Review of Numerical Simulations for Parameter Control in Heap Bioleaching of Copper Sulfide Ore

Heap bioleaching is widely used to extract copper from low-grade sulfide ores thanks to its operational simplicity, low cost, and environmental sustainability. However, current control strategies rely primarily on single-factor optimization and often overlook the synergistic interactions of multiple key parameters, such as ore particle size, pore structure, pH, temperature, microbial activity, and oxygen transfer efficiency. As a result, issues such as low recovery rates, extended leaching periods, and high operational costs persist. Moreover, the “gray-box” nature of heap systems impedes real-time monitoring of internal physical, chemical, and biological processes. In addition, empirical multi-parameter optimization is time-consuming and inadequate for capturing complex interdependencies. This review was conducted to systematically examine the key factors influencing heap bioleaching efficiency and critically evaluate recent advances in numerical simulation and intelligent control strategies. As a result, we identified a major research gap: the existing models—including microscale shrinking core models (SCMs), mesoscale pore-network models based on CT reconstruction, and macroscale continuum models—have inherent limitations. SCMs assume idealized spherical particles with uniform mineral distribution while neglecting pore structure evolution and biofilm dynamics. Mesoscale models offer detailed pore characterization but lack robust multi-physics coupling (thermal–hydro–mechanical–chemical–biological, or THMCB). Macroscale models rely on homogenization assumptions that oversimplify spatial heterogeneity and temporal variations in permeability. This analysis covers the relevant literature from 1985 to 2025, with a focus on three methodological scales (micro, meso, and macro) and their integration with machine learning approaches. A notable finding is that hybrid neural network models (e.g., BP and RBF architectures) outperform purely physics-based models in predicting leaching kinetics under varying operational conditions. However, their accuracy depends heavily on high-quality field data—a limitation rarely addressed in prior reviews. By clearly delineating these model-specific limitations and scale-dependent trade-offs, this review makes two unique contributions: a structured framework for selecting and coupling numerical methods according to process requirements and a roadmap for integrating artificial neural networks with multi-physics simulations to achieve real-time intelligent control of heap bioleaching. The findings offer both theoretical guidance and practical references for optimizing the processing of low-grade copper sulfide ores.