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SGS MINERALS SERVICES T3 SGS 059 02-2014

FLOWSHEET DEVELOPMENT FOR GOLD OREBODIES


OVERVIEW
There are several basic metallurgical
flowsheets used to treat gold orebodies,
with a great many permutations. The
optimum flowsheet from an economic
perspective is always that which
achieves the greatest gold recovery at
the lowest cost. Normally these two are
mutually exclusive and some measure of
compromise is required.
The grade of gold in the orebody can be
critical in establishing the process options.
Maximum gold recovery can normally be
justified for high-grade deposits, even
though this usually means relatively high
capital and operating costs. Conversely,
low-grade deposits must be treated at
the lowest possible cost, even though
The advantages of this process are:
this usually means sacrificing some gold
recovery. Simplicity
Favorable capital
The lowest cost gold is normally
Favorable operating costs, which
produced by open pit mining with minimal
will generally be lower than the
crushing, followed by dump or heap
alternatives
leaching with cyanide. Gold recovery is
usually around 80%, but can be as low The main disadvantage is that gold
as 60%. Recoveries can be improved to recovery is generally lower than that
95-99% by grinding to fairly fine particle achieved by grinding to a finer size and
size, gravity separation, cyanidation and leaching in stirred tanks. In addition, the
flotation, all of which increase capital and rate of leaching is slow and recoverable
CRUSHING AND GRINDING FOLLOWED BY
operating costs. gold can be held up in the heap for
GRAVITY SEPARATION
months, which impacts cash flow. There
In some cases, oxidation of sulphide This method of gold recovery has been
can also be longer term environmental
minerals is needed to liberate gold that practised for over 4,000 years, and was
liabilities associated with heap leaching,
is occluded within the sulphide matrix. the only method of separating gold from
due to the slow release of cyanide and
Sulphides can be oxidized by several its natural environment until the late
other toxins from abandoned heaps.
methods, and the overall costs are similar. 19th century. Many modern gold plants
The factors that are tested to determine
incorporate gravity circuits as part of their
an ores amenability to dump or heap
FLOWSHEET OPTIONS leaching are:
overall flowsheet, and it is estimated that
about 10% of the new gold produced
Its permeability, (which allows each year is recovered by this technique.
CRUSHING FOLLOWED BY DUMP OR HEAP cyanide to diffuse into coarse
The advantages and disadvantages of
LEACHING WITH CYANIDE particles)
gravity separation are similar to heap
Its hardness or competency, (which
This method of gold recovery is the leaching. It is a very simple and low cost
determines the ability of individual
preferred method for treating low- process, but gold recovery is usually low
particles or agglomerates to
grade gold ores because of its low cost.
withstand the pressure of the mass
Between 10-20% of the gold recovered
above them without collapse).
each year from primary sources is
extracted by this technique.
SGS MINERALS SERVICES T3 SGS 059 2

(0 50%). Therefore, gravity recovery created in the public domain. Despite


is usually followed by additional gold its toxicity, the gold mining industry has
recovery operations such as cyanidation worked with cyanide for over 100 years
and/or flotation. The amenability of a gold with remarkably few human fatalities due
orebody to gravity treatment is dependent to cyanide ingestion, and with minimal
on the size and liberation characteristics impact on the environment.
of the individual gold particles in the The factors that are tested to assess the
ore. Relatively coarse gold particles that amenability of an ore to the cyanidation
are liberated from the gangue mineral process are gold leach efficiency and
phase by crushing and grinding are readily cyanide consumption as a function of
recovered by gravity techniques, because the fineness of grind and other leach
of the large difference in specific gravity conditions.
between gold (SG 19.3) and most gangue
minerals (SG 2 to 3).
REFRACTORY GOLD ORE PROCESSES
For gold ores that are amenable to gravity
Refractoriness results in poor gold
separation, recovery of the coarse,
recovery by standard processing
liberated gold invariably leads to lower
techniques, and can be due to either
costs and improved recovery;
chemical or physical interference. An
Lower costs because gravity example of chemical interference is the
concentrates are often of sufficiently presence of minerals in the orebody
high grade to be smelted directly to that consumes excessive amounts of
bullion without further processing cyanide and oxygen, the two components
Improved recovery because the required for gold leaching by cyanidation. the inclusion of very fine particles of
coarse gold particles that respond Another example of chemical interference gold (usually < 1 micron in diameter), in
well to gravity separation are slow to is the presence of graphitic carbon in a minerals that are inert and impervious
leach in a cyanidation circuit. gold ore. This species, which occurs to the cyanide leach liquor. Examples of
naturally in many orebodies, particularly such mineral phases are sulphides such
CRUSHING, GRINDING AND AGITATED in the SW United States and West as pyrite and arsenopyrite, as well as
TANK CYANIDATION Africa, is able to re-adsorb gold cyanide silicates.
The cyanidation process was developed from the leach solution, lowering overall
Techniques exist for dealing with all of
in the late 19th century and was rapidly gold recovery. Finally, refractoriness
these situations. For example, gold
implemented by the gold industry over can be due to physical interference i.e.
that is occluded in sulphides may be
the next 20 years. With its ability to
leach and recover all liberated gold from
the finest to the coarsest particle sizes,
this process resulted in a quantum
improvement in gold recovery from
less than 50%, which was typical prior
to the cyanidation era, to greater than
90% and often as high as 95-99%, with
cyanidation. The cyanidation process
accounted for 80-90% of all gold
recovered by the gold mining industry
from primary resources in the 20th
century.
The advantages of the process are its
relative simplicity, its chemical and
physical durability, its relatively low cost,
and the generally very high recoveries of
gold (and silver), that are achieved.
The disadvantage of the process is the
toxicity of cyanide to human and animal
life, and the negative perception this has
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liberated by ultra-fine grinding or by


oxidizing the sulphides using techniques
such as roasting, pressure leaching or
bacterial leaching. The adverse effect of
graphitic carbon can also be overcome by
roasting the ore or concentrate to burn
off the carbon. All of these techniques
are relatively expensive however, so the
economic cut-off gold grade for refractory
ores is somewhat higher than non-
refractory ores.
The mining industry uses a rule of
thumb of 80% gold recovery to define
the transition from a refractory to a non-
refractory gold ore. Ones under 80% are
considered refractory. In assessing the
economic benefit of the extra processing
that must be done to improve recovery
from refractory or partially refractory
ores, one must consider the incremental
improvement in gold recovery versus
standard grinding and cyanidation, and the
incremental increase in costs to achieve GOLD RECOVERY AFTER CYANIDATION the ore phase to the leachate), and
this improvement. adsorption of gold (from the leachate to
Carbon Processes
the carbon), occur simultaneously. In a
The standard and preferred method of CIP plant, a series of small adsorption
FLOTATION
gold recovery from cyanide leachates tanks is installed after the leach plant
Native gold and gold in sulphide minerals is by adsorption onto activated carbon. and the leaching reaction is essentially
is readily floatable. Therefore, it is often For heap leach operation, gold cyanide complete before adsorption starts. CIL is
possible to achieve high gold recovery is extracted from pregnant leach liquors advantageous when the leaching kinetics
(>90%) in a flotation concentrate. This onto carbon in a series of columns, by are fast and when the ore contains
results in a reduction of up to fifty upflowing leach solution through columns mineral phases that are able to re-adsorb
times in the mass of gold-bearing that are packed with carbon. The process the gold cyanide in competition with
material for further processing. This is known as carbon-in-columns (CIC). For activated carbon (preg-robbing). CIP
is particularly advantageous in the mill, agitated-tank leaching operations, is a more efficient process for slower-
processing of refractory ores, since the gold is extracted directly from the leached leaching gold ores, and has certain other
cost of additional processing such as fine pulp in either a carbon-in-leach (CIL), or a advantages over CIL, such as smaller
grinding or sulphide oxidation is reduced carbon-in-pulp (CIP) plant. In both these carbon elution and regeneration circuits.
by reducing the mass of material to be cases, the coarse granules of activated
treated. In some cases, the grade of SGS has developed a carbon-in-pulp
carbon are mechanically mixed with the
gold in the concentrate is sufficiently high (CIP) / carbon-in-leach (CIL) modeling
pulp in an adsorption tank, and gold-
to ship directly to a smelter, avoiding all package to estimate the performance of
loaded carbon granules are separated
downstream processing costs and greatly a full scale commercial plant and to derive
from gold-depleted pulps by screening.
simplifying environmental compliance. the optimum design criteria based on the
The screening operation is done at screen
results of small scale experiments.
Even in cases where standalone mesh sizes that are intermediate between
flotation is unable to achieve adequate the smallest carbon granules and the In all three processes (CIC, CIL,
gold recovery, the process can still be largest particles of the pulp. CIP), carbon granules are advanced
advantageously incorporated into an countercurrent to the direction of flow of
The basic difference between CIL and
overall flowsheet, which can include the gold leachate. In this way, the twin
CIP is the configuration of the adsorption
standard cyanidation of the flotation objectives of simultaneously achieving
circuit. In a CIL plant, the carbon granules
tailings, combined with special treatment high gold loading on the carbon and very
are added directly into the gold leaching
of the small mass of flotation concentrate. low gold concentration in the final barren
tanks, so that leaching of gold (from
are attained.
SGS MINERALS SERVICES T3 SGS 059 4

Resin Processes liquors. In such cases, the water balance CONTACT INFORMATION
Anion exchange resins are also very in the plant will require the incorporation
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effective adsorbents for gold cyanide, of a hybrid process including both direct
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and resin processes (RIC, RIL, RIP), electrowinning of high-grade solution and
have been developed that are analogous carbon adsorption of low-grade waste or
to the carbon adsorption processes. In bleed streams.
many cases, it can be demonstrated SGS Minerals Services has very extensive
that processing of a gold ore with a experience with all the unit operations
resin will generate superior economic involved in the processing of gold ores,
returns compared to carbon, yet the and in selecting the optimum flowsheet
resin processes have been slow to gain for a particular ore.
acceptance by the gold mining industry.
The main reason for this is the generally
very satisfactory performance and robust ENVIRONMENTAL
economics that can be achieved with the COMPLIANCE
well-established carbon-based processes.
An important factor that must be taken
CIC, CIL, CIP and the analogous resin
into consideration in flowsheet selection
process are particularly advantageous
and economic evaluation of a gold project
over the alternative gold recovery
is the cost of environmental compliance.
processes for treating low-grade gold
This can be significant, and varies with
orebodies in large tonnage operations.
the flowsheet and also from country to
Merrill-Crowe Process country.
For smaller tonnage, higher-grade Cyanide must be destroyed prior to
operations, particularly those in which discharge to a tailings pond in most
the concentration of silver is greater jurisdictions, and must always be
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than gold, the process that yields the destroyed prior to discharge to the
most favourable economics for gold natural environment. The cost of cyanide
(and silver) recovery is Merrill Crowe destruction depends on the specific
cementation. In this process, the method selected and the limits imposed
leachate is separated from the barren, by local regulations. In turn this depends
leached ore, and gold and silver is not only on the concentration of cyanide
precipitated from the pregnant liquor in the effluent, but also the concentrations
by reduction (cementation) on fine zinc of metal cyanide complexes and many
powder. For very high grade solutions other soluble species.
(> 20 mg/L Au + Ag), the process that
produces the best economics in most
cases is direct electrowinning of the
precious metals from the pregnant leach