Heap Leach Stacking Systems
Integrated material handling systems designed to support controlled ore placement, maintain heap permeability and provide the flexibility required for advancing, retreating and expanding heap leach operations.
Successful heap leach performance depends on more than moving ore to the pad. Ore preparation, agglomeration, conveying and stacking all influence the structure of the heap and the distribution of leach solution. Carmaky provides modular mobile equipment that moves conditioned ore from the agglomeration stage through to controlled placement on the heap leach pad.
Heap Performance Starts Before Leaching Begins
The way ore is prepared, transferred and stacked affects the physical structure of the heap. Excessive fines migration, segregation, compaction and uneven placement can restrict solution movement and create areas that are not irrigated consistently. A properly planned material handling system supports the conditions required for more uniform percolation through the heap.
Maintain Permeability
Agglomeration and controlled placement help preserve the void spaces required for leach solution to move through the heap.
Reduce Segregation
Controlled transfer and stacking help limit the separation of coarse and fine particles during heap construction.
Minimise Compaction
Conveyor based placement reduces the need for repeated truck and dozer movement across active stacking areas.
Support Uniform Placement
A planned stacking sequence provides greater control over lift development, heap shape and ore distribution.
The Heap Leach Material Handling Process
A heap leach stacking system connects ore preparation with final placement on the leach pad. Each stage has a specific role in protecting material condition, maintaining flow and supporting a controlled stacking sequence.
- 01
Crushing and Screening
Where required, ore is crushed and screened to the size distribution established by the metallurgical and heap leach design.
- 02
Agglomeration
Crushed ore is conditioned with moisture, reagents and, where required, a binder. Fine particles are attached to larger particles to form more stable agglomerates and support heap permeability.
- 03
Ramp Conveyor
Provides powered transfer where elevation changes or ramped approaches are required between the upstream process, cells or pad levels.
- 04
Grasshopper Conveyors
Create a modular mobile conveying route that can be extended or repositioned as stacking progresses across the pad.
- 05
Transverse Conveyor
Provides the dedicated transfer from the grasshopper string to the Horizontal Index Conveyor.
- 06
Horizontal Index Conveyor
Moves in coordination with the Radial Stacker to support retreat stacking while maintaining material flow.
- 07
Radial Stacker
Places ore across the pad through tracking, luffing, slewing and controlled retreat movements.
- 08
Heap Leach Pad
Receives the stacked ore in planned lifts for irrigation, solution collection and downstream metal recovery.
Crushing, screening and agglomeration are project-specific stages and are not presented as standard Carmaky equipment products.
Equipment Designed as a Complete Stacking System
The Carmaky range can be configured as a complete stacking train or selected to suit a specific transfer, relocation or ore placement requirement. The equipment uses a common system philosophy to simplify integration across the heap leach pad.
Why Conveyor Based Heap Leach Stacking?
Conveyor based stacking gives operators greater control over the continuous movement and placement of ore while reducing reliance on repeated truck haulage and dozer rehandling across the stacking area.
Controlled Ore Placement
A planned conveyor and stacker arrangement supports consistent lift development and ore distribution across the pad.
Reduced Segregation
Appropriate transfer design and controlled discharge help reduce particle separation during conveying and stacking.
Reduced Compaction
Less truck and dozer traffic across the stacking area can reduce surface disturbance and compaction.
Continuous Material Flow
Conveyors provide continuous transfer rather than relying only on cyclic haul and dump movements.
Operational Flexibility
Mobile units can be repositioned as cells advance, lifts change or pad areas expand.
Reduced Mobile Fleet Dependence
The stacking train can reduce the number of trucks, loaders and dozers required for routine ore transfer and placement.
Typical Applications
Gold Heap Leach Operations
Mobile conveying and stacking systems for the controlled placement of crushed and agglomerated ore.
Copper Heap Leach Operations
Scalable material handling arrangements for advancing or retreating across developing leach pads.
Multi Lift Heap Construction
Mobile equipment for transferring and placing ore as pad elevations and lift requirements change.
Dynamic Pad Operations
Relocatable equipment suited to operations with frequent cell changes and stacking progression.
Temporary Stockpiling
Mobile conveying and stacking where permanent conveying infrastructure is not justified.
Dry Material Rehandling
Selected equipment may also support temporary bypass, emergency stockpiling and suitable dry material rehandling duties.
Built for Practical Heap Leach Operations
Carmaky combines material handling experience with modular equipment configured around the operating requirements of the heap leach pad. The objective is a practical system that can be deployed, moved and maintained without losing sight of material flow and heap construction requirements.
- Modular mobile equipment
- Integrated stacking system approach
- Configurations developed around site conditions and throughput
- Equipment suited to advancing and retreat stacking arrangements
- Engineering and project support from South Africa
- Support for individual equipment requirements and complete stacking trains
Heap Leach Resource Centre
Explore practical guides, operational insights and technical articles covering heap leach material handling, equipment selection and stacking system operation.
Industry Guides
Clear introductions to heap leach methods, terminology and stacking approaches.
Operations Guides
Practical guidance for moving, configuring and operating mobile equipment.
Technical Articles
Deeper explanations of material behaviour and system design considerations.
Frequently Asked Questions
Here are some common questions we get asked at Carmaky.
What is a heap leach stacking system?
A heap leach stacking system is a series of conveyors and stacking equipment used to transport and place crushed or agglomerated ore onto a heap leach pad. The system enables controlled ore placement while supporting pad expansion, lift construction and retreat stacking operations.
Why is agglomeration used before heap leaching?
Agglomeration is used to condition crushed ore before stacking. During the process, moisture and, where required, binding agents are added to help attach fine particles to larger particles. This can improve heap permeability and support more uniform distribution of leach solution through the heap.
What is the difference between advance stacking and retreat stacking?
Advance stacking progressively builds the heap in the direction of travel as the stacking equipment moves forward. Retreat stacking places material while the stacking equipment moves backwards across the pad. The most suitable approach depends on the heap layout, operating strategy and project requirements.
What is a grasshopper conveyor used for?
A grasshopper conveyor is a modular mobile transfer conveyor used to extend the conveying route across a heap leach pad. Multiple grasshopper conveyors are commonly connected together to transport ore between the upstream feed point and the stacking equipment while allowing the system to be relocated as operations progress.
What is a Horizontal Index Conveyor?
A Horizontal Index Conveyor is a mobile bridge conveyor used in retreat stacking systems. It works in conjunction with a Radial Stacker and moves progressively across the heap while maintaining continuous material flow, helping to minimise interruptions during stacking operations.
Can heap leach equipment be supplied as individual units?
Yes. Heap leach equipment can be supplied as individual machines or configured as a complete stacking system. The appropriate arrangement depends on the site layout, production requirements, stacking method and operating philosophy.
Planning a Heap Leach Project?
Whether the requirement is for a single conveyor or a complete stacking train, Carmaky can assist with equipment selection, system configuration and budgetary pricing based on the site conditions and operating duty.
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