow pathways (enhanced fluid conductivity) or for achieving a desired level of internal surface area exposure for leaching. For example, several of the following approaches may be used together or in sequence: the use of closely spaced vertical or inclined wells; the use of horizontal wellbores with multi-stage stimulation points through the orebody; hydroshearing, or other approaches that avoid high hydraulic pressure stimulation; hydraulic stimulation or hydraulic fracturing methods, rocket-propellant stimulation, or explosive stimulation (e.g., bottom-hole ammonium nitrate and fuel oil (ANFO) detonation), among other possibilities.
[0053] In some examples, the mineral values can be recovered by an in-situ leach mining method, for example, where the injection of a chemical lixiviation agent (or simply, a lixiviant) to produce a lixiviant flow or circulation pattern through the generated fracture network, causes leaching of the ore to produce a "pregnant" fluid or leachate. In some examples, the lixiviant can be an acid, a
mixture of acids, or an aqueous solution containing chemicals that is designed to preferentially dissolve the mineral values, leaving other minerals, commonly referred to as "gangue minerals" or "gangue", largely undissolved. The chemical composition of the lixiviant depends on the nature of the mineral value. For example, if the metal copper (Cu) is present in the form of copper oxides, CuO or CU2O (a mineral known as tenorite), aqueous sulphuric acid solutions may be used as effective lixiviants. However, for the various silicate copper minerals, a strongly oxidizing lixiviant may be used, such as ferric sulphate. For some mineral values, a biologically-mediated approach may be preferred whereby a suitable bacterium with nutrients can alter the nature of the mineral value so that it becomes soluble in the circulating fluid, or another lixiviant fluid may flushed through the orebody in a cyclic process. Each mineral assemblage may be assessed to determine the best lixiviants and the optimum operational procedures to achieve commercial rates of value recovery.
[0054] In some examples, the lixiviant can be pumped into the injection well 112 and the lixiviant flow can be conducted through the induced fracture network, for example, to form a lixiviant flow network, for example, extending toward production well 114, enabling the leaching of the mineral values. For example, the lixiviant may be designed to preferentially dissolve the mineral values as it flows through the lixiviant flow network, leaving the gangue behind. In examples, pregnant leachate may be received at the production well 114 through fluid communication openings, for example, the lixiviant may be conducted through the lixiviant flow network, where it is received via fluid communication openings in the production well 114. In examples, the flow of lixiviant through the flow conducting network may be determined based on an injection rate (e.g., through the injection well 112) and/or a production rate (e.g., through the production well 114), for example, where the injection rate and/or the production rate may be adjusted during the DLM process according to an injection-production strategy. In examples, the lixiviant may be circulated at a rate commensurate with the response of the orebody, for example, based on a rate of dissolution of the mineral values into the lixiviant, such that the pregnant leachate is recovered with the maximum amount of
the valuable dissolved minerals. In examples, production tubing may transport the pregnant leachate from the subterranean orebody 102 to the surface level 104, where the mineral value can then be recovered, for example, the mineral value may be extracted chemically at a production facility 132, before the lixiviating fluid is reconstituted and re-injected or circulated in a continuous process. In some examples, the pregnant leachate can be produced by artificial lift, for example, using an electrical submersible pump (ESP) assembly (not shown) disposed at a subsurface intake location near the heel of the production well 114.
[0055] FIG. IB shows an in-situ leach mining system 100b for extracting a target mineral or "value" from a subterranean orebody 102, in accordance with example implementations described herein. The in-situ leach mining system 100b is an illustrative example of a system to which the systems, methods, and processor- readable media described herein can be applied, in accordance with examples of the present disclosure.
[0056] In examples, the in-situ leach mining system 100b comprises a multiwell configuration (e.g., multi-well array) including at least one parent well pair 110 and one or more child wells 122 (or infill wells) for optimized extraction of the target ore. In examples, a well pad on the surface 104 provides access to the child wells 122 through respective wellheads 126 of the child wells 122. Although the parent well pair 110 in FIG. IB is shown as a horizontal well pair and the child wells 122 in FIG. IB are shown as deviated wells (e.g., S-shaped), is it understood that the parent well pair 110 and the child wells 122 can be in any configuration, such as horizontal, vertical, or deviated. In some embodiments, for example, the child wells 122 may be configured to intersect a portion of the orebody 102 corresponding to a height 124 of the orebody 102. Further, it is understood that the parent well pair 110 and the one or more child wells 122 may represent either injection wells or production wells, for example, in various combinations according to the multi-well configuration design, and that the injection wells and production wells may be interchangeable, for example, by reversing the flow direction in the well, for example, as directed by an injection-production strategy.
[0057] FIG. 1C shows a perspective view of an example multi-well array configuration at a target depth corresponding to a height 124 of the orebody 102 for implementing the in-situ leach mining system 100b of FIG. IB, in accordance with example implementations described herein. In examples, the multi-well array configuration includes a plurality of injection wells 112 for receiving a lixiviant flow 128 and a plurality of production wells 114 for receiving a recovered leachate 130 and transporting the recovered leachate 130 to the surface for processing.
Consistent with the example in-situ leach mining system 100b of FIG. IB, the injection wells 112 of FIG. 1C may be child wells 122 and the production wells 114 of FIG. 1C may be a parent well pair 110, however it is understood that this configuration is exemplary and the injection wells 112 and production wells 114 need not be child wells 122 and parent well pairs 110, respectively. Further, it is understood that injection wells 112 and production wells 114 may be interchangeable, for example, by reversing the flow direction in the well, for example, as directed by an injection-production strategy.
[0058] In some embodiments, for example, prior to receiving the lixiviant 128, the injection wells 112 may be stimulated to generate induced fractures 120, for example, forming a fracture network within the orebody 102. In examples, upon receiving a lixiviant flow 128 by the injection wells 112, the lixiviant flow may be directed through the fracture network, causing leaching of the mineral values to produce the leachate 130. In examples, the leachate 130 may propagate toward one of the production wells 114 and may be received through openings of the production 114 for transportation to the surface 104.
[0059] In some embodiments, for example, injection and production wells can be alternated as required to change the direction of flow of the leachate.
[0060] FIG. ID shows a perspective view of an example multi-well array configuration for developing an inclined (dipping) orebody 102, in accordance with example implementations described herein. In examples, the design of the wellbore array depends on the geometric disposition of the mineral values in the orebody 102, the existence and nature of natural fracture systems, the orientations of the
compressive stresses in the orebody, and the outcomes of the formation stimulation undertaken to create surface area and interconnectivity, among other possibilities.
[0061] In some embodiments, for example, an inclined (dipping) orebody may be developed by a plurality of wellbores that follow the orebody inclination (dip).
For example, FIG. ID shows an inclined orebody 102 with a dip 154 measured from a horizontal plane, for example, where a dip angle 150 is measured with respect to a dip direction 152. For example, the inclined orebody may be developed by a series of vertical (or substantially vertical) wellbores 140, or the inclined orebody may be developed by a series of horizontal (or substantially horizontal) wellbores 142 placed within the inclined orebody at different depths, or a combination of wellbore orientations may be used. In examples, a multi-well array configuration including horizontal wellbores, for example, where horizontal production wells are positioned below injection wells, may present advantages for leachate production, for example, associated with a higher density of pregnant leachate compared to lixiviant. In examples, higher density leachate may flow preferentially downwards in the lixiviant flow network, for recovery via production wells positioned deep in the multi-well array configuration.
[0062] In examples, the wellbores 140 and 142 shown in FIG. ID are shown as equally spaced, however it is understood that different wellbore spacing may be used. The design of the wellbore array, for example, the choice of wellbore orientations, as well as spacing of the wellbores 140, 142, are affected by the magnitude and orientation of the in-situ stresses. Horizontal stresses that are higher than the vertical stresses mean that stimulation effects will tend to be horizontally distributed, but if the vertical stress is the largest, stimulated zones will tend to be oriented vertically.
[0063] In examples, the generation of fractures in a rock mass is governed by in-situ stress conditions. In response to a stimulation operation, for example, a stimulated zone of enhanced fluid conductivity in a near-wellbore region may include a plurality of induced fractures that can be approximately delineated by an ellipsoid shape, for example, exhibiting larger extents along two dimensions and
relatively limited in a third dimension. For example, induced fractures may be described as having a respective length, width, height and azimuth (e.g., direction of propagation), where the geometry (e.g., dimensions) of the induced fractures and/or induced fracture network is a function of in-situ stress orientations. In examples, the local stress state in a near-wellbore region may be altered in response to a stimulation or restimulation process, for example, causing fracture rotations as the stress system changes. In examples, a changing local stress state responsive to multiple stimulation processes may contribute to the generation of different fracture orientations and/or induced fracture network complexity. In this regard, the shape and/or geometry of the stimulation zone as well as regional and/or local stress orientations may impact the desired wellbore placement (e.g., spacing, orientation, length etc.) in the wellbore array. For example, placement of wells in zones of good connectivity that have been established by the stimulation process may enable a wider well spacing (e.g., with interwell spacing of up to several hundred meters between the wellbores, or more conservatively, with interwell spacing of 30-100 metres), where closer well spacing may enable better control of fluid flow in the stimulation zone over the extraction life. In contrast, wellbores that are oriented along less favorable stress orientations may require a closer wellbore spacing, for example, to account for the poorer fluid flow interconnectivity between wells in that direction.
[0064] FIG. 2 is a block diagram of an example hardware structure of a computing system 200 that is suitable for implementing example embodiments. In some implementations, computing system 200 can be an electronic computing device, such as a networked server. In other implementations, the computing system 200 can be a distributed computing system including multiple devices (such as a cloud computing platform) or a virtual machine running on one or more devices in mutual communication over a network. Other examples suitable for implementations described in the present disclosure can be used, which can include components different from those discussed below. Although FIG. 2 shows a single instance of each component, there can be multiple instances of each component in the computing system 200.
[0065] The computing system 200 includes at least one processor 202, such as a central processing unit, a microprocessor, a digital signal processor, an application-specific integrated circuit (ASIC), a field-programmable gate array (FPGA), a dedicated logic circuitry, a dedicated artificial intelligence processor unit, a graphics processing unit (GPU), a tensor processing unit (TPU), a neural processing unit (NPU), a hardware accelerator, or combinations thereof.
[0066] The computing system 200 can include one or more network interfaces (collectively referred to as network interface 206) for wired or wireless communication over a network. The network interface 206 can include wired links (e.g., Ethernet cable) and/or wireless links (e.g., one or more antennas). The computing system 200 can communicate with one or more user devices (such as user workstation computers) via the network interface 206. The computing system 200 can also communicate with various sensors or other data sources to obtain data used in monitoring the resource extraction system 100. In some embodiments, the sensors can include sensors located within the in-situ leach mining system 100a, 100b. For example, monitoring of various rates, concentrations, locations, flow paths, and other variables may be carried out continuously to understand how the orebody 102 is responding to the DLM process and to maximize the return rate of dissolved mineral value.
[0067] The computing system 200 may include an input/output (I/O) interface 208, which may enable interfacing with an optional input device 210 and/or an optional output device 212. In the example shown, the optional input device 210 (e.g., a keyboard, a mouse, a microphone, a camera, a scanner, a touchscreen, and/or a keypad) and the optional output device 212 (e.g., a display, a speaker and/or a printer) are shown external to the computing system 200. In other example embodiments, there may not be any input device 210 and output device 212, in which case the I/O interface 208 may not be needed.
[0068] The computing system 200 may include one or more memories 204 (individually or collectively referred to as "memory 204"), which may include a volatile or non-volatile memory (e.g., a flash memory, a random access memory
(RAM), and/or a read-only memory (ROM)). The non-transitory memory 204 may store instructions for execution by the processor 202, such as to carry out example embodiments. For example, the memory 204 may store instructions for implementing any of the methods of the examples and example embodiments. The memory 204 may include other software instructions, such as for implementing an operating system (OS) and other applications/functions.
[0069] In some examples, the computing system 200 may also include one or more electronic storage units (not shown), such as a solid state drive, a hard disk drive, a magnetic disk drive and/or an optical disk drive. In some examples, one or more data sets and/or modules may be provided by an external memory (e.g., an external drive in wired or wireless communication with the computing system 200) or may be provided by a transitory or non-transitory computer-readable medium. Examples of non-transitory computer readable media include a RAM, a ROM, an erasable programmable ROM (EPROM), an electrically erasable programmable ROM (EEPROM), a flash memory, a CD-ROM, or other portable memory storage. The memory 204 can also store information or data used in executing the cyclic deep leach mining optimization system 300, for example, a numerical model 320 and a leachate flow simulator 340. The components of the computing system 200 may communicate with each other via a bus, for example.
[0070] FIG. 3 is a block diagram of an example cyclic deep leach mining optimization system 300 of the present disclosure. The cyclic deep leach mining optimization system 300 can be a software that is implemented in the computing system 200 of FIG. 2, in which the processor 202 is configured to execute instructions of the cyclic deep leach mining optimization system 300 stored in the memory 204. The cyclic deep leach mining optimization system 300 in this example includes a numerical model 320, a leachate flow simulator 340 and a DLM process evaluator 360. In some implementations, different functions of the cyclic deep leach mining optimization system 300 can be performed on different devices other than the computing system 200. For example, computationally intensive functions such as building a 3D numerical model (e.g., numerical model 320) and executing the
numerical model 320 or the flow simulator 340 can be performed on a cloud computing platform in communication with a local computing system 200.
[0071] In some embodiments, for example, the cyclic deep leach mining optimization system 300 can receive as inputs 301, numerical model inputs 310, flow simulator inputs 312 and empirical process monitoring data 314 and can output a proposed DLM process modification 370. Analytical or numerical models are commonly employed in resource extraction operations for predicting rock behavior and for designing efficient and safe operations. Flow simulators are often used in resource extraction operations (e.g., hydrocarbon extraction, among others) to model fluid flow and predict recovery volumes. However, these models can be complex, and they are dependent on the quality and resolution of input data. In examples, wellbore monitoring or well and formation testing methods (e.g., injection, production, pressure tests, leaching rate, etc.) may be applied prior to development of the orebody and continually throughout development of the orebody 102, to gather and/or refine inputs for analytical or numerical models or flow simulators. In examples, the continuous monitoring may provide feedback regarding the orebody response to lixiviation and may inform future modifications to the cyclic DLM process, for example, the drilling of child offset (or infill) wells in appropriate locations, for example, to reduce the well spacing and achieve higher recovery factors, among other modifications.
[0072] In examples, the numerical model inputs 310 may include information associated with well configuration, geology (e.g., mapped orebody geometry, richness etc.), drilling information obtained during the drilling of wells during exploration or pre-production phases, such as exploration wells, a parent well pair 110, or any injection wells 112, production wells 114 or monitoring wells, geophysical measurements (e.g., seismic data, geophysical logs etc.), rock mechanics information (e.g., elastic properties, permeability, porosity, conductivity, in-situ stress etc.), well completions data (e.g., pressures, flow rates, volumes, concentrations etc.) or production data (e.g., flow rates, volumes, concentrations etc.) among other data. In examples, determining an in-situ stress state during the
delineation of the orebody is important for optimal wellbore array design. To account for the importance of in-situ stress state in stimulation process design, mathematical (e.g., numerical) modeling may be used to evaluate potential stimulation strategies for optimizing the orebody leaching.
[0073] In examples, the numerical model 320 (e.g., such as continuum models, among other possibilities) may first be generated, based on the numerical model inputs 310. For example, the numerical model 320 can be a software that is implemented in the computing system 200 of FIG. 2, in which the processor device 202 is configured to execute instructions of the numerical model 320 stored in the memory 204. In examples, the numerical model 320 may be generated for a geological environment, including the orebody or a portion of the orebody, for example, based on lithology, geological structures etc., and associated material properties and in-situ stress conditions. Similarly, the leachate flow simulator 340 may also first be generated, based on flow simulator inputs 312 and information provided by the numerical model 320, for example, corresponding to wellbore configurations and induced fracture networks, among other data, to model the lixiviant flow network. In examples, the flow simulator inputs 312 may include information associated with well testing (e.g., for assessing the degree of interwell interconnectivity and preferred spatial flow directions), including pressure migration testing, tracer tests, and formation testing (e.g. injectivity testing and analysis, step-rate flow tests) or other methods to delineate the nature of the flow patterns created with respect to the orebody geometrical and mineral value distribution information. In examples, the flow simulator inputs 312 may also include other information, such as the wellbore configuration, orebody parameters (e.g., mapped orebody geometry, richness etc.), drilling information obtained during the drilling of wells during exploration or pre-production phases, such as exploration wells, parent well pair 110, or any injection wells 112, production wells 114 or monitoring wells, geophysical measurements (e.g., seismic data, geophysical logs etc.), rock mechanics information (e.g., elastic properties, permeability, porosity, conductivity, in-situ stress etc.), well completions data (e.g., pressures, flow rates, volumes, concentrations etc.) or production data (e.g., flow rates, volumes, concentrations
etc.) among other data. In examples, the leachate flow simulator 340 may model the lixiviant flow network (e.g., fluid flow or circulation pattern of lixiviant and/or leachate through the induced fracture network) between a plurality of wells, for example, between one or more injection wells 112 and one or more production wells 114. In examples, continual data collection, analysis and interpretation may inform updates to either the numerical model 320 or the leachate flow simulator 340, for example, empirical process monitoring data 314 may include concentrations of the exiting leachate may be continually measured, along with the distribution of input and outflow, reflecting changes in fluid circulation pattern(s) as they develop in-situ, among other data associated with the cyclic DLM process that is measured during the process, for example, through experimentation or observation. For example, periodic mapping of the disposition of the process in the orebody may be undertaken to determine the shape and position of leached zones, in order to continue to develop and optimize the deep leach mining process.
Without excluding other methods, these activities may include seismic methods (3D surface seismic, cross-hole seismic tomography, vertical seismic profiling, and others), resistivity mapping, interwell hydraulic tests, wellbore logging (temperature logs, tracer logs, etc.) and mathematical modeling of the leaching process in the subsurface. In examples, such empirical process monitoring data may be continually acquired and fed into the numerical model 320 or the leachate flow simulator 340 during cyclic DLM process operations, for updating the numerical model 320 and the leachate flow simulator 340.
[0074] In examples, the numerical model 320 and the leachate flow simulator 340 may interact, for example, in an iterative process, to evaluate the effect of potential modifications to the cyclic CLM process, for example, including modifications to well configuration, wellbore stimulation and/or restimulation, slurry composition, injection-production strategy etc. on the predicted recovery of mineral values. For example, the numerical model 320 may output a simulated DLM process modification 330 (e.g., where the simulated DLM process modification 330 may include a stimulation and/or a restimulation of an existing well in the in-situ deep leach mining system lOOa/lOOb, such as an injection well 112 or a production well
114, or the drilling of a new well, such as a child offset well 122, among other modifications) and the leachate flow simulator 340 may generate a predicted recovery 350 associated with the simulated DLM process modification 330. For example, the leachate flow simulator 340 may perform a flow simulation for a well configuration that incorporates the simulated DLM process modification 330, to evaluate the effect of the modification on the predicted flow dynamics for the lixiviant flow network (e.g. predicted rate of lixiviant flow, predicted leaching rate, predicted recovery of leachate, etc.) on the predicted recovery 350. In examples, the leachate flow simulator 340 may feed information back to the numerical model 320 to inform future simulated DLM process modifications 330. For example, simulated DLM process modifications 330 can be iteratively provided to the leachate flow simulator 340 and evaluated until a predicted recovery meets a predetermined threshold value, among other criteria.
[0075] In examples, a DLM process evaluator 360 may receive the predicted recovery 350 associated with the simulated DLM process modification 330 and may compare the predicted recovery 350 to empirical process monitoring data 314, for example, including a measured recovery, among other information, to determine a DLM process modification 370. In examples, the DLM process modification 370 may be implemented within the in-situ leach mining system lOOa/lOOb, for example, by stimulating or restimulating a portion of the orebody 102 (e.g., performing a hydraulic fracture stimulation on an injection well 112 and/or a production well 114), by drilling one or more new wells for targeting additional portions of the orebody (e.g., drilling a new offset or infill well using directional drilling to intersect a second portion of the orebody, such as adjacent portions of the orebody) for expanding the lixiviant flow network, by optimizing a slurry (e.g., lixiviant) design, by adjusting flow rates and/or pressures through the lixiviant flow network or altering flow paths in the lixiviant flow network (e.g., by adjusting injection rates and/or pressures and/or production rates and/or pressures), according to an injection-production strategy, among other possibilities. In examples, DLM process modifications may occur repeatedly through the life of the orebody development, for example, in a cyclic manner until the orebody is exploited.
[0076] For example, if a produced leachate is determined to have a lower concentration of dissolved mineral values than desired, an example process modification can be to adjust a valve of the production well 114 to reduce the production rate from the wellbore. In examples, reducing a production rate may cause the lixiviant flowing through the lixiviant flow network to flow in an alternate path, for example, toward other production wells 114, for increasing the amount of dissolved mineral values in the produced leachate and maximizing recovery. In other examples, if a produced leachate is determined to have a lower concentration of dissolved mineral values than desired, a modification can be to adjust a slurry design, for example, a concentration or composition of the injected lixiviant for increasing the amount of dissolved mineral values in the produced leachate and maximizing recovery. In some examples, process modifications may be made at each wellhead individually.
[0077] In examples, the DLM process may be guided by empirical data analyses and mathematical modeling to interpret what is happening at depth. In examples, the numerical model and 320 and leachate flow simulator 340 may be repeatedly recalibrated, for example, based on empirical process monitoring data to optimize the DLM process.
[0078] Example implementations of methods for extracting mineral values from a subterranean orebody will now be described, with reference to the cyclic deep leach mining optimization system 300 executed by the example computing system 200 in co-operation with the in-situ leach mining system 100a or 100b.
[0079] FIG. 4 is a flowchart showing operations of a method 400 for extracting mineral values from a subterranean orebody, in accordance with examples of the present disclosure. The method 400 can be performed in the context of the components of the in-situ leach mining system 100b shown in FIG. IB in some embodiments.
[0080] Method 400 begins at step 402 in which a lixiviant flow network of the subterranean orebody is generated by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow
conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody. In examples, the first stimulation process may cause an increase in the surface area within a stimulated volume of a near-wellbore region. In examples, the first stimulation process may generate interconnectivity between adjacent wellbores to enable fluid circulation in the lixiviant flow network (e.g., generating enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody). In examples, the stimulation process may involve some combination of hydraulic fracturing, hydroshearing, blast detonations, rocket propellant stimulation, acid stimulation, or other techniques.
[0081] At step 404, a lixiviant flow is received into a lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate 130 is produced. For example, mineral "values" may leached from the subterranean orebody 102 into the leachate 130. In examples, the well may be a production well 114 and the leachate 130 is received at the production well 114, where the production well 114 is disposed at the target depth 106 in the subterranean orebody 102 and extending to the surface level 104, the production well 114 for transporting the leachate 130 to the surface level 104.
[0082] At step 406, a model corresponding to the cyclic DLM process (such as a numerical model 320 and/or a leachate flow simulator 340) may be updated based on empirical process monitoring data 314. In examples, for example, corresponding to the leachate 130 or the recovered first amount of dissolved mineral value, among other sources of empirical data associated with the DLM process. For example, measurements may include flow rate of the leachate, concentration of the leachate or a mass of the recovered first amount of mineral value, among other possibilities. In this regard, the DLM process represents a cyclic process or iterative process, where monitored data is used to optimize and improve the DLM process using an engineered and/or data-driven approach.
[0083] At step 408, a DLM process modification 370 may be applied to the cyclic DLM process, for example, the first portion of the orebody may be restimulated using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant network. In examples, the second stimulation process may be performed based on the updated numerical model 320 and/or the updated leachate flow simulator 340.
[0084] At step 410, the cyclic DLM leaching process may be repeated to progressively develop other portions of the orebody. For example, the second stimulation process may be repeated and/or performed multiple times on the first portion of the orebody or on other portions of the orebody, among other possibilities. In other examples, other DLM process modifications 370 may be implemented or repeated in a progressive manner within the in-situ leach mining system lOOa/lOOb, for example, by drilling one or more new wells for targeting additional portions of the orebody (e.g., drilling a new offset or infill well using directional drilling to intersect a second portion of the orebody, such as adjacent portions of the orebody) for expanding the lixiviant flow network, by optimizing a slurry (e.g., lixiviant) design, by adjusting flow rates and/or pressures through the lixiviant flow network or altering flow paths in the lixiviant flow network (e.g., by adjusting injection rates and/or pressures and/or production rates and/or pressures), according to an injection-production strategy, by stimulating or restimulating another portion of the orebody 102 using a stimulation process or a restimulation process, among other possibilities. In this regard, continuous monitoring of the cyclic DLM process regarding the orebody response to lixiviation may inform repeated future modifications to the cyclic DLM process and DLM process modifications may occur repeatedly through the life of the orebody development, for example, in a cyclic manner until the orebody is exploited.
General
[0085] Although the present disclosure describes functions performed by certain components and physical entities, it should be understood that, in a distributed system, some or all of the processes can be distributed among multiple
components and entities, and multiple instances of the processes can be carried out over the distributed system.
[0086] Although the present disclosure describes methods and processes with steps in a certain order, one or more steps of the methods and processes can be omitted or altered as appropriate. One or more steps can take place in an order other than that in which they are described, as appropriate.
[0087] Although the present disclosure is described, at least in part, in terms of methods, a person of ordinary skill in the art will understand that the present disclosure is also directed to the various components for performing at least some of the aspects and features of the described methods, either by way of hardware components, software or any combination of the two. Accordingly, the technical solution of the present disclosure can be embodied in the form of a software product. A suitable software product can be stored in a pre-recorded storage device or other similar non-volatile or non-transitory computer readable medium, including DVDs, CD-ROMs, USB flash disk, a removable hard disk, or other storage media, for example. The software product includes instructions tangibly stored thereon that enable a processing device (e.g., a personal computer, a server, or a network device) to execute examples of the methods disclosed herein. In general, the software improves the operation of the hardware in one or more ways.
[0088] The present disclosure can be embodied in other specific forms without departing from the subject matter of the claims. The described example implementations are to be considered in all respects as being only illustrative and not restrictive. Selected features from one or more of the above-described implementations can be combined to create alternative implementations not explicitly described, features suitable for such combinations being understood within the scope of this disclosure.
[0089] All values and sub-ranges within disclosed ranges are also disclosed. Also, although the systems, devices and processes disclosed and shown herein can include a specific number of elements/components, the systems, devices and assemblies could be modified to include additional or fewer of such
elements/components. For example, although any of the elements/components disclosed can be referenced as being singular (e.g., a well), the implementations disclosed herein could be modified to include a plurality of such elements/components (e.g., an array of wells). The subject matter described herein intends to cover and embrace all suitable changes in technology.
Claims
1. A method of extracting mineral values from a subterranean orebody using a cyclic leaching process, comprising: generating a lixiviant flow network of the subterranean orebody by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody; receiving a lixiviant flow into the lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate is produced; updating a model corresponding to the cyclic leaching process, based on empirical process monitoring data obtained during the extraction of mineral values, the model for optimizing an injection and production strategy of the cyclic leaching process; restimulating the first portion of the orebody using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network; and repeating the cyclic leaching process to progressively develop other portions of the orebody.
2. The method of claim 1, further comprising: in response to recovering a first amount of dissolved mineral value from the leachate at the surface level, updating the model based on empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral value; applying one or more modifications to the cyclic leaching process for extracting additional mineral values from the subterranean orebody, based on the updated model; and recovering a second amount of dissolved mineral value, based on the modified
injection and production strategy.
3. The method of either claim 1 or claim 2, further comprising: applying further one or more modifications to the cyclic leaching process modifications in a cyclic manner until the orebody is exploited.
4. The method of any one of claims 1 to 3, wherein the empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral values comprises at least one of: a flow rate of the leachate; a concentration of the leachate; or a mass of the recovered first amount of dissolved mineral values.
5. The method of any one of claims 1 to 4, wherein applying the modification to the injection and production strategy of the leachate process comprises: modifying a restimulation strategy for restimulating the first portion of the orebody or other portions of the orebody.
6. The method of any one of claims 1 to 5, wherein applying the modification to the injection and production strategy of the leachate process comprises: modifying a well configuration design of the plurality of wells.
7. The method of any one of claims 1 to 6, wherein applying the modification to the injection and production strategy of the leachate process comprises: adjusting a volume, flow rate, and/or pressure of lixiviant flowing through the lixiviant flow network.
8. The method of any one of claims 1 to 7, wherein applying the modification to the injection and production strategy of the leachate process comprises: modifying a lixiviant composition.
9. The method of any one of claims 1 to 8, wherein applying the modification to the injection and production strategy of the leachate process comprises: drilling a plurality of new wells using directional drilling to intersect a second portion of the orebody, based on the updated model; and generating an expanded lixiviant flow network in communication with the plurality of new wells by stimulating and/or restimulating at least the second portion of the orebody using a third stimulation process.
10. The method of claim 9, further comprising: receiving drilling information during the drilling of the plurality of new wells; and updating the model based on the drilling information.
11. The method of any one of claims 1 to 10, wherein the first stimulation process and the second stimulation process is a hydraulic fracturing stimulation process, and the hydraulic fracturing stimulation process is conducted via the plurality of wells.
12. The method of claim 11, further comprising: updating the model based on one or more empirical process measurements corresponding to the hydraulic fracturing stimulation process.
13. The method of any one of claims 1 to 12, wherein the plurality of wells includes at least one injection well and at least one production well.
14. The method of claim 13, further comprising: receiving the leachate at the at least one production well disposed at the target depth in the subterranean orebody and extending to the surface level, the production well for transporting the leachate to the surface level.
15. The method of claim 12, wherein the plurality of wells may have at least one well that is both and injection and production well.
16. A system for extracting mineral values from a subterranean orebody using a cyclic leaching process, the system comprising: one or more processor devices; and one or more memories storing machine-executable instructions, which when executed by the one or more processor devices, cause the system to: generate a lixiviant flow network of the subterranean orebody by stimulating a first portion of the orebody using a first stimulation process, the first stimulation process causing enhanced fluid flow conductivity via a plurality of fractures or fluid flow pathways generated in the first portion of the orebody, the lixiviant flow network in fluid communication with a plurality of wells extending from a surface level to a target depth in the subterranean orebody; receive a lixiviant flow into the lixiviant flow network of the subterranean orebody via at least one well of the plurality of wells, with effect that a leachate is produced; update a model corresponding to the cyclic leaching process, based on empirical process monitoring data obtained during the extraction of mineral values, the model for optimizing an injection and production strategy of the cyclic leaching process; restimulate the first portion of the orebody using a second stimulation process, based on the updated model, for enhancing a conductivity of the lixiviant flow network; and repeat the cyclic leaching process to progressively develop other portions of the orebody.
17. The system of claim 16, wherein the machine-executable instructions, when executed by the one or more processors further cause the system to: in response to recovering a first amount of dissolved mineral value from the leachate at the surface level, update the model based on empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral value;
apply one or more modifications to the cyclic leaching process for extracting additional mineral values from the subterranean orebody, based on the updated model; and recover a second amount of dissolved mineral value, based on the modified injection and production strategy.
18. The system of either claim 16 or claim 17, wherein the machine-executable instructions, when executed by the one or more processors further cause the system to: apply further one or more modifications to the cyclic leaching process modifications in a cyclic manner until the orebody is exploited.
19. The system of any one of claims 16 to 18, wherein the empirical process measurements corresponding to the leachate or the recovered first amount of dissolved mineral values comprises at least one of: a flow rate of the leachate; a concentration of the leachate; or a mass of the recovered first amount of dissolved mineral values.
20. A non-transitory computer-readable medium storing machine-executable instructions which, when executed by one or more processors, cause the processor to perform the steps of the method of any one of claims 1 to 15.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AU2024312723A AU2024312723A1 (en) | 2023-06-22 | 2024-06-21 | Methods and systems for in-situ leach mining |
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| US202363509681P | 2023-06-22 | 2023-06-22 | |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2026011212A1 (en) * | 2024-07-09 | 2026-01-15 | LJF Consultants Pty Ltd | A method and system for in-situ recovery of metals |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6644848B1 (en) * | 1998-06-11 | 2003-11-11 | Abb Offshore Systems Limited | Pipeline monitoring systems |
| US20100224365A1 (en) * | 2009-03-06 | 2010-09-09 | Carlos Abad | Method of treating a subterranean formation and forming treatment fluids using chemo-mathematical models and process control |
| WO2012090174A2 (en) * | 2010-12-30 | 2012-07-05 | Schlumberger Canada Limited | System and method for performing downhole stimulation operations |
| US20210131255A1 (en) * | 2019-11-01 | 2021-05-06 | 102062448 Saskatchewan Ltd. | Processes and configurations for subterranean resource extraction |
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2024
- 2024-06-21 WO PCT/CA2024/050843 patent/WO2024259540A1/en not_active Ceased
- 2024-06-21 AU AU2024312723A patent/AU2024312723A1/en active Pending
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6644848B1 (en) * | 1998-06-11 | 2003-11-11 | Abb Offshore Systems Limited | Pipeline monitoring systems |
| US20100224365A1 (en) * | 2009-03-06 | 2010-09-09 | Carlos Abad | Method of treating a subterranean formation and forming treatment fluids using chemo-mathematical models and process control |
| WO2012090174A2 (en) * | 2010-12-30 | 2012-07-05 | Schlumberger Canada Limited | System and method for performing downhole stimulation operations |
| US20210131255A1 (en) * | 2019-11-01 | 2021-05-06 | 102062448 Saskatchewan Ltd. | Processes and configurations for subterranean resource extraction |
Cited By (1)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2026011212A1 (en) * | 2024-07-09 | 2026-01-15 | LJF Consultants Pty Ltd | A method and system for in-situ recovery of metals |
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| AU2024312723A1 (en) | 2026-01-22 |
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