Future-Proofing Canada’s Mining Operations with Precision Heap Leaching

Written by Tom Claridge, Sales Manager, Mining North and Shaun Ebert, Key Account Manager, Orbia, Netafim

Heap leaching has been the backbone of metal recovery for decades, yet some operations still rely on outdated irrigation leaching systems. Legacy solutions like flood methods and impact sprinklers often deliver uneven coverage that over-saturate some areas while leaving others under-irrigated causing a loss of valuable solutions through runoff. In some cases, poor application can also create overlay, which may cause serious damage to operations.

With commodity prices fluctuating, a skilled workforce in decline, and environmental regulations tightening, making sure operations are running efficiently and effectively is imperative. Transitioning toward systems that are able to sustain diffusion uniformity (DU), along with automated technology helps streamline operations to improve metal recovery while reducing costs and environmental impact.

While heap leaching is an effective way to extract metals from lower-grade ore, when solution application is uneven or poorly monitored, there are reductions in mineral recovery. In 2024, a heap leach failure in Yukon sent millions of tonnes of cyanide-soaked ore down into local groundwater and stopped operations in its tracks. Several factors led up to this incident, like steep slope angles and drainage issues to a rising water table made worse by irrigation.

Without high DU or an efficient way to monitor pad conditions, early warning signs can go undetected, allowing small inefficiencies or imbalances to escalate. To future-proof operations, investing in systems that ensure consistency and provide real-time insights can transform heap leaching into a more predictable, efficient, and resilient process.

Uneven solution application is one of the biggest challenges to both recovery and pad stability in mining operations. Too much in one area and the ore becomes saturated, putting a strain on drainage systems, while too little leaves valuable minerals unrecovered. Precision leaching systems solve both problems by applying solutions directly to the ore at a steady, controlled rate. Precision systems have emitters that deliver uniform flow across the pad, eliminating the overlay and dry zones common with legacy systems. By maintaining control over water and solution delivery, precision heap leaching provides even percolation through the ore, improves extraction efficiency and reduces waste and chemical consumption.

Canada’s mining regions face some of the harshest environments, from freezing weather to remote sites that are hard to reach for replacement parts. In cold climates, repeated freeze-thaw cycles can damage infrastructure and disrupt drainage systems, making long-term performance a constant challenge. Industry standards for cold-region mining emphasize the importance of systems that can withstand extreme shifts and chemical exposure common in leaching operations. Precision heap leaching tools that are engineered for these conditions with emitters built to resist clogging and maintain performance, will work better. For remote operations, this durability helps keep systems running, reducing the need for emergency repairs and supports a steady leaching performance.

While precision drip leaching solves the challenge of uneven solution application, many operations still rely on manual valve check and in-field adjustments that are labour-intensive and leave room for human error. With demand for critical minerals surging, the pressure on Canada’s mining workforce is only increasing. Surveys from the Mining Industry Human Resources Council (MiHR) report that one in five mining workers is over the age of 55 and nearing retirement. Other surveys report that 80,000 new workers will need to be hired by 2030 to meet demands and actively fill the skills gap.

Automated technology offers relief from these labour pressures and greater operational control. With remotely controlled valves and real-time pressure monitoring, operators can make adjustments from anywhere at any time, limiting the need for constant in-person inspections. This not only reduces workers’ exposure to dust and chemicals but also allows operators to allocate staff to focus on other important tasks to keep production moving. Automated systems can also be programmed for on and off scheduling, ensuring leach cycles run efficiently to prevent recovery compromise from over- or under-application.

Beyond efficiency, precision application also helps operators meet environmental regulations. The Metal and Diamond Mining Effluent Regulations (MMER) set limits on chemicals like copper, cyanide, lead, nickel, and zinc in mining wastewater and require testing and reporting. By delivering solutions only where and when they’re needed, precision heap leaching eliminates overspray and chemical drift, keeping chemicals within containment boundaries. This also means using less water by reducing evaporation and runoff, while ensuring more of the applied solution reaches the ore. For operators, this makes it easier to stay in compliance by conserving water while reducing waste and environmental risks.

For mining operations looking to improve recovery, cut operating costs, and reduce environmental impact, precision heap leaching offers these benefits and more. By delivering uniform solution applications, conserving water, and enabling automation, mining operations can address some of the industry’s most persistent challenges.

More than just a technology upgrade, precision heap leaching is future-proofing operations against labour constraints, tightening regulations, and volatile market conditions. Mines that start with a review of their current leaching methods and implement precision systems can position themselves to meet the pressing challenges with greater efficiency and confidence.