Chapter 9

Metal Production
David A. Milligan, Omar A. Muhtadi, and R. Bruce Thorndycraft

Precious metals i n a leach s o l u t i o n a r e e x t r a c t e d , c o n c e n t r a t e d , and

p u r i f i e d t o complete t h e process begun i n t h e heap and t o produce an end
p r o d u c t which w i l l p r o v i d e an economic payback t o t h e mine d e v e l o p e r / o p e r a t o r .
Several d i f f e r e n t processes are r e q u i r e d t o c o n v e r t t h e d is s o l ved prec i o u s
m e t a l s i n t o pure metal bars. This c h a p t e r discusses t h e a c t u a l p r o d u c t i o n o f
metal once i t has been recovered from t h e pregnant l e a c h s o l u t i o n s by t h e z i n c
cementation ( M e r r i 11 -Crowe) o r carbon a d s o r p t i o n processes. Metal p r o d u c t i o n
i s g e n e r a l l y taken t o mean t h e p r o d u c t i o n o f a f a i r l y pure "dore" b a r . T h i s
c h a p t e r a l s o r e i t e r a t e s some i n f o r m a t i o n from Chapter 8 i n a s l i g h t l y
d i f f e r e n t c o n t e x t , since t h e focus o f Chapter 8 was a f a i r l y d e t a i l e d
d e s c r i p t i o n o f the two a c t u a l r e c o v e r y processes, whereas t h e focus o f t h i s
c h a p t e r i s metal p r o d u c t i o n .

The s a l e o f an i n t e r m e d i a t e p r e c i o u s metal p r o d u c t i s p o s s i b l e (as

opposed t o t h e p r o d u c t i o n o f dore b a r s a t t h e mine s i t e ) ; however, t h e v a l u e
o f the precious metals i s reduced by t h e v a r i o u s charges and r i s k s a s s o c i a t e d
w i t h precious metal processing. For t h i s reason, most o p e r a t o r s choose t o
produce t h e most r e f i n e d metal p o s s i b l e i n o r d e r t o maximize p r o j e c t
economics. Precious metals may be e x t r a c t e d from t h e l e a c h s o l u t i o n by b o t h
c o n v e n t i o n a l and unconventional processes. The c o n v e n t i o n a l processes a r e
a c t i v a t e d c a r b o n / e l e c t r o w i n n i n g (ACE) and z i n c p r e c i p i t a t i o n ( Z I P ) . The
unconventional processes a r e r e s i n i o n exchange, s o l v e n t e x t r a c t i o n , and
d i r e c t electrowinning.

A t y p i c a l ACE process has two c i r c u l a t i n g loops. The f i r s t l o o p adsorbs

t h e cyanide-metal complexes from t h e d i l u t e l e a c h s o l u t i o n o n t o t h e a c t i v a t e d
carbon. A second, separate s o l u t i o n l o o p removes t h e cyanide-metal co~nplexes
f r o m t h e a c t i v a t e d carbon i n t o a s t r o n g solution, the electrowinning
electrolyte. A c t i v a t e d carbon i s t r a n s f e r r e d from one f l u i d l o o p t o t h e
o t h e r . The o p e r a t i n g c o s t o f t h e ACE p r o c e s s i s d i r e c t l y p r o p o r t i o n a l t o t h e
q u a n t i t y o f carbon s t r i p p e d and thus t o t h e q u a n t i t y o f p r e c i o u s metal
produced.

A t y p i c a l ZIP process c o n t a i n s a s i n g l e c i r c u l a t i n g l o o p . The s o l u t i o n

i s f i l t e r e d , deaerated, contacted w i t h z i n c , and f i l t e r e d again. The b a r r e n
l e a c h s o l u t i o n i s then r e t u r n e d t o the heap. The z i n c sludge recovered i n t h e
137
138 PRECIOUS METAL HEAP LEACHING PROJECTS

second f i l t e r i n g s t e p c o n t a i n s t h e p r e c i o u s metal. This sludge i s t y p i c a l l y

d r i e d , f l u x e d , and s m e l t e d t o a d o r e . The o p e r a t i n g c o s t o f t h e ZIP process i s
d i r e c t l y p r o p o r t i o n a l t o t h e q u a n t i t y o f s o l u t i o n t r e a t e d , w i t h dependence
upon t h e m e t a l c o n t e n t o f t h e s o l u t i o n . The ZIP process r e q u i r e s t i g h t c o n t r o l
f o r e f f i c i e n t g o l d and s i l v e r r e c o v e r y .

A p r e c i o u s m e t a l s l u d g e i s produced from both t h e ACE and t h e ZIP

p r o c e s s e s . T h i s s l u d g e must be t r e a t e d t o form pure metal bars. The
c o n v e n t i o n a l method i n v o l v e s a p y r o m e t a l l u r g i c a l t r e a t m e n t w i t h t h e necessary
f l u x e s t o form a d o r e o f g o l d , s i l v e r , and copper. The dore i s u s u a l l y s o l d t o
metal r e f i n e r s . There, t h e d o r e i s r e f i n e d h y d r o m e t a l l u r g i c a l l y t o p u r e
m e t a l s . The p u r e m e t a l s a r e m e l t e d and c a s t i n t o bars o f gold and s i l v e r f o r
sale.

The r e m a i n d e r o f t h i s c h a p t e r discusses a1 t e r n a t i v e carbon elution

processes, e l ec t r o w i n n i n g , c a r b o n r e g e n e r a t i o n and smelting.

9.2 CARBON ELUTION

Loaded c a r b o n i s s t r i p p e d o f i t s p r e c i o u s metals i n t h e carbon e l u t i o n

c i r c u i t . The s t r i p p i n g c i r c u i t c o n t a i n s f o u r major components: 1) c a r b o n
s t r i p columns; 2 ) m e t a l c o n c e n t r a t i o n equipment; 3 ) carbon hand1 i n g equipment;
and 4 ) h e a t exchange and h e a t i n g equipment. The carbon s t r i p columns may be
o p e r a t e d i n a c o u n t e r c u r r e n t manner; however, a s i n g l e vessel i s o f t e n used.
The key o p e r a t i n g p a r a m e t e r s a r e t h e c h a r a c t e r i s t i c s o f t h e carbon, t h e
terrlperature o f t h e s t r i p p i n g column, t h e c i r c u l a t i o n r a t e , and t h e e f f i c i e n c y
o f t h e m e t a l c o n c e n t r a t i o n equipment.

The e l u a t e i s s u b j e c t e d t o e i t h e r e l e c t r o w i n n i n g o r z i n c cementation f o r
e v e n t u a l r e c o v e r y and s m e l t i n g o f g o l d and s i l v e r .

9.2.1 H e a t i n g Equipment

The s t r i p c i r c u i t c y c l e s f r o m a c o l d c i r c u i t w i t h c o l d carbon t o a h o t
o p e r a t i n g c i r c w it. The h e a t i n g equipment, a b o i l e r o r e l e c t r i c a l heater, h e a t s
t h e s t r i p s o l u t i o n t o o p e r a t i n g temperature. The h o t s o l u t i o n h e a t s t h e
c i r c u i t components and m a i n t a i n s t h e temperature o f t h e s t r i p column. The
s t r i p c o l u m n must be i n s u l a t e d t o prevent excessive losses o f heat. Once t h e
c i r c u i t i s h o t , a s e r i e s o f h e a t exchangers t r a n s f e r heat t o c o o l t h e s t r i p
s o l u t i o n l e a v i n g t h e column and h e a t t h e s t r i p s o l u t i o n e n t e r i n g t h e column.
Heat l o s s e s a r e h i g h , w i t h f r e q u e n t c y c l e s .

Packaged h o t w a t e r o r steam b o i l e r s a r e commonly used t o p r o v i d e t h e

energy n e c e s s a r y f o r h e a t i n g t h e s t r i p s o l u t i o n . A heat exchanger t r a n s f e r s
h e a t from t h e steam o r h o t w a t e r t o t h e s t r i p s o l u t i o n . The maximum d u t y o f
t h e b o i l e r , w h i c h i s t h e t o t a l o f t h e heat requirements f o r s t a r t - u p and t h e
system h e a t l o s s e s , c a n be c a l c u l a t e d from s t a r t - u p c o n d i t i o n s . The
equipment, t h e carbon, and t h e s o l u t i o n must be heated t o o p e r a t i n g
t e m p e r a t u r e f r o m a m b i e n t t e m p e r a t u r e . From t h e mass o f the components, t h e
h e a t c a p a c i t y o f t h e components, t h e temperature increase r e q u i r e d , and t h e
t i m e a1 l o w e d f o r a t t a i n i n g o p e r a t i n g temperature, t h e energy requirements a r e
c a l c u l a t e d , and t h e n d i v i d e d by t h e t i m e a l l o t t e d . Heat losses from t h e s y s t e m
must a l s o be i n c l u d e d i n t h e d u t y . Losses i n c l u d e convection and r a d i a t i o n
from t h e s t r i p column, t h e p i p i n g , t h e heat exchangers, t h e b o i l e r p i p i n g , and
 METAL PRODUCTION 139

t h e metal c o n c e n t r a t i o n equipment. These h e a t l o s s e s can be c a l c u l a t e d based

upon the o p e r a t i n g t e m p e r a t u r e o f t h e equipment and t h e o v e r a l l h e a t t r a n s f e r
c o e f f i c i e n t from t h e i n s i d e o f t h e equipment t o t h e s u r r o u n d i n g e n v i r o n m e n t .
The d u t y i s then the sum o f t h e heat-up d u t y and t h e h e a t - l o s s d u t y .

9.2.2 S t r i p p i n g Columns

The s t r i p p i n g columns p r o v i d e c o n t a c t between t h e h o t s t r i p s o l u t i o n and

t h e loaded a c t i v a t e d carbon a t t h e c o n d i t i o n s necessary f o r s t r i p p i n g o f t h e
cyanide-metal complexes. The s t r i p column i s i n s u l a t e d t o reduce h e a t l o s s .
The carbon i s loaded i n t o t h e s t r i p column, u s u a l l y by pumping. The system i s
sealed and t h e carbon s t r i p p e d . The carbon i s then unloaded from t h e column
and t r a n s f e r r e d back t o t h e a d s o r p t i o n c i r c u i t . For e f f i c i e n t c o n t a c t w i t h t h e
carbon, t h e vessel i s t y p i c a l l y a column w i t h a h e i g h t t o diameter r a t i o o f 3
t o 6.

The e q u i l i b r i u m l o a d i n g o f carbon f o r a p a r t i c u l a r l e a c h s o l u t i o n may

exceed 750 ounces per t o n ( 2 6 kg/mt) o f carbon; however, t h e o p e r a t i n g l o a d i n g
l e v e l i s much lower. An o p e r a t i n g carbon l o a d i n g l e v e l o f 150 t o 200 o z / t o n (5
t o 7 kg/mt) p r e c i o u s m e t a l can be achieved under normal g o l d l e a c h i n g
c o n d i t i o n s w i t h leach s o l u t i o n c o n c e n t r a t i o n s above 1 ppm. The carbon may a l s o
c o n t a i n o t h e r cyanide-metal complexes such as copper, mercury, and z i n c .

To s t r i p t h e carbon, a h o t s o l u t i o n i s c i r c u l a t e d t h r o u g h t h e carbon.
Many s t r i p p i n g s o l u t i o n c o m p o s i t i o n s a r e p o s s i b l e . The s o l u t i o n c o m p o s i t i o n
s e l e c t i o n i s based upon s a f e t y , ease o f o p e r a t i o n , c a p i t a l c o s t , and o p e r a t i n g
c o s t comparison. Each s o l u t i o n must o p e r a t e a t a p a r t i c u l a r t e m p e r a t u r e and
f o r a p a r t i c u l a r t i m e t o o b t a i n an e f f i c i e n t s t r i p o f t h e a c t i v a t e d c h a r c o a l .
The USBM o r i g i n a l l y s t r i p p e d carbon w i t h a s o l u t i o n o f 1 p e r c e n t c a u s t i c ,
NaClH, p l u s 0.1 percent sodium c y a n i d e near t h e b o i l i n g p o i n t o f water. Two t o
t h r e e days o f s t r i p p i n g were r e q u i r e d . T a b l e 9.1 i l l u s t r a t e s s e v e r a l d i f f e r e n t
s o l u t i o n s w i t h t h e i r r e q u i r e d times and temperatures. Other s o l u t i o n s w i t h
v a r y i n g q u a n t i t i e s o f o r g a n i c s have been used i n South A f r i c a and A u s t r a l i a .

TABLE 9.1
STRIPPING SOLUTIONS

Solution S t r i p Temgerature Time

Composition P
Hrs

1 % NaOH
0.1% NaCN

1 % NaOH
0.5% Ethanol

1 % NaOH

0.1% NaCN
20 % Ethanol
140 PRECIOUS METAL HEAP LEACHING PROJECTS

The f l o w r a t e o f t h e s o l u t i o n must be s u f f i c i e n t t o p r o v i d e good c o n t a c t

w i t h t h e c a r b o n . Two bed volumes o f s t r i p s o l u t i o n per hour a r e o f t e n s e l e c t e d
t o o b t a i n a compromise between sweep e f f i c i e n c y and s o l u t i o n grade. Flow
r a t e s o f l e s s t h a n 0.5 bed volumes p e r h o u r may r e s u l t i n dead s p o t s i n t h e
column, w h i l e s o l u t i o n f l o w r a t e s i n excess o f s i x bed volumes w i l l o f t e n
g e n e r a t e l o w grade s o l u t i o n . These p a r a m e t e r s may v a r y s i g n i f i c a n t l y i f t h e
e o m e t r y o f t h e s t r i p columns i s s i g n i f i c a n t l y d i f f e r e n t t h a n a f o u r t o one
9 h e i g h t t o diameter) r a t i o .

There a r e a number o f commonly used methods t o s t r i p t h e l o a d e d g o l d and

s i l v e r o f f t h e c a r b o n . The most commonly used e l u t i o n methods a r e Zadra S t r i p ,
alcohol (Heinen) s t r i p , and t h e Anglo American Research L a b o r a t o r i e s
(A.A.R.L.) s t r i p . I n a d d i t i o n , a number o f v a r i a t i o n s o f each o f t h e s e
s t r i p p i n g methods a r e known and h a v e been used.

The Zadra s t r i p and a l c o h o l ( H e i n e n ) s t r i p ( a m o d i f i c a t i o n o f t h e Zadra

s t r i p ) a r e b o t h r e c i r c u l a t o r y ( c o n t i n u o u s l o o p ) methods and w i 11 be d i s c u s s e d
j o i n t l y below. The A.A.R.L. s t r i p i s a "once pass t h r o u g h " p r o c e s s . The Zadra
s t r i p i s now t h e most common p r o c e s s f o r c a r b o n s t r i p p i n g .

Zadra-Heinen E l u t i o n Process. I n t h e a t m o s p h e r i c Zadra s t r i p , t h e l o a d e d

c a r b o n i s l e a c h e d w i t h a s o l u t i o n ( e l u a n t ) c o n t a i n i n g 1.0 p e r c e n t NdOH and 0.1
p e r c e n t NaCN, and heated t o b o i 1 i n g t e m p e r a t u r e , a p p r o x i m a t e l y 212 F (lOOC).
F i g u r e 9.1 shows a g e n e r a l i z e d f l o w s h e e t used w i t h t h e Zadra s t r i p .

FIGURE 9.1 - GENERALIZED ZADRA STRIPPING FLOWSHEET

 METAL PRODUCTION 141

I n a m o d i f i c a t i o n t o t h e atmospheric Zadra s t r i p , t h e p r e s s u r e Zadra

s t r i p i n v o l v e s l e a c h i n g t h e l o a d e d carbon w i t h t h e same e l u a n t as t h e
atmospheric Zadra (1.0 p e r c e n t NaOH, and 0.1 p e r c e n t NaCN), b u t a t a p r e s s u r e
o f a p p r o x i m a t e l y 100 p s i g ( 6 9 0 kPa). The s t r i p p i n g t e m p e r a t u r e i n t h i s case i s
usual l y around 3 0 0 ' ~ (1480C).

Alcohol s t r i p p i n g was developed by Heinen e t a l . (1976) i n o r d e r t o

speed up t h e t i m e r e q u i r e d
value. The e l u a n t used i n
p e r c e n t by volumg a l c o h o l
a p p r o x i m a t e l y 170 F (770C),
t o 275 kPa) pressure.
f o r s t r i p p i n g t h e carbon t o a r e q u i r e d b a r r e n
t h i s process c o n t a i n s 1.0 p e r c e n t NaOH, and 20
( u s u a l l y e t h a n o l ) . The e l u t i o n i s conducted a t
a t atmospheric p r e s s u r e , o r a t 35 t o 40 p s i g (240

The major advantages and d i s a d v a n t a g e s o f t h e Zadra-Heinen process a r e

l i s t e d below.

Advantages :

The systems can t o l e r a t e l o w qua1 i t y water f o r e l u t i o n ( i .e., w a t e r

w i t h f a i r l y h i g h t o t a l d i s s o l v e d s o l i d s and h i g h c o n c e n t r a t i o n s o f
Ca and Mg i o n s ) . The e l u t i o n can be s i m p l y c o n t i n u e d u n t i l i t i s
a n t i c i p a t e d t h a t s u f f i c i e n t g o l d has been removed o f f t h e carbon;

The temperature o f t h e s t r i p p i n g systems i s i n h e r e n t l y m a i n t a i n e d .

Because t h e e l u a n t i s r e c y c l e d , t h e o n l y h e a t i n p u t needed i s t h a t
o f m a i n t a i n i n g t h e s t r i p p i n g t e m p e r a t u r e ; and

The e l u a n t volume i s relatively small with consequently small

r e a g e n t consumption.

Disadvantages :

For f a s t e r e l u t i o n t i m e s , a r e l a t i v e l y h i g h pressure i s required

f o r t h e Zadra;

I m p u r i t i e s which accumulate d u r i n g t h e s t r i p a r e r e c y c l e d and

promote poor e l e c t r o w i n n i n g . The g o l d t h a t i s r e c y c l e d depresses
e l u t i o n ; and

Alcohol ( i n t h e Heinen s t r i p ) i s expensive and dangerous from an

operational viewpoint.

A.A.R.L. E l u t i o n Process. F i g u r e 9.2 r e p r e s e n t s a s i m p l i f i e d f l o w s h e e t

o f an A.A.R.L. circuit. Loaded carbon i s d i s p a t c h e d i n t o t h e e l u t i o n column
from t h e f l o o d e d carbon s t o r a g e hopper. The e l u t i o n column i s c o m p l e t e l y
f i l l e d , and t h e carbon i s f i r s t a c i d washed w i t h one bed volume o f t h r e e
p e r c e n t by volume h y d r o c h l o r i c a c i d ( 3 1 t o 33 p e r c e n t s t r e n g t h ) . T h i s i s
followed by a wash o f one t o two bed volumes o f w a t e r ( t h e bed volume r e l a t e s
t o t h e volume o f the empty c o l u m n ) . During t h i s period theosystem iso raised
t o t h e r e q u i r e d e l u t i o n t e m p e r a t u r e ( 2 3 0 ' ~ t o 2 4 8 ' ~ o r 110 C t o 120 C) and
pressure (35 t o 50 p s i g o r 240 t o 275 kPa), w h i l e t h e a c i d i s d i s c h a r g e d .
 PRECIOUS METAL HEAP LEACHING PROJECTS

LOADED
CARBON

--
FLOODED CARBON
STORAQE

4-, . :>::..'.-
y! ;,::.a .
,;:: .:'.'.'
.:.',$.l'.. ,,..,:.
WATER SUPPLY
,;:.:.:. i;: ;i
.:;:*:i
..
,;. ::::.,':
. . .,..
;;..;~~;A..,....~.
.
........,.,>,;....:,. .
,...<
; 5.::. :
I:.'.
:;::.<:.;:
7;:;:'.
, ..;:::.:;,
91~:
I'

:.>....
, ..,...T".!
,.,.I
,
.,.;..,,,.
,;.; :;.\>.;)'
...:;.:
..,.;';',.:..I.
, ;J ',:;
.

ELUTION COLUMN

ELUATE ,-
STORAQE
RE-HEATER

ACID
DRAIN

5 ELUTED
CARBON

V COLUMN
DRAIN
HEAT
I EXCHANQER

FIGURE 9.2
A A R L GOLD ELUTION FLOWSHEET
 METAL PRODUCTION 143

The a c i d washed c a r b o n i s now p r e t r e a t e d w i t h 0.6 bed volumes o f 2.0

p e r c e n t NaCN + 2 p e r c e n t NaOH s o l u t i o n . The c a r b o n t h e n soaks i n t h i s reagent
f o r a p p r o x i m a t e l y 30 m i n u t e s .

Gold and s i l v e r a r e e l u d e d by t h e use o f w a t e r . The w a t e r f l o w s t h r o u g h

t h e carbon bed a t a f l o w r a t e e q u i v a l e n t t o two bed volumes p e r h o u r , u s i n g a
t o t a l o f f i v e t o s i x bed volumes. The w a t e r used f o r e l u t i o n s h o u l d be o f a
h i g h q u a l i t y , p r e f e r a b l y c o n t a i n i n g l e s s t h a n 1,500 ppm TDS.

The major advantages and d i s a d v a n t a g e s o f t h e A.A. R. L. e l u t i o n process

a r e 1 is t e d be1 ow.

Advantages :

The A.A.R.L. e l u t i o n system i s o p e r a t i o n a l l y v e r y f l e x i b l e because

o f t h e r e l a t i v e l y s h o r t e l u t i o n t i m e . The t o t a l e l u t i o n c y c l e can
g e n e r a l l y be e x e c u t e d i n a s i n g l e e i g h t hour s h i f t ;

The A.A.R.L. e l u t i o n system l i m i t s carbon r e g e n e r a t i o n k i l n

d e g r a d a t i o n . T h i s i s because c o n t a m i n a n t s a r e always e l u t e d o u t o f
t h e carbon by f r e s h e l u a n t ; and

The A.A.R.L. system works w e l l a t 110'~ and, therefore, a high

p r e s s u r e system i s n o t r e q u i r e d .

Disadvantages :

A.A.R.L. r e q u i r e s r e l a t i v e l y good q u a l i t y water, p r e f e r a b l y l e s s

t h a n 1,500 ppm TDS, f o r f a s t e l u t i o n and i s p a r t i c u l a r l y s e n s i t i v e
t o t h e presence o f Ca and Mg much i n excess o f 100 ppm; and

The q u a n t i t y o f e l e c t r o l y t e g e n e r a t e d by t h e A.A.R.L. procedure f o r

e l e c t r o w i n n i n g i s l a r g e compared t o t h e p r e s s u r e Zadra system
( a p p r o x i m a t e l y 5 1 ) T h i s e l e c t r o l y t e volume d i f f e r e n c e balances
t h e o p e r a t i n g c o s t i n terms o f t h e r m a l energy, d e s p i t e t h e much
l o w e r t e m p e r a t u r e a p p l i e d f o r t h e A.A.R. L. system.

9.3 METAL CONCENTRATION

S o l u t i o n s may be e i t h e r electrowon or p r e c i p i t a t e d w i t h zinc.

E l e c t r o w i n n i n g i s t h e c o n v e n t i o n a l method. Z i n c p r e c i p i t a t i o n i s used
e x t e n s i v e l y d i r e c t l y on 1each s o l u t i o n ; r e c e n t l y z i n c was used t o p r e c i p i t a t e
g o l d from a carbon s t r i p s o l u t i o n . S e v e r a l advantages f o r t h e u s e o f ZIP over
e l e c t r o w i n n i n g a r e c l a i m e d . 'These i n c l u d e : 1) reduced c a p i t a l investment; 2 )
more e f f i c i e n t removal o f p r e c i o u s m e t a l f r o m s o l u t i o n ; and 3 ) l o w e r o p e r a t i f l g
costs.

9.3.1 Electrowinning

E l e c t r o w i n n i n g removes t h e p r e c i o u s m e t a l s f r o m t h e s t r i p s o l u t i o n by
t h e passage o f c u r r e n t t h r o u g h an e l e c t r o w i n n i n g c e l l . The cathode, t h e
anode, and an e l e c t r o l y t e a r e p l a c e d i n a c o r r o s i o n r e s i s t a n t c o n t a i n e r . These
components a r e known as t h e e l e c t r o w i n n i n g c e l l . A d i r e c t c u r r e n t power supply
144 PRECIOUS METAL HEAP LEACHING PROJECTS

i s connected t o t h e anode and c a t h o d e . As c u r r e n t passes t h r o u g h t h e c e l l ,

m e t a l i s d e p o s i t e d upon t h e c a t h o d e . The c e l l compartment i s o f a f l o w - t h r o u g h
d e s i g n , e i t h e r l i n e a r o r r a d i a l . As m e t a l i s removed f r o m t h e e l e c t r o l y t e ,
f r e s h s t r i p s o l u t i o n added t o t h e c e l l r e p l a c e s t h e d e p l e t e d s o l u t i o n t h r o u g h
the c i r c u l a t i o n paths provided.

The c a t h o d e i s made o f an extended s u r f a c e area c o n d u c t o r . The e x t e n d e d

surface i s required t o minimize the c u r r e n t density ( t o t a l c u r r e n t t o t o t a l
cathode s u r f a c e a r e a r a t i o ) . T h i s a i d s i n t h e t r a n s f e r o f m e t a l t o t h e s u r f a c e
o f t h e cathode. As t h e c o n c e n t r a t i o n o f t h e m e t a l s decreases, t h e e f f i c i e n c y
o f t h e c e l l a l s o decreases. T h i s i s d e m o n s t r a t e d by t h e f o r m a t i o n o f hydrogen
a t t h e cathode a t h i g h c u r r e n t d e n s i t i e s .

'The cathode can be o f v a r i o u s d e s i g n s . The m a j o r r e q u i r e m e n t s i n c l u d e :

1) h i g h s u r f a c e a r e a ; 2 ) l a r g e open a r e a f o r d e p o s i t i o n o f m e t a l s and f l o w o f
e l e c t r o l y t e ; 3) h i g h c o n d u c t i v i t y ; and 4 ) good mechanical s t r e n g t h . A t y p i c a l
c e l l uses a p l a s t i c frame w i t h a s t e e l wool p a c k i n g two t o f o u r i n c h e s t h i c k .
The c r o s s - s e c t i o n a l area o f t h e frame i s d e t e r m i n e d by t h e s o l u t i o n f l o w
through t h e electrowinning c e l l . I n a rectangular c e l l w i t h l i n e a r flow, the
cathodes a r e suspended down t h e a x i s o f t h e c e l l a l t e r n a t e l y w i t h anodes. I n
t h e o r i g i n a l Zadra c e l l w i t h r a d i a l f l o w , s t e e l woo1 was l o o s e l y wrapped
around a s t a i n l e s s s t e e l s p o o l w i t h t h e anode p l a c e d c o n c e n t r i c a l l y around t h e
cathode. C e r t a i n c e l l s may u s e a f l u i d i z e d o r a packed bed o f p a r t i c l e s as
t h e cathode.

The anode must a l s o be a c o n d u c t i v e s u r f a c e , t y p i c a l l y f l a t o r c u r v e d

m e t a l . The s u r f a c e may be p e r f o r a t e d p l a t e , s h e e t , o r screen; a1 though i t may
a l s o be an extended s u r f a c e c o n d u c t o r s i m i l a r t o t h e cathode. The anode must
be c o r r o s i o n r e s i s t a n t under t h e h i g h l y o x i d i z i n g c o n d i t i o n s i n c o n t a c t w i t h
the e l e c t r o l y t e . Stainless s t e e l i s the t y p i c a l material o f construction,
a l t h o u g h c a r b o n o r t i t a n i u m may a l s o be used. I n c e r t a i n c e l l s , t h e w a l l s o f
t h e c e l l o r t h e c o n t a i n e r may s e r v e a s t h e anode. I n a r e c t a n g u l a r c e l l , t h e
anode, a p e r f o r a t e d p l a t e o r g r i d mesh, i s suspended down t h e a x i s o f t h e c e l l
a l t e r n a t e l y w i t h t h e cathodes. Power i s t r a n s m i t t e d t o t h e e l e c t r o d e s by buss
b a r s on each s i d e o f t h e c e l l . I n t h e Zadra c e l l , t h e anode i s a c y l i n d r i c a l
s t a i n l e s s s t e e l s c r e e n p l a c e d c o n c e n t r i c a l l y o u t s i d e t h e cathode. I n f l u i d i z e d
beds, t h e anode i s o f t e n t h e e x t e r n a l w a l l s o f t h e c e l l .

The e l e c t r o l y t e , a t a s u i t a b l e t e m p e r a t u r e , e n t e r s t h e e l e c t r o w i n n i n g
c e l l a t a r e l a t i v e l y h i g h c o n c e n t r a t i o n o f p r e c i o u s m e t a l . The s t r i p s o l u t i o n
may be c i r c u l a t e d t h r o u g h a s i n g l e c e l l o r a s e r i e s o f c e l l s . The c o p p e r ,
mercury, s i l v e r , and g o l d c o n t e n t o f t h e s o l u t i o n i s d e p o s i t e d upon t h e
c a t h o d e as m e t a l s as t h e s o l u t i o n f l o w s t h r o u g h t h e c e l l . The s o l u t i o n e n t e r s
a t a c o n c e n t r a t i o n v a r y i n g f r o m 2,000 ppm t o 50 ppm i n p r e c i o u s m e t a l s . As t h e
p r e c i o u s m e t a l i s s t r i p p e d f r o m t h e c a r b o n , t h e grade o f s o l u t i o n decreases.
Once t h e c a r b o n i s s t r i p p e d t o a r e s i d u a l g o l d l e v e l o f a p p r o x i m a t e l y f i v e
o z / t o n ( 1 5 0 g/mt), t h e c a r b o n i s c o n s i d e r e d f u l l y s t r i p p e d . The l o w e r t h e
c o n c e n t r a t i o n o f m e t a l i n t h e e l e c t r o l y t e , t h e more d i f f i c u l t m e t a l removal
becomes. The e l e c t r o l y t e t e m p e r a t u r e i s n o t c r i t i c a l as l o n g as t h e s o l u t i o n
i s c o o l e d below t h e b o i l i n g p o i n t p r i o r t o p a s s i n g t h r o u g h t h e e l e c t r o w i n n i n g
cell. Where p l a s t i c s a r e used, t h e s o l u t i o n may r e q u i r e f u r t h e r c o o l i n g t o
140OF ( 6 0 ' ~ ) .
 METAL PRODUCTION I45

The o p e r a t i o n o f t h e c e l l depends upon t h e c i r c u l a t i o n r a t e , c e l l

v o l t a g e , and s o l u t i o n c o n d u c t i v i t y . The v e l o c i t y o f s o l u t i o n i n t h e c e l l
determines t h e c e l l ' s m e t a l t r a n s f e r c h a r a c t e r i s t i c s . Higher c i r c u l a t i o n r a t e s
w i t h i n t h e c e l l i n c r e a s e mass t r a n s f e r and g i v e b e t t e r m e t a l d e p o s i t s on t h e
cathode s u r f a c e . C o n d u c t i v i t y o f t h e e l e c t r o l y t e , d i s t a n c e between t h e anode
and t h e cathode, and c u r r e n t d e n s i t y d e t e r m i n e c e l l v o l t a g e .

The power r e q u i r e d f o r e l e c t r o w i n n i n g i s d e t e r m i n e d by c e l l v o l t a g e and

c u r r e n t . A p p r o x i m a t e l y 2.5 v o l t s a r e a p p l i e d between t h e anode and c a t h o d e o f
a c e l l . C u r r e n t e f f i c i e n c y w i l l approach 100 p e r c e n t a t 2,000 ppm o f g o l d and
0 p e r c e n t a t 1 ppm o f g o l d . The power r e q u i r e m e n t s a r e l o w ; however, capital
c o s t o f t h e c e l l s and t h e power s u p p l y can o f t e n b e s i g n i f i c a n t .
E l e c t r o w i n n i n g o p e r a t i n g c o s t s a r e m a i n l y o p e r a t i n g l a b o r . E l e c t r o d e s must be
s u p p o r t e d w i t h c o n d u c t i v e c o n t a c t t o t h e e l e c t r o w i n n i n g power s u p p l y .

When s u f f i c i e n t m e t a l has been d e p o s i t e d on t h e c a t h o d e , t h e c a t h o d e , a

mass o f s t e e l wool and s l u d g e , i s removed from t h e c e l l and r i n s e d and d r i e d
f o r f u r t h e r t r e a t m e n t . The s l u d g e f r o m t h e b o t t o m o f t h e c e l l i s a l s o removed
p e r i o d i c a l l y f o r treatment t o recover the precious metal .
9.3.2 Electrowinning C e l l Designs

Over t h e y e a r s , s e v e r a l e l e c t r o w i n n i n g c e l l d e s i g n s have been d e v e l o p e d

i n o r d e r t o improve t h e e f f i c i e n c y o f p r e c i o u s m e t a l s e l e c t r o w i n n i n g . These
d e s i g n s i n c l u d e d C y l i n d r i c a l Zadra c e l l , A.A.R.L. diaphram c e l l , Micron c e l l ,
and HSA ( h i g h s u r f a c e a r e a ) c a r b o n f i b e r c e l l . However, t o d a y one c e l l d e s i g n
i s a l m o s t u n i v e r s a l l y s e l e c t e d f o r new o p e r a t i o n s o f any s i z e . T h i s i s a
r e c t a n g u l a r c e l l t a n k , accorr~modat i ng mu1 t ip l e anode-cathode p a i r s suspended
v e r t i c a l l y f r o m busbars i n t o t h e e l e c t r o l y t e .

F i g u r e 9.3 shows t h e e l u t i o n a r r a n g e m e n t a t t h e C o r t e z Gold Mine,

i n c l u d i n g a c u t o u t v i e w o f t h e Zadra c e l l . F i g u r e 9.4 shows t h e " b a s k e t " t y p e
Bateman e l e c t r o w i n n i n g c e l l d e s i g n .

The anode o f t h e Zadra c y l i n d r i c a l c e l l i s a c y l i n d r i c a l s t a i n l e s s s t e e l

screen p o s i t i o n e d o u t s i d e t h e cathode h o l d e r . B o t h t h e c a t h o d e c o n t a i n e r and
t h e anode a r e p o s i t i o n e d one i n s i d e t h e o t h e r i n s i d e t h e c e l l t a n k c o n s i s t i n g
o f a c y l i n d r i c a l t a n k ( F i g u r e 9.5). Pregnant s o l u t i o n flows through the
c e n t r a l feed t u b e and t h e n f l o w s upward and o u t w a r d t h r o u g h t h e s t e e l wool.

Zadra-type c y l i n d r i c a l c e l l s have s e v e r a l d i s a d v a n t a g e s :

Solution f l o w i s unevenly d i s t r i b u t e d ;
* Electrode spacing i s large;
S t e e l wool c a t h o d e i s t h i c k and t h e r e i s a p o t e n t i a l d r o p a c r o s s
it;
Each c e l l c o n t a i n s o n l y one cathode-anode p a i r ; and
The c e l l s a r e b u l k y .
 PRECIOUS METAL HEAP LEACHING PROJECTS

H O T PREQNANT

5 STEELWOOL CATHODES

RUBBER LINED CELL

H E A T EXCHANGER

MAKEUP REA0ENT -
0.2% N r C N 1.0% N r O H

112' THICK PRESSED

RUBBER GASKET GRAPHITE ANODE
SOLUTION 9.8. CONTACT8
ANODE BUSBAR SHORTCIRCUITIN0

RUBBER I M E ROP'YLENE
OOL BA8KE

OUT

Ib, S T E E L W O O L
CATHODES

FIGURE 9.3
-

CORTEZ GOLD MINE ELUTION ARRANGEMENT

 METAL PRODUCTION

FIGURE 9.4
E.L. B A T E M A N E L E C T R O W I N N I N G CELL
 PRECIOUS METAL HEAP LEACHING PROJECTS

FIGURE 9.5 - CYLINDRICAL CELLS AT NORTH KALGOORLI MINES LTD.

914' S T E E L M E S H C A T H O D E

CATHODE
CONTACT + - PLASTIC BASKET

P L A S T I C CELL TANK

PERFORATED
IN P L A T E OR STEEL
M E S H ANODE

0 0 0 0 0 0 PLAN VIEW O F
P L A S T IC B A S K E T

0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0
0 0 0 0 0 0 0 0

Zinc P r e c i p i t a t i o n

As has been p r e v i o u s l y s t a t e d , t h e s t r i p s o l u t i o n can a l s o be t r e a t e d

w i t h powdered z i n c t o p r e c i p i t a t e t h e p r e c i o u s m e t a l s . The m e t a l s o f o t h e r
cyanide-metal s may a1 so be p r e c i p i t a t e d . These i n c l u d e copper and mercury. The
p r e c i p i t a t i o n i s s i m i l a r t o t h e ZIP process f o r h a n d l i n g t h e l e a c h l i q u o r .
Depending upon t h e volume o f s o l u t i o n t o be t r e a t e d , t h e p r o c e s s may be
performed i n a c o n t i n u o u s o r b a t c h manner. The s o l u t i o n grade i s much h i g h e r
than leach s o l u t i o n and t h e e f f i c i e n c y o f m e t a l removal can be v e r y h i g h . The
l o w p r e c i o u s metal c o n t e n t o f t h e r e c y c l e s t r i p s o l u t i o n can a i d i n t h e
stripping rate.

9.4 CARBON HANDLING AFTER S T R I P P I N G

Three o t h e r c a r b o n h a n d l i n g o p e r a t i o n s a r e a l s o p r e s e n t i n most
s t r i p p i n g c i r c u i t s - c l e a n i n g , r e g e n e r a t i o n , and s i z i n g . The o b j e c t i v e o f
these o p e r a t i o n s i s t o p r e p a r e t h e c a r b o n f o r f u r t h e r use. The c a r b o n r e q u i r e s
a h i g h s u r f a c e area, good m e c h a n i c a l s t r e n g t h , and a p o r e s i z e d i s t r i b u t i o n
which promotes t h e k i n e t j c s o f a d s o r p t i o n o f t h e c y a n i d e - m e t a l complexes. The
carbon i s s i z e d t o p r e v e n t l o s s e s u n d e r o p e r a t i n g c o n d i t i o n s .
 METAL PRODUCTION

Two t y p i c a l carbon sizes f o r a d s o r p t i o n columns a r e 6 mesh x 12 mesh and

12 mesh x 30 mesh. The smaller t h e s i z e , t h e cheaper t h e carbon and f a s t e r t h e
a d s o r p t i o n r a t e . Small s i z e a l s o r e s u l t s i n l a r g e r carbon usages and l o s s e s .

During carbon c l e a n i n g , mud and m i n e r a l d e p o s i t s a r e removed f r o m t h e

carbon. Carbon may be cleaned e i t h e r b e f o r e o r a f t e r t h e s t r i p p i n g o p e r a t i o n .
Mud and mineral d e p o s i t s are removed by f i r s t r i n s i n g w i t h w a t e r t o remove
cyanide and then t r e a t i n g w i t h h o t a c i d s o l u t i o n ( 1 t o 3 p e r c e n t h y d r o c h l o r i c
o r n i t r i c a c i d s s o l u t i o n s ) . T$e a c i d t r e a t m e n t may be conducted a t e l e v a t e d
temperatures up t o 1 9 0 ' ~ (88 C ) . This i s a dangerous o p e r a t i o n and must be
performed under s t r i c t c o n t r o l s w i t h t r a i n e d o p e r a t o r s . The m i n e r a l de o s i t s
a r e o f t e n c a l c i u m compounds ( i .e., c a l c i u m carbonate o r c a l c i u m s u l f a t e
a c i d must be compatible w i t h d i s s o l u t i o n o f t h e s e d e p o s i t s . Hydrochloric acid
The !.
o r n i t r i c a c i d a r e common choices. Organic a c i d s should be a v o i d e d , due t o
t h e i r e f f e c t upon carbon a c t i v i t y .

A f t e r t h e carbon has been s t r i p p e d o f m e t a l s and cdeaned o f # i n e r a 1

d e p o s i t s , i t can be r e a c t i v a t e d i n a k i l n a t 1,100 t o 1,470 F (600-800 C) f o r
15 t o 20 minutes under a n e u t r a l o r s l i g h t l y o x i d i z i n g atmosphere c o n t a i n i n g
water vapor t o r e s t o r e t h e a c t i v e s i t e s . High carbon l o s s e s may o c c u r i n t h e
k i l n and heat requirements a r e high. The c a p i t a l investment i s a l s o h i g h .
Both conventional h o r i z o n t a l furnaces and v e r t i c a l furnaces can be used.
Carbon e x i t i n g a t t h e f u r n a c e ' s o p e r a t i n g temperature must be c o o l e d t o
p r e v e n t i t s o x i d a t i o n . Carbon can be quenched o r s l o w l y cooled i n an i n e r t
atmosphere. To reduce t h e heat d u t y o f t h e furnace, cat-bon should be d r i e d t o
reduce water c o n t e n t p r i o r t o r e g e n e r a t i o n .

9.5 SMELTING

Smelting o f products from e i t h e r t h e M e r r i l l - C r o w e o p e r a t i o n o r t h e

e l e c t r o w i n n i n g o p e r a t i o n i s t h e f i n a l s t e p i n dore p r o d u c t i o n . The f l u x and
equipment s e l e c t i o n may s i g n i f i c a n t l y a f f e c t t h e e f f i c i e n c y o f t h i s o p e r a t i o n .
Sludge t o be smelted can c o n t a i n s i g n i f i c a n t q u a n t i t i e s o f p r e c i o u s m e t a l s , as
w e l l as v a r i o u s contaminants. These contaminants may i n c l u d e copper, l e a d ,
mercury, cadmium, and o t h e r metals. I n a d d i t i o n , t h e sludge w i l l a l s o c o n t a i n
s i l i c a , gypsum, c a l c i t e , and o t h e r components o f t h e heap.

9.5.1 Merrill-Crowe Precipitates

Zinc p r e c i p i t a t e s a r e produced by t h e M e r r i l l -Crowe process f o r p r e c i o u s

metal recovery. The z i n c p r e c i p i t a t e s c o n t a i n u p t o 75 p e r c e n t p r e c i o u s m e t a l .
Two methods o f r e f i n i n g these p r e c i p i t a t e s a r e p o s s i b l e . The p r i n c i p a l method
o f treatment i s by s m e l t i n g f l u x e d precipitates, either d i r e c t l y o r after
a c i d treatment. The second method i s t h r o u g h chemical r e f 1 n i ng methods
r e s u l t i n g i n a h i g h - p u r i t y g o l d w i t h o u t use o f pyrometal l u r g i c a l methods.

Precious metal i s c o n c e n t r a t e d f r o m the heap l e a c h s o l u t i o n by

cementation u s i n g z i n c p r e c i p i t a t i o n . These p r e c i p i t a t e s c o n t a i n a l l l e a c h
s o l u t i o n metals present above z i n c i n t h e e l e c t r o m o t i v e chemical s e r i e s ( i . e . ,
copper, lead, mercury, cadmium, gold, and s i l v e r ) . The p r e c i p i t a t e s a1 so
c o n t a i n any excess z i n c o r f i l t e r a i d added t o t h e process t o a i d i n r e c o v e r y
o f t h e p r e c i p i t a t e s . The f i r s t p r e c i p i t a t e s produced a f t e r s t a r t - u p w i l l be
much lower grade than those e v e n t u a l l y produced. Grades as low as 1,500 o z o f
150 PRECIOUS METAL HEAP LEACHING PROJECTS

p r e c i o u s m e t a l per t o n ( 5 1 kg/mt) o f p r e c i p i t a t e s a r e p o s s i b l e d u r i n g s t a r t -
up. As t h e o p e r a t o r s g a i n e x p e r i e n c e , p r e c i p i t a t e s grades s h o u l d a v e r a g e 6,000
o z / t o n ( 2 0 0 k g / m t ) where f i l t e r a i d i s added t o promote f i l t r a t i o n and 12,000
t o 20,000 o z / t o n ( 4 0 0 t o 700 k g / m t ) where no f i l t e r a i d i s added. Converting
t h i s m a t e r i a l t o p r e c i o u s m e t a l d o r e g i v e s t h e o p e r a t o r more c o n t r o l o v e r t h e
c o s t s , i n v e n t o r y , and c u s t o m e r . I f t h e p r e c i p i t a t e i s n o t converted t o dore,
t h e c o s t s i n c l u d e reduced s a l e s p r i c e s , l o s s o f i n t e r e s t w h i l e a w a i t i n g a s s a y
r e s u l t s , a s s a y c h a r g e s , c o s t s o f p a c k i n a , t r a n s p o r t a t i o n , and i n s u r a n c e , and
t h e r e f i n e r ' s f e e s and p r o f i t s .

P r e t r e a t m e n t . P r e c i p i t a t e s may be t r e a t e d t o remove base m e t a l s and

r e s i d u a l z i n c . The p r e c i p i t a t e s a r e f i r s t washed t o remove r e s i d u a l c y a n i d e
c o n t e n t , t h e n mixed w i t h s u l f u r i c a c i d w h i l e b e i n g aereated. This dissolves
t h e e x c e s s z i n c and t h e o t h e r b a s e m e t a l s s u c h as c o p p e r and cadmium. Lead and
m e r c u r y w i l l t e n d t o r e m a i n w i t h t h e p r e c i p i t a t e s . The p r e c i p i t a t e s a r e washed
a g a i n and d r i e d . I f p r e c i p i t a t e s c o n t a i n s i g n i f i c a n t m e r c u j y , t h e d r i e d
p r e c i p i t a t e s may be r e t o r t e d i n a m e r c u r y r e t o r t a t 7 5 0 ' ~ (400 C) f o r s e v e r a l
h o u r s t o d r i v e o f f t h e m e r c u r y i n t o a w a t e r c o o l e d condenser. M e r c u r y i s
c o l l e c t e d u n d e r w a t e r t o p r e v e n t t h e escape o f m e r c u r y vapor. The p r e c i p i t a t e s
a r e t h e n r e a d y f o r smel ti n g .
Flux Selection. Zinc p r e c i p i t a t e s are d r i e d p r i o r t o mixing w i t h the
f l u x e s . The f l u x e s a r e c a l c u l a t e d based upon t h e a n a l y s i s o f t h e p r e c i p i t a t e s .
An a n a l y s i s o f s e v e r a l c o n s t i t u e n t s ( m o i s t u r e , s i l i c a , z i n c , s i l v e r , and g o l d )
i s necessary. The f l u x must o x i d i z e m e t a l l i c z i n c and o t h e r base m e t a l s and
f o r m a b o r o s i l i c a t e g l a s s s l a g . N i t e r r e q u i r e m e n t i s based on z i n c c o n t e n t and
t h e s l a g i s n e x t b a l a n c e d between a c i d c o n t e n t and base c o n t e n t . The a c i d
c o n t e n t i s based on t h e s i l i c a c o n t e n t , w h i l e t h e base c o n t e n t i s based o n t h e
z i n c , base m e t a l , and n i t e r c o n t e n t . The b a l a n c e i s made by a d d i n g s u f f i c i e n t
s i l i c a . B o r a x i s added t o make a b o r o s i l i c a t e g l a s s o f b o t h s i l i c a p r e s e n t i n
t h e p r e c i p i t a t e s and s i l i c a added. F e l d s p a r i s added as a v i s c o s i t y m o d i f i e r
(approximately t h r e e percent o f t h e charge).

Furnace O p e r a t i o n . The f u r n a c e i s o p e r a t e d i n a c o n t i n u o u s mode. Once

h o t , t h e f u r n a c e m e l t s p r e c i p i t a t e s f o r s e v e r a l h o u r s . The p r e c i p i t a t e s and
f l u x e s a r e w e l l mixed i n b a t c h e s w h i c h a r e g r a d u a l l y f e d t o t h e f u r n a c e . The
f u r n a c e , e i t h e r gas f i r e d o r i n d u c t i o n , i s f i l l e g w i t h t h e o m i x t u r e and h e a t e d
t o o p e r a t i n g t e m p e r a t u r e - a p p r o x i m a t e l y 2,100 F (1,150 C). As t h e f i r s t
c h a r g e m e l t s , a d d i t i o n a l m a t e r i a l i s added and m e l t e d u n t i l t h e f u r n a c e i s
full. A p p r o x i m a t e l y h a l f o f t h e f u r n a c e i s e m p t i e d o f s l a g and t h e f i l l - u p
c y c l e i s repeated. This continues u n t i l t h e furnace i s e i t h e r one-third f u l l
o f p r e c i o u s m e t a l , a l l o f t h e p r e c i p i t a t e s have been m e l t e d , o r t h e f u r n a c e i s
t o be s h u t down. The s l a g above t h e d o r e i s poured and a b o t t o m p o u r i s t h e n
made w h i c h c o n t a i n s t h e b o t t o m h a l f o f t h e r e m a - i n i n g s l a g and t h e d o r e . W i t h
each s l a g p o u r , t h e b o t t o m o f t h e s l a g must be checked f o r a d o r e b u t t o n t o
assure t h a t t h e metal i s n o t poured from t h e furnace. I f t h e s l a g i s v e r y
v i s c o u s , c o m p o s i t i o n o f t h e m i x t u r e o r f u r n a c e t e m p e r a t u r e must be a d j u s t e d t o
reduce v i s c o s i t y . A low v i s c o s i t y i s r e q u i r e d t o prevent metal l o s s e s t o t h e
s l a g . The s l a g may be saved f o r f u r t h e r p r o c e s s i n g .
 METAL PRODUCTION

9.5.2 E l e c t r o w i n n i n g Cathodes and Sludge

Steel wool cathodes f r o m e l e c t r o w i n n i n g a r e p r o d u c t s o f carbon

a d s o r p t i o n / e l e c t r o w i n n i n g o p e r a t i o n s . The p r e c i o u s m e t a l - b e a r i n g s t e e l wool
cathodes and sluclge from t h e b o t t o m o f e l e c t r o w i n n i n g c e l l s c o n t a i n up t o 50
percent p r e c i o u s metal. Two methods o f r e f i n i n g these p r o d u c t s a r e p o s s i b l e ,
as w i t h p r e c i p i t a t e s from z i n c p r e c i p i t a t i o n . The p r i n c i p a l method o f
treatment i s again d i r e c t s m e l t i n g ; however, f l u x i n g r e q u i r e m e n t s a r e g r e a t l y
d i f f e r e n t . S t e e l wool cathodes may a l s o be a c i d t r e a t e d p r i o r t o s m e l t i n g .
The a l t e r n a t i v e i s again t h e u s e o f chemical r e f i n i n g t o produce a h i g h - p u r i t y
gold.

As p r e v i o u s l y i n d i c a t e d , t h e d i s s o l v e d p r e c i o u s metal i s t r a n s f e r r e d
from t h e heap l e a c h s o l u t i o n t o s t e e l wool cathodes. These cathodes c o n t a i n up
t o 100 oz o f g o l d per 1b (1.4 kg o f g o l d p e r k g ) o f s t e e l wool. Converting
t h i s m a t e r i a l t o r e f i n e d g o l d w i l l reduce t h e o p e r a t i n g c o s t s b u t w i l l
increase c a p i t a l investment as a s m a l l f u r n a c e i s r e q u i r e d . The p r e c i o u s metal
c o n t e n t i s t r a n s f e r r e d i n t o a dore. The d o r e can be e i t h e r s o l d o r r e f i n e d
further.

Pretreatment. The p r e t r e a t m e n t o f s t e e l wool cathodes and e l e c t r o w i n n i n g

sludge i s s i m i l a r t o t h e t r e a t m e n t o f z i n c p r e c i p i t a t e s . The cathodes a r e
t r e a t e d w i t h s u l f u r i c a c i d t o remove base m e t a l s and r e s i d u a l i r o n . This
d i s s o l v e s excess i r o n and t h e o t h e r base m e t a l s such as copper. Lead and
mercury w i l l remain. The r e s i d u e i s washed and d r i e d . I f t h e r e s i d u e c o n t a i n s
s i g n i f i c a n t mercury, t h e d r i e d cathodes may be r e t o r t e d . The cathodes a r e t h e n
ready f o r smel t i ng .
Flux S e l e c t i o n . The d r i e d cathode and s l u d g e r e s i d u e o r t h e p r e t r e a t e d
r e s i d u e a r e mixed w i t h t h e p r o p e r f l u x e s and smelted. The f l u x e s a r e
c a l c u l a t e d based upon an a n a l y s i s o f t h e cathode and sludge m i x t u r e . The
f o l l o w i n g must be analyzed: m o i s t u r e , s i l i c a , i r o n , s i l v e r , and g o l d . The
a d d i t i o n o f t h e o x i d i z e r , n i t e r , i s based upon t h e base m e t a l c o n t e n t . S i l i c a
i s added t o balance t h e a c i d - b a s e c o n t e n t o f t h e s l a g . Sodium b o r a t e i s a l s o
added t o form a b o r o s i l i c a t e g l a s s s l a g . Feldspar i s added as a v i s c o s i t y
m o d i f i e r . The charge i s w e l l mixed.

Furnace Operation. Furnace o p e r a t i o n w i t h cathode m a t e r i a l i s s i m i l a r t o

t h a t w i t h z i n c p r e c i p i t a t e s . The major d i f f e r e n c e i s i n t h e h i g h e r y i e l d o f
precious metal due t o the h i g h e r grade o f p r e c i p i t a t e s . The furnace i s f i l l e d
w i t h t h e m i x t u r e and heated t o o p e r a t i n g feed. As t h e charge me1 t s , a d d i t i o n a l
m a t e r i a l i s added t o t h e f u r n a c e and m e l t e d u n t i l t h e f u r n a c e i s f u l l . Ift h e
feed m a t e r i a l grade i s h i g h , t h e f u r n a c e w i l l c o n t a i n s u f f i c i e n t d o r e f o r a
pour. Low-grade feed w i l l r e q u i r e s e v e r a l s l a g pours t o accumulate s u f f i c i e n t
metal f o r a pour o f dore. The s l a g may be saved f o r f u r t h e r p r o c e s s i n g .

9.6 REFERENCES

Heinen, H.J., D.G. Peterson and R.E. L i n d s t r o m (1976). Gold d e s o r p t i o n f o r

a c t i v a t e d carbon w i t h a l k a l i n e a l c o h o l s o l u t i o n s , fi World m i n i n g and
metals technology, ed. A. Weiss (Chapter 3 3 ) . AIME, N.Y., pp. 551-563.