NAME : THANDEKA NCUBE

STUDENT NUMBER : N0183156F

FACULTY : INDUSTRIAL TECHNOLOGY

PROGRAMME : CHEMICAL ENGINEERING

COURSE CODE : SMA 2217

COURSE NAME : ENGINEERING MATHEMATICS

ASSIGNMENT : MINI PROJECT

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TABLE OF CONTENTS
1.0 INTRODUCTION .................................................................................................................................. 3
2.0 AIM ......................................................................................................................................................... 4
3.0 OBJECTIVES ......................................................................................................................................... 4
4.0 PROBLEM STATEMENT ..................................................................................................................... 4
5.0 SIGNIFICANCE OF STUDY ................................................................................................................ 4
6.0 METHOD ............................................................................................................................................... 5
7.0 RESULTS ............................................................................................................................................... 8
8.0 CONCLUSION ....................................................................................................................................... 9
9.0 REFERENCES ....................................................................................................................................... 9

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1.0 INTRODUCTION

The present trend in the processing of minerals is the processing of low grade ore and the high
grade ones become exhausted. The effective liberation of values from these low grade ores
remains one of the major challenge for mineral processor, hence an interesting area of research.
The depletion of high grade ore reserves has resulted in the increase of prices for this metal
mainly due to high operational costs encountered in processing the available low grade reserves.
The feasibility challenges in the gold sector, offers incentive for researchers to propose efficient
techniques that can be used to commercially recover as much of the gold as possible. Gold is
obtained from its ore by several operations of which one of them is leaching. Leaching is a
separation process whereby we utilize a solvent to recover a valuable solid solute substance. It
occurs when a liquid solvent is passed through a solid producing the illusion of a solute in that
solid. Sodium cyanide (NaCN) is the solvent utilized. Size reduction of the gold particles plays a
significant role in the rate of leaching. Moreover handling of smaller size particles is much easier
as compared to that of bigger particles. One of the primary reasons for milling material down to
smaller particle size is to unlock the value material in the host matrix. Once the material is small
enough, and the value material has been liberated, a downstream process such as leaching is then
used to recover the unit operation. Therefore it must be understood that milling products should
be tailored to satisfy leaching requirements. Thus milling must be studied for the determination
of the trade-off between itself and leaching. Two size reduction techniques are to be used, dry
milling and wet milling.

Wet milling is an important unit operator for size reduction in the mining industries. It is a
process in which feed material is steeped in a liquid by shearing, crushing or attrition to soften
the material and aid in the separation process. It reduces a material into fine particles. A mill is
charged with media and activated by a high speed agitator shaft to separate the individual
particles. When the agitator rotates it transmits kinetic energy to the media. When the material is
pumped in through the mill, this energy acts on the solid suspended in a liquid to tear them apart
or crush them, reducing their particle size to 70μm.

Dry milling is also important in size reduction in the mining industries. It is described as a
process whereby large material is ground, without the addition of a liquid, into extremely fine
powders. During the dry milling process, the collision between the tiny rigid balls in a concealed
container will generate localized high pressure. Usually, ceramic, flint pebbles and stainless steel
are used. Dry milling reduces the particles to a particle size of 100μm.

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2.0 AIM
The aim of the project is to recover as much gold as possible from leaching at a lower cost of
production.

3.0 OBJECTIVES
This project entails a vital investigation on the effect of particle size to the leaching rate and the
amount of yield or mineral recovered over a specific time interval. This is carried out by
comparing the particle sizes from the two above stated processes of size reduction, that is, wet
milling and dry milling. The range of the average particle size recovering most gold will be
determined from the 95% confidence interval.

4.0 PROBLEM STATEMENT

A process engineer is interested in recovering as much gold as possible from a leaching process
after his material size particle was reduced by two different methods, dry milling and wet
milling. The average particle size produced by each method is 100μm and 70μm respectively. He
is to carry out leaching after size reduction has been carried out with either of the methods. From
experience, the maximum amount of yield produced is 46.14% gold per hour. A sample of 20
experiments producing the maximum yield at certain average particle size is selected and the
average particle sizes recorded below. Determine the 95% confidence interval of the average
particle size producing the maximum yield of Gold recovery.

123.45, 98.7, 56.98, 67.56, 45.67, 69.90, 54.65, 45.7, 78.60, 75.00, 67.56, 79.69, 56.45, 99.6,
72.78, 83.70, 45.61, 67.67, 100.00, 89.45

5.0 SIGNIFICANCE OF STUDY

Ensuring that more gold is recovered from a small sample of its ore is the most important aspect
of the investigation. This is because gold is the most valuable mineral as it has several functions
that benefit the whole world, such as alloying, jewellery manufacturing and ornament making,
financial use as money or a medium of exchange. Ensuring that more of it is obtained from a
small ore sample at the lowest cost of production means that more funds are to be directed in
ensuring a more effective leaching process. The implementation of a milling operation with the
least operation cost therefore ensures that the production rate of gold is increased to meet up with
the demands and also results in a reduction in labor and energy costs as less energy would then
be required to operate the milling machines and hence significant for sustainable commercial
use.

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6.0 METHOD
After the ore has been obtained from the mine it is then channeled milling sector where either
dry milling or wet milling is carried out to grind the ore and reduce the particle sizes. It is then
taken into a sieve for screening of particle size. The smallest particle size obtained is taken and
the remaining material is rechanneled to the mill for further grinding. In this case of the project
equal amounts of 400g are to be ground in the two above mentioned processes and their average
particle size recorded.

Dry milling

Dry milling is a process whereby large particles are ground into smaller particles without
addition of a liquid. 400g of feed was charged into the ball mill along with 10 balls and the
machine was allowed to run for 5 minutes. After 5 minutes the material was removed and
screened and the largest particle size obtained was recorded to be 100μm.

Wet milling

Wet milling is process whereby large particles are ground into small particles with addition of a
liquid. In this case water is the liquid that was used. 400g of feed was charged into the ball mill
along with 10 balls and 2 litres of water was added. The machine was allowed to run for 5
minutes. After 5 minutes the material was removed and screened and the largest particle size
obtained was recorded to be 70μm.

A confidence interval test was then carried out to test at 95% confidence interval for the best
method to use to ground the ore as a way to produce more gold recovery. This test was carried
out by use of particle sizes collected from different mining sectors that claimed that those were
the particles sizes that yield the maximum percentage of gold recovery. The sample number, n is
less than 30 hence a t- distribution confidence interval is to be used.

From the sample data given, the standard deviation the mean was calculated;

Let x be the particle size giving out the maximum yield of gold recovery.

∑
Mean,X =

.
=

=73.936μm

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 ∑( )^
Standard deviation, s =

= 20.897μm

For the dry milling particles,

H0: μ=100

H1: μ<100

For a t- test

X – t(α/2)( ) < μ < X + t(α/2)( )

√ √

At 95% confidence interval, t(α/2) = 2.26

. .
73.936 – 2.26( ) < μ < 73.936 + 2.26( )
√ √

63.376 < μ < 84.496

H0 is not within the range therefore we reject H0 and conclude that there is no evidence to prove
that the maximum amount of gold recovery can be obtained at particles of 100μm.

For the wet milling particles,

H0: μ=70

H1: μ<70

For a t- test

X – t(α/2)( ) < μ < X + t(α/2)( )

√ √

At 95% confidence interval, t(α/2) = 2.26

. .
73.936 – 2.26( ) < μ < 73.936 + 2.26( )
√ √

63.376 < μ < 84.496

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H0 lies within the range therefore we fail to reject H0 and conclude that there is enough evidence
to prove that the maximum amount of gold recovery can be obtained at particles of 70μm.

Leaching

After testing for the milling process that gives a particle size in the range that produces
maximum yield of gold recovery, the particles collected were then taken to carry out a down-
stream process known as leaching. Leaching refers to a separation process whereby we utilize a
solvent to recover a valuable solid solute substance. It occurs when a liquid solvent is passed
through a solid producing the illusion of a solute in that solid. The particles where then taken into
a leaching column and charged along with 5 cubic meters of sodium cyanide (leaching solvent
and combined with oxygen in a process known as carbon-in-pulp. As the oxygen and cyanide
react chemically, gold in the pulp dissolves. The leaching process was allowed to run for a period
of 1 hour. The leached solution was then collected and gold was then extracted through a process
known as electro-winning. The solution was poured into a container known as a cell. Positive
and negative terminals in the cell then delivered a strong electric current to the solution and then
electrolysis took place with gold collecting at the negative terminal, the anode. The gold was
taken and weighed and its weight percent was recorded to be 57.6% of gold recovery. The
leaching process is illustrated in the chart below:

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7.0 RESULTS
Based from the results obtained after the experiment was conducted, more gold is recovered at
particle sizes in the range 63.376 < μ < 84.496μm. After leaching was carried out at 70μm
particle size of gold ore, 57.6% of gold was recovered. This therefore shows that at as we reduce
the particle we increase the surface area and increase the accessibility of the gold portion in the
host matrix and this generally increases the rate of leaching and at the end more of the gold is
recovered over a short time interval. When the leaching process is carried out at particle size
greater than 84.496μm the rate of leaching is reduced and the amount of gold recovered is also
reduced. This is due to the reduction in the surface area and the further the mineral is in the host
matrix hence reducing accessibility and generally lowering the rate of leaching. After the
confidence interval test was carried out it can be seen that only particle within the range can
produce maximum gold recovery, taking note that as we reduce the particle size to lesser than
63.376μm, the leaching process rate is also reduced. This is due to the fact that finer particles
have got less void space to allow penetration of the solvent to the base of the leaching column
thereby reducing the effectiveness of the leaching process as the solvent will then take more time
trying to penetrate to leach the contents at the base than just focusing on the leaching process
itself. The aim of the investigation was to recover as much gold as possible at a lesser operational
cost, and as seen from the investigation, wet milling uses water and there is little or no escape of
gases and the mineral as dust particles hence no other alternative means of trapping the escaping
mineral required hence less cost of production. Also the cost of installing dust trappers and more
pipes to channel the dust particles into the leaching column is reduced and the amount of solvent
used to leach a certain amount of gold is less compared to that of the dry milling particles hence
saves on solvent costs. Addition of water to the ore for milling ensures its softness and the lesser
the energy required to perform the operation. The power required in a ball mill in which the
given material is being wet ground is 30% less than that of a similar mill dry grinding, thus, less
cost of energy production. Furthermore, the wet milling process results in an increase in the
replacement of ball mills period due to the fact that the softer the material the lesser the collision
impact of the balls and the reduced damage to them hence can be used for quite an extended
period before being replaced hence reduced labor.

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8.0 CONCLUSION
Particle size showed noteworthy effect into the dissolution of gold, the optimum values that gave
a maximum gold recovery where in the range 63.376μm to 84.496μm. Therefore, wet milling
was the best chosen method of grind as it reduces the cost of production at the same time
producing maximum gold recovery. The efforts now should then be directed at ensuring that
particles are ground to particle sizes in the above stated range to produce maximum gold
recovery and this can be carried out by use of different ball mills after careful consideration of
the strength of the ore. The coarser the feed material is, the larger and denser the grinding media
should be. This is because the greater media generates a greater impact force therefore increasing
the rate at which fines are produced and generally increasing the yield of recovered Gold.

9.0 REFERENCES
Gareth JamesDanielaWitten, Trevor Hastie, Robert Tibshirani an introduction to statistical
learning．2013．

J CrawshawJChambers a concise course in advanced level statistics．2001．

optimisation of the leaching parameters of a gold ore in sodium cyanide solution

Dr N HlabanganaNonhlanhlaMguni ,Gwiranai Danha, Siboniwe Bhebhemarch 2018．

undertanding mineral liberation during crushing ． LeonLGuldrisfebruary 2020．