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How Gold and Silver Heap Leaching Works: From Ore to Doré

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Gold and silver heap leaching extracts metal by placing mined ore on a lined pad, irrigating it with dilute alkaline cyanide solution, and collecting the metal-bearing liquid that drains out. The solution also needs dissolved oxygen, and operators control pH to keep cyanide effective and limit formation of toxic hydrogen cyanide. After dissolved metal is recovered from the solution, the adjusted liquid is usually recycled to the heap. The method suits some low-grade, permeable ores because it avoids the capital cost of grinding and tank-leaching them—but it is slower and often recovers less metal.

What is heap leaching?

Heap leaching is a percolation process: solution passes through a bed of ore, dissolves some of its metal, and is collected below. The ore sits on an engineered, impermeable pad rather than directly on the ground. The collected, metal-bearing liquid is called pregnant solution; after metal recovery and reagent adjustment, the remaining barren solution can be sent back over the heap.

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For gold and silver, the common leachant is dilute alkaline sodium cyanide. A gold heap is not the same recipe as a copper-oxide heap, for which acid leaching is common. Heap leaching also differs from dump leaching: a heap is designed and operated to meet a recovery target and production rate, while dump leaching generally places material more cheaply and accepts whatever recovery it yields. In vat leaching, ore sits in a bedded vessel and solution flows through it more quickly. Agitated leaching instead grinds ore and mixes it with solution in tanks.

Heap and dump methods have a long history, but modern cyanide heap leaching of precious metals is a twentieth-century practice. The U.S. Bureau of Mines proposed heap-leach cyanidation of porous, low-grade gold ore in 1967; the first named commercial gold heap leach was at Cortez in 1969, according to Daniel W. Kappes’s design paper.

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How does cyanide dissolve gold and silver?

Cyanide forms soluble complexes with gold and cyanide-soluble silver minerals. Dissolution requires both cyanide and oxygen, and the leach solution must remain alkaline. The classic overall reaction for gold, known as the Elsner equation, is:

4Au + 8CN− + O2 + 2H2O → 4Au(CN)2− + 4OH−

The product, Au(CN)2−, is a soluble gold-cyanide complex. Oxygen is a reactant, not an optional extra: it may enter through aeration of solution and contact with air as the solution is sprayed or dripped over the ore. A two-stage description of the reaction includes hydrogen peroxide as an intermediate.

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Operators commonly maintain pH around 9.5 to 11, often near 10 to 10.5. Below about 9.5, cyanide consumption can rise as cyanide converts toward volatile, highly toxic hydrogen cyanide. At higher pH, metal recovery may decrease. Lime (calcium oxide) or caustic soda (sodium hydroxide) is used to maintain alkalinity. The U.S. Environmental Protection Agency’s gold and silver processing profile identifies high pH and oxygen as conditions for cyanide dissolution and gives 10.5 as an optimum pH.

Concentration figures depend on the ore and are reported in different units. In Kappes’s early-2002 survey of 28 operations, onflow solution contained 100 to 600 parts per million (ppm) sodium cyanide, averaging 240 ppm. The EPA profile reports 0.5 to 1 pound of sodium cyanide per ton of solution, equivalent to roughly 250 to 500 ppm when “ton” means a 2,000-pound short ton. A separate historical methods review gives a much wider operating range, 0.3 to 5 pounds per ton, noting that stronger solutions are generally associated with ores high in silver. These are reported operating ranges, not a universal recipe or a current permit limit.

Why does silver recovery usually lag gold recovery?

The difference is mainly mineralogical. Gold in heap-leach ores is commonly present as native metal or an alloy such as electrum, so it is often accessible to cyanide once exposed. Silver can occur in several forms, including sulfide minerals that cyanide does not readily dissolve. A process that works well on gold therefore cannot be assumed to recover silver equally well.

The EPA lists native silver, argentite, silver chloride, and several complex sulfide minerals among silver-bearing forms. It also notes that much of the world’s silver resources occur in copper, lead, and zinc deposits rather than in primary precious-metal ores. That association affects how much silver a cyanide heap can extract.

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In a survey of 32 operations, Kappes reported average gold recovery of 71 percent, with a range of 49 to 90 percent; run-of-mine heaps averaged 63 percent. Typical silver recovery was 45 to 60 percent, and only 15 to 25 percent where silver was a minor constituent. These are historical survey results from the early 2000s, not guaranteed outcomes for a new project. A 2005 chapter rounded the same author’s figures to about 70 percent gold recovery and about 55 percent silver recovery. The range and the mineralogy caveat are more informative than a single “typical” percentage.

What are the steps in a gold and silver heap-leach operation?

The flowsheet varies with ore, climate, and the plant’s recovery circuit, but the sequence below describes the common route from mined material to metal. Laboratory tests and engineering design must establish the crush size, heap permeability and stability, reagent consumption, need for agglomeration, leach duration, and expected recovery before a project commits to a full-scale layout.

  1. Mine and classify the ore. The mining plan separates material suited to heap leaching from ore requiring another route. Some run-of-mine ore is leached without crushing, though blasting may be designed to produce suitably sized fragments. Ore that is unoxidized, sulfide-locked, or rich in preg-robbing carbon may need treatment in a mill or another process instead.
  2. Crush selectively, or leave the ore run-of-mine. Crushing can expose more surface and improve recovery or leach rate, but adds equipment and cost. Kappes describes oxidized Carlin-type ore that can be coarse-crushed to about 75 millimetres, with 70 percent or better recovery reported even at run-of-mine size. Low-sulfide volcanic or intrusive ore may need crushing below about 12 millimetres to achieve reported recoveries of 65 to 85 percent. Jaw and cone crushers are conventional options in these examples.
  3. Agglomerate when fines threaten permeability. Fine clay and crushed particles can clog the spaces that solution must pass through. Agglomeration binds fines to coarser pieces, commonly with Portland cement and water, sometimes using cyanide-bearing solution. Where ore is already sufficiently permeable, the step may not be needed.
  4. Prepare the pad and stack the ore. The graded pad is lined and sloped so that solution drains toward collection points. Ore is placed in layers, or lifts. The EPA profile describes permanent heaps built in lifts 5 to 30 feet thick; on/off pads, which are unloaded after a leach cycle, were less common in that profile. Truck stacking can suit coarse, strong material. Conveyors are often preferable for fine, soft, or agglomerated ore because truck tires can compact it and create poorly permeable layers. Keeping heavy traffic off placed ore helps preserve drainage.
  5. Cure and irrigate. Agglomerated ore may be allowed to cure before irrigation; if cyanide solution was used in agglomeration, leaching can begin during that period. Irrigation applies solution over the heap. Sprinklers appear in older operating descriptions; drip systems are now more common in the overview cited by the heap-leaching reference, with potential benefits including reduced evaporation and more even distribution. The method of application does not remove the need for oxygen in the leach chemistry.
  6. Collect the pregnant solution. Solution percolates through the ore and drains across the liner to a pond or tank. Channeling, compaction, and loss of permeability can keep solution from contacting ore evenly. This is why column tests that perform well in a laboratory do not, by themselves, guarantee heap-scale performance.
  7. Recover dissolved metal. The pregnant solution is sent through activated-carbon adsorption, zinc precipitation (Merrill-Crowe), or a circuit designed around the site’s existing equipment. The choice affects clarification, downstream processing, and operating complexity.
  8. Recycle, rinse, and close. After dissolved metal is removed, cyanide and pH are adjusted and the barren solution is reused. At the end of leaching, spent ore is rinsed and residual cyanide is treated or stabilized before closure. Reclamation and closure requirements differ by jurisdiction, so they need to be considered in the project design from the start.

How does agglomeration keep a heap working?

A heap needs open pathways for solution and air. When fines and clay pack together, flow can become uneven or stop, leaving portions of the ore poorly leached. Agglomeration makes the fine material adhere to larger particles; cement also contributes alkalinity and can reduce the later lime addition needed for pH control.

A historical Bureau of Mines practice description gives a starting range of 5 to 15 pounds of Portland cement per short ton of ore and water equal to 8 to 16 percent of ore weight, followed by tumbling and about 72 hours of curing. These figures describe a reported recipe, not a prescription for every ore. One case in that account increased recovery from 37 to 90 percent after agglomeration. That result shows what correcting a permeability problem can do at a particular site; agglomeration cannot expose gold still locked inside unoxidized sulfide.

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How is metal recovered from pregnant solution?

The two standard choices are activated carbon and Merrill-Crowe zinc precipitation. Both remove dissolved metal from solution, but they have different feed requirements and downstream steps.

Recovery route How it works Important fit and trade-off
Carbon adsorption Pregnant solution contacts activated carbon, which adsorbs dissolved gold and silver. The loaded carbon is stripped; the concentrated metal solution is then processed further, and carbon is regenerated. Carbon can be used with less-clarified solution and is a common choice for dilute heap solutions. Carbon fouling by organics or carbonate can require washing or regeneration.
Merrill-Crowe The solution is clarified and deaerated, then zinc dust is added. Gold precipitates as metal and is recovered by filtration as a zinc-gold sludge for further processing. It requires clear solution; suspended clay can coat zinc and slow precipitation. It can be attractive where a suitable zinc-precipitation plant already exists or solution chemistry favors it.

In the simplified zinc-displacement reaction, zinc takes the place of gold in the dissolved complex, allowing gold metal to precipitate. Carbon-in-column systems pass solution through columns containing activated carbon. A historical recovery review describes flow rates of 15 to 25 gallons per minute per square foot and carbon regeneration at 600 to 800 °C; these are reported practice parameters, not universal modern design specifications. The same review notes that both recovery routes ultimately produce a concentrate for smelting or further refining. Fluxes and smelting produce doré, a gold-silver bar; mercury, if present, may require retorting before smelting.

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Some integrated plants combine steps—for example, carbon adsorption followed by elution and zinc precipitation on a smaller, richer solution. That is one possible flowsheet, not a requirement. Resin ion exchange, solvent extraction, and direct electrowinning have also been described as alternatives or developing options in recovery literature, but the baseline choices in the sources are carbon and Merrill-Crowe.

Which ores are suitable for heap leaching?

Oxidation state, mineralogy, particle size, clay content, and permeability matter at least as much as head grade. Heap leaching is most suitable when the ore can be wetted evenly, solution can percolate through it, and cyanide can reach the precious metal.

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  • Oxidized Carlin-type sedimentary ore: This can leach well, sometimes after only coarse crushing or at run-of-mine size. Kappes reports production recovery of 80 percent or better for suitable oxidized material. Unoxidized Carlin-type ore is a very different case: gold may be locked in sulfides, while organic carbon adsorbs dissolved gold from solution (the “preg-robbing” effect). Reported heap recovery for that material was only 10 to 15 percent, and Kappes says it is not suitable heap-leach feed.
  • Low-sulfide volcanic or intrusive ore: Oxidized ore may yield 65 to 85 percent, but finer crushing can be necessary. Unoxidized ore may yield about 45 to 55 percent and nearly always requires crushing in Kappes’s examples. At Round Mountain, he described separate routes: roughly 150,000 tons per day of low-grade oxide on run-of-mine heaps, 30,000 tons per day of high-grade oxide crushed to 12 millimetres and conveyor-stacked, and 12,000 tons per day of unoxidized ore sent to a plant. The units here are the source’s “tons,” not metric tonnes.
  • Oxidized massive sulfide: Gold and silver may be associated with iron oxides. Some of these ores are soft and naturally permeable, so crushing below 75 millimetres may not improve recovery. Kappes cites Filon Sur in Spain and Hassai in Sudan; cement agglomeration and conveyor stacking were used in the examples.
  • Saprolite and laterite: Tropical weathering can create a thin laterite cap above soft, wet saprolite clay, sometimes with gold in quartz veinlets. Kappes notes that silver is usually absent in this ore class, but the cited material does not supply a recovery percentage.

Sulfide ore that needs oxidation pretreatment may be roasted or pressure-oxidized in an autoclave before leaching, according to the EPA profile. Those are pretreatment routes, not a substitute for designing a permeable heap. A specialized microbial process that oxidizes sulfides in a heap before cyanidation is distinct from the standard cyanide heap flowsheet.

When is a heap preferable to a mill?

Heap leaching trades lower capital requirements for slower metal recovery and, in many cases, a lower ultimate recovery. The decision is not “heap for low grade, mill for high grade” in isolation: reserve size, ore response, financing and political risk, construction cost, and the time value of delayed production all matter.

Kappes’s early-2002 design paper describes a multi-million-tonne ore at 7 grams of gold per tonne for which agitated leaching recovered about 92 percent and heap leaching about 80 percent. The spreadsheet favored a mill, but the owner chose the heap because political instability made a smaller-capital project easier to finance and maintain. In another example, the Sterling mine near Beatty, Nevada, began with 100,000 tons at 11 grams per tonne, too little reserve to justify a mill; over 15 years it processed nearly a million tons, and early heaps reached 90 percent recovery from ore crushed to 100 millimetres.

For a “typical” Nevada-type ore at 3 grams per tonne, Kappes cited a 1998 review’s estimate that mill recovery would need to exceed heap recovery by 21 percentage points to match the heap’s return on investment. That is a historical case analysis, not a universal cutoff. In his early-2002 sample of 37 operations, half had head grades between 0.65 and 1.50 grams per tonne; the author argued that an agitated plant was usually difficult to justify at such grades. A silver example makes the time trade-off clear: Comsur’s Comco heap at Potosí, Bolivia, took months but matched the recovery of a tank plant requiring up to four days of residence time, and the heap still won on economics.

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Leaching can take weeks, months, or longer; a 2026 revision of the heap-leaching overview gives about one or two months for simple oxide gold ores, while Kappes’s design paper emphasizes that cycles vary with ore and can extend much longer. The slow cycle affects both when cash begins to return and how much metal has ultimately been recovered. No single irrigation-stop threshold or schedule fits every heap.

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What do the pad and water controls do?

The pad, collection system, ponds, and water balance are core process infrastructure—not optional add-ons. The liner is intended to prevent pregnant solution from entering the ground; the drainage layer and grading direct it to collection. A heap-leach site also needs ponds or tanks, a process plant, and monitoring and support facilities. A general overview cites geomembrane liners typically at least 1.5 millimetres thick, but that is an encyclopedia synthesis, not a permit standard or a design specification for a particular project.

Most solution is recycled, but water still enters with ore moisture and rainfall and leaves through evaporation, retention in spent ore, or treatment and discharge. Rainfall can create a surplus that must be managed; a poor treatment step can pollute water. Design has to account for climate, pad capacity, collection, and the site’s permitted discharge conditions. A heap can be engineered in different climates, but the water balance and containment strategy must suit the location.

Cyanide is acutely poisonous. Alkaline pH, lined containment, solution collection and reuse, and treatment before any permitted release are important controls described in the sources. Closure involves rinsing and treating or stabilizing residual cyanide, with exact requirements set by jurisdiction and permit. In the United States, the legal overview summarized by the heap-leaching reference describes federal-land plans of operations, reclamation plans, and reclamation bonds, as well as Clean Air Act and Clean Water Act requirements applying to operations on federal, state, and private land. Actual closure and discharge conditions are site-specific; the sources do not establish a single current cyanide discharge limit for all U.S. permits.

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What production figures can be stated accurately?

Heap-leach production statistics should be read with their dates and geography attached. Kappes estimated in the early 2000s that about 120 mines worldwide conducted gold and silver heap leaching. A late-2001 count in the same paper identified 78 active precious-metal heaps—34 in the United States and 22 in Nevada—while describing the actual total as certainly above 100. These are one author’s historical estimates, not independent counts or a current census.

Kappes reported that 37 surveyed operations produced 198 tonnes of gold per year, or 6.15 million ounces, equal to 7.4 percent of world gold production in the early 2000s. He estimated that including unsurveyed mines, heap leaching likely produced 12 percent of world gold. Separately, the U.S. EPA profile states that heap leaching accounted for 39 percent of gold production in 1993, without specifying world production in that sentence. The figures refer to different dates and stated scopes; the EPA figure should not be presented as a global share or combined with the later worldwide estimate. No current 2024–2026 world share or operating-heap count is established by the cited material.

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For silver, Kappes said heap operations produced only a small fraction of world production, without giving a percentage. The gold and silver process shares should not be conflated: the chemistry overlaps, but silver mineralogy and recovery differ.

What should a project establish before building a heap?

Testing and engineering should resolve the uncertainties that determine whether a heap will work and what it will cost. The cited design chapters call for a comprehensive laboratory program that establishes:

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  • Crush size and whether run-of-mine ore can meet the target recovery and leach rate.
  • Heap stability and permeability as heap height increases.
  • Whether clay or fines require agglomeration, and the cement and moisture levels needed.
  • Cyanide strength, pH control, reagent consumption, and any mineralogical interferences.
  • Expected leach time and recovery, including differences between ore types.
  • Pad, water-balance, solution-collection, rinse, and closure requirements for the site.

These decisions are linked. More crushing may improve exposure but increase capital and create fines; agglomeration may restore permeability but cannot solve refractory mineralogy; a highly recoverable ore may still favor a mill if a higher-value, faster route justifies its cost. Conversely, modest recovery may be economically sensible where reserves are small or capital risk dominates.

The central engineering idea is straightforward: a lined, well-drained heap lets alkaline cyanide and oxygen contact accessible gold and silver over time, while a recovery circuit removes dissolved metal and recycles the solution. Whether that produces an acceptable result depends on ore mineralogy, permeability, water management, recovery design, and containment—not simply on the presence of precious metal in the rock.

Frequently Asked Questions

Is heap leaching the same as cyanide leaching?

No. Heap leaching describes how solution is brought into contact with ore in a pile; cyanide describes the common chemical used to dissolve gold and silver in that pile. Cyanide can also be used in vat or agitated-tank leaching, which are different contact methods.

Can heap leaching recover gold from ore with carbon in it?

It depends on the type and effect of the carbon. Organic carbon in some unoxidized ores can adsorb dissolved gold from the leach solution, a problem called preg-robbing; that can make heap recovery uneconomic even if the ore contains gold.

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Does heap leaching work in rainy or tropical climates?

It can, but rainfall changes the site water balance and may create surplus water that needs treatment and permitted discharge. The pad, collection ponds, and treatment plan have to be designed for local rainfall and water-management rules.

Why can the same mine use both a heap and a mill?

Different ore zones can have different oxidation, grade, clay content, and gold accessibility. A mine may send permeable oxide ore to a heap while routing refractory or higher-grade material to a plant that can use pretreatment or more intensive leaching.

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