Physics-guided machine learning for saturation control across variable hydraulic conditions in heap leaching

Abstract

Heap-leaching hydraulics vary between regions of an ore bed, motivating fast prediction models that accommodate different material properties. This study develops a parameter-conditioned physics-guided machine-learning (PGML) surrogate and demonstrates its use in simulated saturation control. A dataset of 4096 numerical Richards-equation trajectories was divided into 2867 training, 614 validation and 615 evaluation cases. The network predicts hourly saturation profiles from the current profile, irrigation rate and four hydraulic parameters, and is trained with an approximate Gardner mass-balance penalty. A daily predictive controller compared 200 constant irrigation rates over a 24-hour horizon. Across the evaluation cases, the median full-cycle tracking deviation was 4.9% of a 0.70 saturation target, equal to that of a tuned proportional-integral (PI) controller, while the PGML controller reached the target without overshoot in the median and applied approximately 4% less irrigation. Moderate physics guidance reduced long-horizon prediction error by approximately 30% relative to data-only training and reduced irrigation-bound activity, but slightly worsened closed-loop tracking. For a matched prediction workload, the surrogate was approximately 70 times faster than the numerical solver, and batched evaluation cost under 2 ms per column for 5000 columns. The results support a reusable physics-guided surrogate for large-scale saturation control in simulation.