UNIVERSITY OF DAR ES SALAAM

DEPARTMENT OF MINING AND MINERAL

PROCESSING ENGINEERING
PRACTICAL TRAINING REPORT (PT1)
NAME OF STUDENT: BRIGHTON YOHANA
REGISTRATION No: 2021-02-00406
PROGRAMME: METALLURGY AND MINERAL
PROCESSING
ACADEMIC YEAR: 2021/2022
YEAR OF STUDY: 1st year
COMPANY NAME: STAMIGOLD BIHARAMULO MINE.
SITE SUPERVISOR: Eng. FRANCK CHARLES
PIT SUPERVISOR: Eng. KYALUZI
DURATION: 18/07/2022 TO 09/09/2022
Site supervisor signature
……………………………………………….
ACKNOWLEDGEMENT
First of all, I want to thank the almighty GOD, who powered and enriched me during all the time
in my practical industrial training.

I honestly wish to acknowledge STAMIGOLD BIHARAMULO MIN (SBM) for offering me a

room to do my Industrial Practical Training (IPT 1) for the academic year 2021/2022. Special
thanks to our hosts, the training department, Mr Mwalusambo and Mr Donald

Likewise, I highly acknowledge the school mine under the supervision of practical training
coordinator Mr: Brushi for allocating me a practical training area and my family, especially my
parents, for supporting me during my practical industrial training.

I wish to extend thanks to the process plant management Eng:kutika (plant manager), kyaluzi, as
a Metallurgist who leads me throughout my valuable training time at stamigold biharamulo mine.

Moreover, I also acknowledge the contribution of the community of SBM (especially process
plant operators), my fellow students at UDSM, and the Metallurgists whom we were with during
Practical Training for their cooperation and encouraging ideas that helped me in doing my
practical industrial training successful.

To all those who might have assisted me but do not appear, I appreciate their morals and any
other support given to me.

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ABSTRACT
This Industrial Practical Training (IPT) done at stamigold biharamulo mine is divided into major
three categories as follows;

The first category composes the weekly report explaining all those activities done each day for a
week with the main job explained in detail.

The second category composes the process description; this explains the flow of material
received from underground and open pits through all the processing stages, where Gold is
obtained at last. Processes include crushing, grinding, leaching, and elusion.

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 Table of Contents
ACKNOWLEDGEMENT................................................................................................................i
ABSTRACT....................................................................................................................................ii
ABBREVIATIONS........................................................................................................................vi
PART ONE......................................................................................................................................1
WEEKLY REPORTS......................................................................................................................1
PART TWO.....................................................................................................................................2
MAIN REPORT..............................................................................................................................2
CHAPTER ONE..............................................................................................................................3
1.0 INTRODUCTION.....................................................................................................................3
1.1 HISTORICAL BACKGROUND...........................................................................................3
1.2 SAFETY ISSUES..................................................................................................................4
1.3. INCIDENCE REPORT.........................................................................................................5
1.4 GEOGRAPHICAL LOCATION...........................................................................................5
1.5 REGIONAL GEOLOGY AT SBM.......................................................................................6
CHAPTER TWO.............................................................................................................................7
2.0 COMMINUTION......................................................................................................................7
2.1 Crushing.................................................................................................................................7
2.1.1 Apron feeder....................................................................................................................8
2.1.2 Primary crusher...............................................................................................................8
2.2 Pebble crusher........................................................................................................................9
2.3 Conveyor..............................................................................................................................11
2.3.1Conveyor belt components:............................................................................................11
2.4 Grinding circuit....................................................................................................................12
2.4.1SAG mill.........................................................................................................................13
2.5 Classification........................................................................................................................13
2.5.1 Hydro cyclone...............................................................................................................13
2.5.2 Cyclone cluster..............................................................................................................15
2.5.3 Factors Affecting Cyclone Performance.......................................................................16
2.5 Gravity concentration circuit...............................................................................................17

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 2.5.1 Knelson concentrator.....................................................................................................17
2.6 ACACIA reactor...............................................................................................................19
CHAPTER THREE.......................................................................................................................23
3.1 CIL CIRCUIT......................................................................................................................23
3.1.1 Leaching........................................................................................................................24
3.2 Carbon adsorption................................................................................................................26
3.2.1 Factors affecting adsorption..........................................................................................26
3.3 Stamigold CIL Circuit equipment........................................................................................27
CHAPTER FOUR.........................................................................................................................31
4.0 Thickener.................................................................................................................................31
CHAPTER FIVE...........................................................................................................................34
5.1 ELUTION CIRCUIT...............................................................................................................34
5.1.1 Acid Washing................................................................................................................35
5.2 Strip solution heater circuit..................................................................................................36
5.2.1 Elution column..............................................................................................................36
5.3 Spiral concentrator...............................................................................................................40
5.4 Carbon regeneration.............................................................................................................40
5.4.1 Carbon Fouling..............................................................................................................40
5.4.2 Regeneration kiln..........................................................................................................41
4.5 Electrowinning.....................................................................................................................43
5.5.1 Electrolysis of a gold solution.......................................................................................43
5.5.2 Calcination.....................................................................................................................45
5.5.3 Smelting.........................................................................................................................45
CHAPTER SIX..............................................................................................................................46
6.2 Tailings storage facility........................................................................................................46
CHAPTER SEVEN.......................................................................................................................47
7.0 Fire assay..............................................................................................................................47
7.1.1 Objective of Fire Assaying............................................................................................47
7.2 Fire Assay Procedures..........................................................................................................47
References.....................................................................................................................................50

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v
List of figures
Figure 1: Safety PPE........................................................................................................................5
Figure 2: Stamigold location...........................................................................................................6
Figure 3: Jaw crusher schematics....................................................................................................9
Figure 4: Section view of pebble crusher......................................................................................10
Figure 5:cross-section view of the cyclone...................................................................................15
Figure 6: cross-sectional view of the knelson concentrator...........................................................19
Figure 7: Acacia reactor.................................................................................................................20
Figure 8: Trash screen...................................................................................................................29
Figure 9: TAC cyanide analyzer....................................................................................................30
Figure 10: The cross-section showing parts of thickener..............................................................31
Figure 11: SBM thickener.............................................................................................................32
Figure 12: Elution column showing its parts.................................................................................37
Figure 13:Quench tank at SBM.....................................................................................................42
Figure 14: Crucible........................................................................................................................48
Figure 15:Fire furnace...................................................................................................................48
Figure 16: mould............................................................................................................................49
Figure 17: After separation of slug and lead botton......................................................................49

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ABBREVIATIONS
A – Ampere

Au – Gold

CIL – Carbon in leach

CV – Conveyor belt

GC – Gravity concentrator

HCN – Hydrogen cyanide gas

IPT – Industrial practical training

kPa – Kilopascal

kW – Kilowatt

L/h – Litre per hour

Min – Minute

Mm – millimetre

m3/h – meter cubic per hour

NaCN – Sodium cyanide

SBM– STAMIGOLD BIHARAMULO MINE

P50– Fifty per cent passing

pH – Potential of hydrogen

ppm – Parts per million

ROM – Run of mine

SAG – Semi autogenous

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SC – Screen

SG – Specific gravity

TSF – Tailings storage facility

viii
 PART ONE

WEEKLY REPORTS.

1
 PART TWO

MAIN REPORT.

2
 CHAPTER ONE

1.0 INTRODUCTION
1.1 HISTORICAL BACKGROUND
Biharamulo Gold mine, formally known as Tulawaka Gold mine, is currently operated by
STAMIGOLD Company Limited as a subsidiary of The State Mining Corporation (STAMICO).
It is located 160km southwest of Mwanza in the western part of the Lake Victoria Goldfield, in
Biharamulo District, Kagera Region.STAMIGOLD was incorporated on 28th October 2013 and
mandated to engage in prospecting, exploration, development, production, and processing of
gold and market gold within the country and foreign markets.

Initially, the mine was known as Tulawaka Gold Mine and was owned by African Barrick Gold
(ABG). However, due to the gradual decrease of reserves, ABG ceased its operation in 2013 and
transferred ownership of the mine and its surrounding exploration licences to STAMICO so that
the Corporation could operate profitably on a medium scale for not less than two years. The
Tulawaka Gold Mine was initially developed as an open-pit operation in 2005, whereby the East
Zone deposit was mined, and it was converted to an underground mine operation in 2008. As a
result of the reserve decrease and high operating costs, its operation ended by ABG in 2013.

STAMIGOLD Company Limited is a growing gold company with having estimated resource of
more than 200,000 troy ounces. The main ore body is located in the western zone and Moja Moja
area s, with potential for near-plant mining around the mineralized Eastern Zone. Adjacent to the
special mining licence, there are a number of highly prospective grounds owned by
STAMOGOLD Company Limited through a number of Prospecting Licences (PLs). Based on
the available resources, STAMIGOLD Company Limited is expected to be operational for at
least three years. This life of mine is expected to increase as more exploratory work is conducted
in the area.

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1.2 SAFETY ISSUES
Mine managers and individual miners need to adhere strictly to operational safety procedures.
Employers need to provide the right tools and training to every employee to protect the life,
health and safety of the workforce, as well as to protect valuable worksites and assets. As leading
mining organizations already know, creating a safe working environment means a more
productive and profitable mining operation. It also leads to higher levels of worker morale and
job satisfaction, which in turn improves employee retention.
Taking a holistic view toward improving worker safety education and safe work practices is a
sound business investment that pays dividends for long-term success. General mine induction at
SBM was done to familiarize students with the mine environment so that they will be working in
a safe way while they are at the field site. This is done to create greater awareness of risk in the
workplace and goes a long way to preventing fatalities. Also, make sure everyone wears PPE
during working time at the site.

The PPE that all staff who was conducting fieldwork at SBM were provided with;

1. Long sleeve shirt and long pants

2. Safety boots
3. Hard hat
4. Respirator
5. Safety glasses
6. Gloves

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 Figure 1: Safety PPE

1.3. INCIDENCE REPORT

All workers were required to complete a safety environmental incident hazard report form
immediately after a safety/healthy incident, or an impact on the environment occurs. If the safety
environmental incident hazard report cannot be completed immediately, the report must be
completed within 24 hrs.

1.4 GEOGRAPHICAL LOCATION

The STAMIGOLD mine property is situated approximately 160km southwest of Mwanza in the
Lake Victoria Goldfields District. The property lies between latitudes approximately 3°12'5.17"
S 31°32'22.54" E in the Global Positioning System (GPS). The main tarmac road from the
railhead at Isaka to the Burundi border passes about 20km to the south of the property, while the
old Dar es salaam to the Burundi border road crosses the property about 3km south of the East
Zone. The mine is situated within the Biharamulo forest reserve, 460km from Mwanza, by road
via Kahama and Shinyanga.

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 Figure 2: Stamigold location

1.5 REGIONAL GEOLOGY AT SBM

The STAMIGOLD Mine, located in the Lake Victoria Goldfields region, consists of two
greenstone belts of the Archean Nyanzian Systems, distributed in two concentric arcs. These
greenstone belts are a major component of the Archean Tanzania Craton. There is no
outcropping exposure on the property itself, but isolated ridges and hills of banded iron
formation and granite are observed in the vicinity of STAMIGOLD on the Muhama and
TanRange property. The volcanic sediments sequence of STAMIGOLD property is tentatively
interpreted as being part of the Lower Nyanzian, the BIF observed in the Muhama and TanRange
properties and associated units of the Upper Nyanzian lying unconformable over it. To the
southwest of Muhama, the rocks are interpreted to the part of the Kavirondian system.

The area of the deposit has no outcrop. Typically, there are 0.5-4 metres of silly sand was
originally believed to have originated from essentially in-place weathering of the underlying
bedrock; however, a reinterpretation of the soil profile shows that this sandy soil is transported
probably from the north to the south, eroded from the Bukoban sedimentary rocks. The general
area is gently sloping down from the Bukoban hills to the Muhama River.

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 CHAPTER TWO

2.0 COMMINUTION
Comminution is the first stage of processing ore, which is breaking down ore-bearing rock from
large size rocks to smaller sizes. Because most minerals are finely disseminated and intimately
associated with the gangue, they must be initially "unlocked" or "liberated" before separation can
be undertaken. This is achieved by comminution, in which the particle size of the ore is
progressively reduced until the clean particles of mineral can be separated by such methods as
are available.

This comminution involves three stages which are

 Blasting
 Crushing
 Grinding

Blasting of ore occurs in the mine then the ore is delivered to the crushing circuit for the next
stage of comminution, which is called Run of Mine material. Explosives are used in mining to
remove ores from their natural beds, and blasting can be regarded as the first stage in
comminution. Comminution in the mineral processing plant, or "mill," takes place as a sequence
of crushing and grinding processes.

2.1 Crushing
Crushing is the process of reducing the size of material (ore). Crushing is the first mechanical
stage in the process of comminution in which the main objective is the liberation of valuable
materials from ROM; it is the reduction of the large-size rocks into small particles for further
process. Crushing is accomplished by compression of the ore against rigid surfaces or by impact
against surfaces in a rigidly constrained motion path.

ROM ore, with a maximum top size of 600 mm, is delivered to the dumping station by truck and
deposited on the ROM stockpile. Front-end loaders transfer the ore from the Stockpile to the

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ROM bin grizzly screen, which has 600-mm openings. The ROM bin is required with high or
low-level alarms, and the operator can manually change dump traffic lights at a grizzly dumping
station. The ROM bin provides a 60-tonne surge volume ahead of the apron feeder.

2.1.1 Apron feeder.

The apron feeder withdraws ore from the ROM bin and delivers it to the jaw crusher. The apron
feeder has a maximum capacity of 200 tph ( tonnes per hour) and is driven by a 4-kW motor and
gearbox. The feeder is 1.219 meters wide by 6 metres. Long, and the pans are 25 mm thick. The
jaw crusher ore feed rate can be adjusted up to 200 tonnes per hour by manually adjusting the
speed of the variable-speed drive, controlling the speed of the feeder and, thus, the discharge
tonnage.

An apron feeder is a short, slow-moving conveyor belt. The carrying surface consists of pans
joined together to form a flexible belt. Ore falls onto the feeder from a discharge chute, where it
drops onto a higher-speed, conversational rubber- belt conveyor. The feeder constantly shears off
a layer of rock from the draw point. The high amount of force required to do this means that the
feeder must be of very rugged construction.

2.1.2 Primary crusher

Primary crushers are heavy-duty machines used to reduce ROM ore down to a size suitable for
transport and for feeding the secondary crushers

The jaw crusher used in SBM is a Nordberg Model C110 single-toggle unit with a feed opening
of 110cm. The crusher is powered by a 132-kW drive motor model number D31552; a motor of
jaw crusher produces 380-415 v and 289-219 A. The crusher is designed to operate with a
minimum closed-side setting (CSS) of 70 mm and a normal setting of 100 mm. This setting
produces a product size of 100 per cent passing 90mm, and 80 per cent passing 80 mm.

2.1.2.1 Principal of operation jaw crusher.

The single-toggle jaw crusher consists of a fixed plate called the stationary jaw and a moving
plate called the sewing jaw. The bottom of the moving jaw is held in place by a single-toggle
plate, while the top is moved back and forth by means of a rotating eccentric shaft that runs
through the top of the swing jaw. This strength allows the moving jaw to move back and forth, as
8
well as up and down, as the eccentric shaft rotates. Material enters the crusher through the
opening at the top of the two plates and is crushed as the swing jaw moves toward the stationary
jaw.

As the swing jaw moves toward the stationary jaw, large forces are exerted on the material
wedged between the jaws, and it breaks into smaller fragments.

Figure 3: Jaw crusher schematics

2.2 Pebble crusher

A Pebble crusher is used as a secondary crusher to crush the pebbles from the SAG mill. It
crushes to product size (CSS) of approximately 12 mm. Crushed pebbles are transferred back to
the SAG mill feed conveyor (CV 03). If the pebble crusher is required to be taken offline during
the operation of the grinding circuit, the pebbles can be passed directly back to the SAG mill.

Pebble crushers are lighter than heavy-duty, rugged primary machines. Since they take the
primary crushed ore as feed, the maximum feed size will normally be less than 15 cm in

9
diameter, and because most of the harmful constituents in the ore, such as tramp metal, wood,
clays, and slimes, have already been removed,

The Pebble crusher being used at SBM has a mass of 5900kg also; a type of this pebble crusher
is H2800. MF/HZ/C-16/13.1 SANDVIK. A motor used in a pebble crusher produces 415 V,
92.9A, and 55KW From size D250sc. A pebble crusher progressively reduces the material to the
size of 18-20 mm as the throughput of the next stage.

The operational principle of the cone rusher, as the materials fall on the plate of the mantle that
rotates on the influence of the eccentric drive, they are distributed in a gap made between the
mantle and the liners.

The rotational motion of the mantel induces sufficiently energy that reduces the material to the
size required. This is the second stage of the crusher, where materials from the jaw crusher are
reduced to a size which is desirable to the SAG mill for further grinding.

Figure 4: Section view of pebble crusher

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2.3 Conveyor
This is the material handling system designed to transport dry crushed ore through a moving belt,
which is supported by rollers and pulleys. Belt conveyor consists of different pulleys, including
head, tail, bend, take-up, gearbox and driver motor. In crushing and grinding circuits, conveyor
belts are used to transport material from one point to another.

2.3.1Conveyor belt components:

Take-up pulley: This is used to tension the conveyor belt. Gravity-type pulleys, using a
counterweight, are the most common kind. Tension can also be applied by winches, hydraulic
jacks, or screw jaws. The tail pulley is often used as a take-up pulley.

Tail pulley: This is used to turn the belt from the return direction to the loaded travel direction.

Carrying idlers: These rollers are installed underneath the loaded belt and support the belt
conveyor and its load.

Impact idlers: These are carrying idlers directly underneath the material feed point. They are
usually closely spaced to share the load and to prevent excessive flexion of the belt.

Return idlers: These rollers are underneath the return side of the belt and support the weight of
the returning empty conveyor belt.

Tracking idlers: These are idlers pivoted at their centre support so that they swivel. They have
vertical rollers that contact the edge of the belt if it is off-centre and pivot to steer it back in the
opposite direction.

Blocked chute detected: These level switches in the discharge chute on the head end of the
conveyor automatically stop the conveyor belt when the ore level in the discharge chute is high.

Underspeed switch: An underspeed switch on one of the large diameter pulleys, usually the tail
pulley, is used to direct a loss of belt motion. This could be due to belt slippage on the drive
pulley, broken or jumped belts, or motor stoppage. The conveyor motion is interlocked to
automatically stop whenever the conveyor belt stops moving.

Safety pulcods: These are provided along the length of the conveyor belt where access is
available.

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Belt Drift switches: Belt drift switches are used as an emergency stop or alarm device for moving
equipment that moves off-centre enough to physically operate a lever switch.

Conveyor Drive system: Each conveyor is driven by a drive motor direct coupled to a gearbox.

A weight meter is used to record the number of materials crushed or milled in tons. This is an
instrument which is used

Figure 06: Conveyor belt parts

2.4 Grinding circuit

Grinding is the final stage of comminution, which is a progressive size reduction of ore by the
combined effect of impact and abrasion. Grinding is performed in rotating steel vessels known as
tumbling or grinding mills. Loose crushing bodies, known as grinding medium, are placed inside
the shell. Pebbles, rods or balls are used as grinding mediums; the purpose of this is to liberate
Gold and to provide a high surface area for CIL treatment. The circuit reduces the size to less
than 15 mm and thereby is classified into a three cyclones cluster. The grinding section starts
from Stockpile. Ore from Stockpile is conveyed to the SAG mill by CV 03 from the SAG mill
hope.

The current set-up of feed rate to the SAG mill is 85t/h. The ground ore slurry from the SAG mill
is discharged onto a trommel screen with a 15 × 20 mm apertures panel. The discharge is

12
classified into two categories called Undersize and Oversize. Undersize (-15 mm) goes to the
Cyclone feed hopper, where the Slurry is pumped to the Cyclone cluster for classification.

2.4.1SAG mill
A SAG mill is an autogenous mill that uses steel balls in addition to the natural grinding media.
SAG milling at SBM is wet. It is 7.32 m diameter × 3.35 m effective grinding length fitted with
85 tonnes and 2800 – 3000 kW drive. Variable speed control of the mill is provided by a water-
cooled liquid resistance starter. A speed range of 60 to 82 per cent of its critical speed. Inside the
milling chamber, the mill is lined with wearing plates held by lifter bars bolted to the shell. Lifter
bars are essential to reduce slippage of the mill load, which causes rapid wear of the liners and
also impairs the grinding action. The shape and geometry of the lifter bars, particularly the height
and the face angle, have a significant influence on milling performance and wear rates. The SAG
mill charge consists of new ore, steel grinding balls, recycled SAG mill oversize, and water. The
SAG mill is designed to hold approximately up to 30% of the volume of steel grinding balls;
Steel grinding balls are 100 mm in diameter.

The SAG mill feed conveyor (CV 03) discharges ore and balls into the feed chute of the SAG
mill. Also, a SAG mill in SBM has 3 phases, 5.5KW,56HZ frequency, 380Vand 12A. Grinding
water range of 120 – 130 m3/h is added to the feed chute. The ore, balls and water cascade in the
mill. The ore size is reduced until it flows through the slotted mill discharge grates. The water
that is added to the mill is in proportion to the weight of the new ore being fed from the ore
stockpile. Normally the undersize slurry density in the SAG mill discharge is in the range of 75%
- 80%.

2.5 Classification
Classification is a method of separating mixtures of minerals into two or more products on the
basis of the velocity with which the grains fall through a fluid medium. Wet classification is
generally applied to mineral particles.

2.5.1 Hydro cyclone

Hydro cyclone is a continuously operating classifying device that utilizes centrifugal force to
accelerate the settling rate of particles, a cyclone used in SBM has a maximum pressure of 162

13
kph, but the average pressure is 131kpa also, materials that inter in cyclone is up to 280 m³/h. its
main use in mineral processing is as a classifier which has proved extremely efficient at fine
separation sizes. It is widely used in closed circuit grinding operations.

A typical hydro cyclone consists of a conically shaped vessel, open at its apex or underflow,
joined to a cylindrical section, which has a tangential feed inlet. The top of the cylindrical section
is closed with a plate through which passes an axially mounted overflow pipe. The pipe is
extended into the body of the cyclone by a short, removable section known as the vortex finder,
which prevents short-circuiting of feed directly into the overflow.

The feed is introduced under pressure through the tangential entry, which imparts a swirling
motion to the pulp. This generates a vortex in the cyclone, with a low-pressure zone along the
vertical axis. An air core develops along the axis, normally connected to the atmosphere through
the apex opening, but in part created by dissolved air coming out of solution in the zone of low
pressure.

The classical theory of hydro cyclone action is that particles within the flow pattern are subjected
to two opposing forces, an outward centrifugal force and an inwardly acting drag. The
centrifugal force developed accelerates the settling rate of the particles, thereby separating
particles according to size, shape, and specific gravity.

Due to the action of the drag force, the slower-settling particles move towards the zone of low
pressure along the axis and are carried upward through the vortex-finder to the overflow. Faster
settling particles move to the wall of the cyclone, where the velocity is lowest, and migrate to the
apex opening.

Two forces are involved: -

 Centrifugal force

This is the force created by the swirling motion as the pulp is pumped tangentially into the feed
chamber under pressure. This force increases as the particle size become larger.

 Drag force

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This is an inward force caused by the viscous resistance of the pulp; this increases proportionally
as the particle size becomes smaller. The small material will not travel as far as the larger
material because the drag force of the water is proportionally greater compared to the size and
momentum force of the larger material.

Figure 5:cross-section view of the cyclone

2.5.2 Cyclone cluster

Cyclone cluster consists of 3 cyclones, each with a spigot having a diameter of 100 mm and
vortex finder of a diameter of 172 mm, which operate at a pressure ranging between 110 – 120
kPa. 11 cyclones operate while one cyclone is a standby. Standby cyclone is available so that
when an operating cyclone is not performing correctly, a standby cyclone can be brought online.
The defective cyclone is taken offline and can then be repaired. Slurry discharging from mills is
collected into a cyclone feed hopper. Thereby a centrifugal pump is used to pump the Slurry via
hydraulic feed to the cyclone cluster. The cyclones overflow targeted size (P 80) is 106 microns,
with a density of <40% solids, and the underflows discharge (+106 microns) with a density of
70-79% solids.

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2.5.3 Factors Affecting Cyclone Performance
 Cyclone Separation Performance Indicator
The separation or cut point produced by a cyclone is normally defined in terms of the D50.
The P50 separation is the particle size for which 50% of the cyclone overflow is finer than that
size. For example, if a sample of cyclone overflow was passed through a bank of screens and
50% of the sample was found to pass through (finer than) the 106μm screen, then the P50 point
for the overflow is 106μm.
 Vortex Finder and Spigot Diameters
The size of the cyclone openings (spigot and vortex finder) will affect the cut point considerably.
The reasons are complicated but can be simplified by saying that increasing the size of either
opening will allow more of the feed material out of that opening.
Therefore, at a given operating pressure, an increase in the diameter of the vortex finder will
result in a coarser cut point as more feed material reports to the overflow. Hence it is important
that the vortex finder diameters are monitored regularly and replaced if excessively worn.
Similarly, too large a spigot diameter will allow more fines and excess water to report to the
underflow. Hence the overflow becomes finer, and the underflow more dilute. Hence, like the
vortex finder, the cyclone spigot should be periodically measured and replaced when worn.
Smaller spigot diameters will increase the pressure of the vortex and force more heavy coarse
particles to overflow. Too small a spigot diameter may lead to a condition known as 'roping',
where an extremely thick pulp stream of the same diameter as the spigot is formed, and the air
vortex may be lost, and oversize material will discharge through the vortex finder.
 Feed Pulp Density (% Solids)
In a cyclone, a higher feed density is analogous to a higher density (more particles) in the glass
of Slurry. Particles will find it harder to sink so that only the large, heavy particles will make it to
the wall. On the other hand, a lower feed density will allow the smaller, lighter particles to sink,
reducing the cut point.
Therefore, operating the cyclones at high feed % solids will reduce separation efficiency and
result in a coarser overflow, as the drag force is increased on each particle, causing the particles
to remain nearer the Centre. The cyclones should ideally be operated at the lowest feed density
possible while still maintaining the required separation and overflow density.
 Feed size distribution

16
The cyclone feed size distribution will affect the cyclone cut to size and mass flows. A fine feed
size distribution will result in fine product size, with the majority of the feed reporting to the
overflow. A coarse feed size distribution will result in coarse product size, with the majority of
the feed reporting to the underflow. It may be necessary to adjust the cyclone pressure/feed rate
and feed density to achieve the required separation size to account for changes in feed size
distribution.
 Cyclone Operating Pressure
The pressure at which the cyclones operate is an important parameter as it affects the cut point.
Pressure can be achieved by increasing the flow of Slurry to a cyclone (e.g. by adding more
water to the discharge hopper or speeding up the cyclone feed pump). Within limits, an increase
in operating pressure will cause the cut point to drop (finer overflow). This is because the
centrifugal force on the particles is increased, forcing more fine particles to the cyclone wall and
hence reporting to the underflow. However, too great a pressure increase may exceed the
operating capacity of the cyclones, causing coarse particles to report to the overflow.
It is important that the operating pressure is maintained by keeping an adequate cyclone feed
hopper level. If the hopper level drops too far, the cyclone feed pump will cavitate, and the
pressure will drop. During this transition, coarse solids will report to the overflow. Pressure in
cyclones ranges from 131kpa to 162 kPa.

2.5 Gravity concentration circuit

The gravity concentration circuit consists of a screen and two Knelson concentrators. The portion
underflow of a cyclone is sent to a vibrating screen. SC 25 of the aperture size of 4 mm × 4 mm
feeds the undersize to the knelson concentrator while the oversize is returned to the ball mill for
grinding.

2.5.1 Knelson concentrator

knelson concentrator is a device that is predominantly used in the gold mining industry. It is used
for the recovery of fine particles of free heavy Gold, meaning Gold that does not require gold
cyanidation for recovery.

17
 2.5.1.1 Working principle of knelson concentrator
Materials enter the knelson concentrator, which is a high-speed centrifuge that combines
centrifugally enhanced gravitational force with a fluidization process to recover free Gold from
mineral slurries. The main components of the concentrator are a feed pipe, rotating concentrating
cone, water chamber, multiport hub, and a drive system.

Feed slurry is introduced into the unit through a stationary feed tube. The Slurry flows down the
feed tube onto the rotor deflector pad and is subsequently driven outward to the cone wall by
centrifugal force. As the solids reach the wall of the cone, they fill each ring starting from the
bottom. Once every ring has reached capacity, concentrating bed is established. This bed is
subsequently fluidized by the water that is injected into the water chamber through the
fluidization holes.

The fluidization water flow rate is determined by the characteristics of the feed stream and
influenced by such things as particle size distribution, gangue density, and the per cent solids in
the stream. Optimum fluidization is achieved when the inward flow of water through the bed
reaches a balance with the outward force of the solids. This enables the fine-grained gold
particles to migrate through the bed toward the cone wall where they concentrate. The heavier
particles displace the lighter particles in the ring. Provided that the flow of fluidization water is
maintained, the selective concentration of high specific gravity particles occurs. The lighter
particles (tails) overflow the concentrating cone and flow to the ball mill.

The duration of the concentrating cycle varies depending on the application. The concentrating
cycle is in the range of 40 minutes. The concentrating cycle duration is influenced by the amount
of free Gold present in the feed, the number of heavy minerals, and the amount of tramp metal
present.

At the conclusion of the concentrating cycle, the feed is shut off, and the flush cycle is initiated.
When the flush cycle is initiated, the rotor drive motor is turned off. After the rotor has come to a
complete stop, the fluidization valve is fully opened for several seconds. By opening the valve
while the rotor is stationary, the anticlockwise flow of water into each ring causes the
concentrate to be dislodged from the rings. The concentrate is then flushed from the cone
through the multiport hub to the Acacia reactor.

18
 Figure 6: cross-sectional view of the knelson concentrator

The operating parameters of the gravity circuit are: -

Motor Amps (A) = 11.1-11.2

Water flow (m3/h) = 9-11

Bowl pressure (kPa) = 120-130

Concentrating time (min) = 40

Speed (rpm) = 400-500

2.6 ACACIA reactor

This reactor is a high-efficiency leaching device using a high-intensity cyanidation method to
achieve very high recovery. The process consists of an up-flow fluidized reactor, which has been
developed to produce ideal solid-liquid interaction in order to maximize gold leaching reaction
kinetics without mechanical agitation. The product from the process is in the form of cathode
gold which is ready for the traditional smelting step (Campbell & Watson, 2003).

19
 Figure 7: Acacia reactor

The acacia reactor relies on a simple flow sheet with a design that incorporates processing stages.
About eight stages are considered to recover Gold in the acacia reactor process, as shown in the
following flow sheet.

For the complete dissolution of Gold in the acacia reactor, the following listed process is done: -

 Transfer the concentrated from the day storage hopper

The ACACIA reactor uses a convectional technology concentrates storage hopper for the daily
storage of the batch concentrates. The hopper is designed to provide surplus capacity but is
generally designed to have an active volume to match the reactor size.

 Stratification of the concentrates

The success of the fluidized bed leaching is dependent upon segregating the concentrates upon
the layer's particle with equal minimum fluidized velocities such that channelling of the solution
will not occur; this is achieved by flowing a limited amount of water through the distributor at
the rate considerably higher than the fluidizing flow rate. The flow is terminated before the

20
reaction vessel is already full to avoid the carry-over of the concentrates particles to the
overflow. The concentrate is allowed to settle, and supernatant water is decanted.

 Desliming of the concentrates

The pre-washing stage is the most critical stage of the process and must be carefully controlled
for maximum recovery from the acacia reactor. This stage removes all fines that may be
entrained in the concentrates; in regard to the electrowinning also, the overflow solution is
ensured that it does not carry any suspended particles that may interfere with the electrowinning
of Gold. Water and, subsequently, the pregnant solution can be recovered by drainage through
the settled solids. The concentrated solids are fluidized for about 30 minutes, reaction vessel
overflow solution containing fine solids is estimated at 30 microns and is back discharged to the
grinding section.

 Mixing of the leaching reagents

The reagents are mixed in the reactor feed tank, which is fitted with the mounted side mixer; the
solution in the tank contains portable water, caustic solution (NaOH), sodium cyanide (NaCN),
and leach aids. While other oxidants have been tested, leach aids have been shown to provide the
greatest process stability and offer significant process flexibility while maximizing overall
recoveries.

 Leaching of the concentrates

Declined solids are subjected to up flow of leach solution. The up-flow solution causes
expansion of the solids bed to allow a fluidized bed to form in the reactor. Leach times specific
are site decisions.

 Recovery of the pregnant solution and washing of the residues

The pregnant solution is recovered at the completion of the leaching process. This is achieved
simply by draining the reactor from the bottom; the solids are then washed to remove the residue
pregnant solution entrained within the solids

 Electrowinning of Gold from pregnant solution

21
On this side, two options exist where one of the options is to transfer the pregnant solution to the
main eluate tank for electrowinning with the rest of the plant solution. Another option is to use a
dedicated electrowinning system. The extensive electrowinning concept on this part is clearly
done on the electrolysis of the combined elution solution and the acacia solution in the CIL
process.

 Disposal of electrowinning tails

At the completion of the electrowinning, the final tails solution can either be partially recycled or
sent to leach feed, where the chemical residue chemicals have added value to the CIL train; it is
not recommended to recycle the total solution as it will result in the formation of Na + levels in
the solution with potential precipitation of cyanide complex.

22
 CHAPTER THREE

3.1 CIL CIRCUIT

The Carbon in leach (CIL) circuit consists of seven tanks, each with a live capacity of 359m3.
The tank has a retention time of 3.6 hours. The are six CIL agitated tanks of the same size for a
total leach and CIL tank retention time of 25 hours for leaching and adsorption. Each is equipped
with an agitator driven by an 18.5-KW electric motor connected to a gear reducer. The first tank
is used for leaching, and the following six tanks are adsorption tanks. The tanks are connected
with launders to allow the flow of Slurry from one tank to another. All tanks are fitted with an
agitator to ensure uniform mixing and bypass facilities to allow any tank to be removed from
service for any maintenance. Tank 1 to tank six is fitted with an inter-tank screen to retain
activated Carbon.

Fresh or regenerated Carbon enters in CIL circuit through tank six and is advanced counter-
current to the slurry flow by pumping and by using air lifters. In counter-current, Carbon is
moved in the opposite direction of the slurry flow; Carbon cannot flow in the same direction as
the slurry flow because it is retained by the inter-tank screen. This counter-current process
repeats until the Carbon reaches tank one, where adsorption starts.

A facility to add sodium cyanide into the leach tank is provided. Cyanide dosing is controlled via
flow measurement and dosing valves. Manual titrations are carried out by the CIL operator to
monitor free cyanide levels in the CIL tanks. A wet lab station is located alongside the central
control room to facilitate this activity.

Discharge from the last tank gravitates to the carbon safety screen, a carbon safety screen is a
vibrating single deck heavy duty screen designed to recover any carbon leaking from a holed
screen in the last tank. Carbon recovered on the carbon safety screen is collected in the carbon
collection bin. Carbon safety screen undersize flows by gravity to the cyanide destruction
facility.

23
CIL process
The process that occurs in the CIL circuit involves two main chemical reactions which are:-
 Dissolution of Gold by cyanide (leaching)
 Adsorption of gold particles into Carbon

3.1.1 Leaching
Leaching is the actual extraction of Gold from the ore using a process known as cyanidation.
Cyanidation involves mixing the ore slurry in large agitated tanks together with the reagents,
which are: -

 Cyanide
 Lime
 Oxygen
 Dilution water

At STAMIGOLD BIHALAMLO GOLD MINE, the leaching reagents are added to the leach
tank to maintain a 160-200 ppm, which will form free cyanide up to tank six and pH of 9.5_10.5
as a necessary condition to prevent the evolution of deadly gas hydrogen cyanide.

Leaching theory

Sodium cyanide, when mixed with Slurry, produces free cyanide, which reacts with gold
particles, forming a dissolved gold cyanide complex. The dissolution of Gold takes place
according to the following reaction.

4Au + 8NaCN + O2 + H2O → 4Na[Au(CN)2] + 4NaOH

3.1.1.1 Factors affecting leaching

 Size, the coarse material takes much more time to leach than fine materials; therefore, the
better grind, the better the leaching that takes place as more material surface area is
exposed to the cyanide in solution, the good set point of percentage solid is 80% of 106
microns.
 Density, Reagent consumption is minimized by maximizing slurry density since optimal
concentrations can be achieved at lower dosages due to the smaller volume of solution
per unit mass of material.

24
 Cyanide concentration, When NaCN dissolves, it reacts with the water in the Slurry to
form Hydrogen cyanide gas (HCN). The more the acid in the pulp or low pH value on
CIL tanks, the more the (HCN) gas, which is dangerous. And the less free cyanide in a
solution that is available to leach the Gold in the pulp. Therefore, we need to keep the
good cyanide dosed into the CIL circuit in solution so as to have maximum available for
leaching and to ensure that HCN gas does not reach dangerous levels.
 Slurry pH, Slurry pH modification is achieved by adding lime to the ore prior to milling,
which makes the slurry alkaline (high pH). This has the function of controlling the acidity
and alkalinity of the Slurry, low pH results in the formation of HCN gas. The formation
of hydrogen cyanide gas reduces the amount of cyanide available to leach the Gold and is
also potentially fatal if inhaled at certain concentrations. Also, if the pH is high, then the
reaction will cause the free cyanide ion to be the stable species. Therefore, it is important
that high pH levels are maintained to prevent HCN gas formation and excess cyanide
consumption. The optimum pH ranges from 9.5_10.5
 Agitation, Effective agitation allows the reactants to homogenously and intimately mix
and prevents the solids from settling out in the tanks. Agitation also ensures that the gold
cyanide complex ions forming on the surface of a gold particle are removed into the
wider solution to allow 'access' on the gold particles' surface for more unreacted cyanide
ions to leach more Gold from the particle.
 Oxygen, Oxygen is essential for the dissolution of metal and provides the optimum
concentration of the dissolving reagents maintained so that high dissolution efficiencies
can be achieved.
 Temperature, Higher temperatures increase the rate of gold dissolution; however, it is
not economical to heat the Slurry. High temperatures also reduce the capacity of Carbon
to adsorb Gold and lower the solubility of Oxygen in the Slurry. Therefore, leaching and
adsorption are conducted at ambient temperatures.
 Residence time, Residence time in the CIL circuit is the time taken for the Slurry to flow
through the tanks. The longer the gold particles are in contact with the cyanide in the
Slurry, the more gold will be leached. Residence time is determined by the volume of the
tanks, which is fixed, the slurry flow rate and the slurry density. So if the residence time

25
 of the material in the tanks is short, the leaching will be poor due to lack of enough time
for cyanide to work on.

3.2 Carbon adsorption.

In the carbon-in-leach (CIL) tanks, most of the gold and silver cyanide complex ions become
physically attached to the surfaces of the carbon particles in a process called adsorption.

3.2.1 PRINCIPAL OF OPERATION ADSORPTION AND DESORPTION OF GOLD ON

ACTIVATED CARBON.

Adsorption is a process in which molecules from within a fluid are concentrated on the surface of
a solid by chemical forces, physical forces, or both.

A description is an opposite process, during which the molecules are released from the surface.

Activated Carbon is a family of carbonaceous substances manufactured by processes that

develop adsorptive properties. The adsorptive properties of Carbon are functions of both the
chemical condition of the carbon surface and the area of the surface. Very irregular shapes
provide a larger surface area for a given weight of Carbon. It has been found that one of the best
carbons for the adsorption of Gold is coconut-shell charcoal.

3.2.1 Factors affecting adsorption

 Time, the longer the time Carbon is in contact with the leached Gold, the more gold
will be adsorbed. This means the time taken for one particle to pass from the feed to
the discharge point.
 Gold concentration, the more gold that is in solution, the more Carbon will adsorb.
A lower gold concentration requires fresher Carbon. For example, the last has less
Gold in solution and therefore must be contacted with the largest available surface
area of Carbon to maximize chances of recovery as the last tank is the last tank to
recover before it goes to the tails.

26
  Inorganic foulants, these organic species will be absorbed by activated Carbon, thus
reducing the efficiency of the Carbon to be loaded with Gold.
 Carbon property, the property of activated Carbon, determines its ability to perform
in the absorption circuit. The most important are its activity, hardness and particle
size. The carbon activity is a measure of how much Gold can be faster. With time all
of the microspores in Carbon will be either loaded with Gold or clogged with
foulants.
 Hardness, the hardness process property of Carbon, is as equally important as the
gold adsorption properties. Therefore, the harder the Carbon, the less carbon attrition,
so the longer the life and lower the circuit carbon consumption.
 Particle size, the activated carbon particle size is important to ensure that the
production of fine Carbon is minimized as both increases both the carbon
consumption and often gold losses due to high loading of the fine Carbon. The
particle size of the Carbon was chosen on the basis of the most efficient separation of
the Carbon and the pulp. As the particle size becomes smaller, the attrition rate
increases due to the increased rate of breakage and increasing consumption. The
concentration of Carbon in each tank is known as the carbon profile of the circuit.
 Density, the Carbon in the tanks should be homogeneous with the Slurry means equal
distribution through the tank. If the density is high, the Carbon will tend to float on
top of the Slurry, and if it is too low, the Carbon will sink to the bottom of the tanks.
So density must be maintained.

3.3 Stamigold CIL Circuit equipment

 CIL Tanks
Each CIL tank at Stamigold has a live capacity of 359m3. There are six CIL agitated tanks of
the same size. Each is equipped with an agitator; Slurry enters into the top of the tank, flows
down to the mixing zone at the base of the tank, and then out to the next tank in series. Slurry
leaves the tank by gravity flow on the opposite side, from which it enters through an inter-
tank screen and overflows into a launder with two manually-operated dart valves. One valve
directs the flow to the next tank in the series, and the other can be used to bypass the adjacent
downstream tank when required for maintenance, etc. Each downstream tank is slightly

27
lower than the previous tank to ensure proper gravity flow of Slurry without the solids
settling and plugging the launder.
 Tank Agitators
The CIL tank agitator shafts have low-pressure air forced down through the Centre of the
shaft, which is dispersed evenly throughout the tank by the mixing action of the dual impeller
blades. The Oxygen contained in the air is a vital element in the cyanidation reaction. The
amount of air is initially set by the operator using a flow valve and is monitored and
controlled based on the flow rate indicator and the general appearance of the air bubbles on
the surface of the Slurry. Air bubbles should appear evenly across the entire surface of the
tank. Large bubbles are indicative of excessive airflow. Low flow and few or small bubbles
are obvious indications of a plugged distribution line or agitator nozzle
 Inter-Tank Screens
The purpose of inter-tank screens is to allow Slurry to pass through the mesh so that it can
flow by gravity out of the tank while at the same time preventing Carbon from passing
through. Screen assemblies are supported by hooks on the side of the transfer launders at the
top of the tank and are sealed at the base by a soft rubber gasket, allowing screened Slurry to
flow into the launder and into the next tank. Manual dart valves in the launder can be closed
to bypass the downstream tank so that maintenance can be performed on the screen
assembly. Screens require high-pressure cleaning on a regular basis to stop blinding. A spare
screen is available to replace the out-of-service screen while cleaning or repairs take place.
 Carbon advancing Pumps
Carbon is advanced counter-currently to the slurry flow by periodically airlifting some of the
contents of each tank to the preceding tank. The airlift pump routes the advancing Slurry and
Carbon into the fourth CIL tank upstream. The slurry component re-joins the forward flow of
Slurry in the system, whilst the loaded Carbon is held within the tank due to the inter-tank
screen.
 Loaded Carbon Recovery pump
There is one loaded carbon recovery pump in tank 1 in the series. The carbon transfer pump
is started in accordance with the predetermined transfer sequence, which is initiated by the
operator. Carbon-rich Slurry is pumped to a loaded carbon screen. Similarly to the vibrating
trash screen, an oversized fraction is generated containing the desired loaded carbon product,

28
which is directed to the acid wash column. The slurry product from the carbon screen reports
back to the leach circuit.
 Trash Screen
The primary cyclone overflow slurry feeds the feed box for the trash screen. The feed box
decreases the slurry velocity before the Slurry flows onto the trash screen. The trash screen is
inclined and is equipped with process water sprays. The sprays help wash the trash on the top
of the screen and ensure that all undersized particles are recovered. The screen is also
equipped with a vibration mechanism to assist in particle size separation. The screen panels
have 0.8 mm square openings. During normal operation, the particles of ore in the screen
slurry feed are virtually all less than the screen opening size: almost all of the ore particles
and solution should pass through the screen and enter the next process stage, leaving only
oversize trash and ore particles. The screen underflow reports to the sample cutter before
entering a lich tank. The trash falls into a trash container and is periodically disposed of in an
approved location. The main purpose of the vibrating trash screen is to remove material
larger than the screen openings, preventing negative impacts on downstream equipment
and/or processes. This material typically comprises plastic and wood particles, which can
block Inter tank screens and filters in the elution circuit. The wooden material can also
adsorb gold-cyanide complexes, so it is important that it is removed before entering CIL. Due
to the lime content, the screen can get blinded with scale; this will require regular high-
pressure cleaning and occasional acid washing.

Figure 8: Trash screen

29
  Carbon safety screen
At the end of the CIL tanks, Slurry from tank six flows to the carbon safety screen before it has
discharged to the thickener. Carbon safety screens retain all the carbon present in tails due to
Carbon being abraded over time and is a screen. Holing of tank six inter-tank screen. The seal
between the launder and carbon pass. If the screen was not present, Carbon would end up in the
tailing dam resulting in Gold and carbon losses. Generally, the Carbon in the safety screen is due
to the screen being holed or the launder seal not sealing properly; hence these carbons are
collected and put back into the circuit. All Slurry leaving CIL must report over the screen.
 Carbon sizing screen
Above the CIL tank, six Carbon flows to the carbon sizing screen before it enters the tank.
Carbon sizing screen oversize enters the tank, and the undersize is dumped because it is not
required for adsorption. Fine Carbon has a high surface area for adsorption but is not required for
adsorption because the stripping cannot be done well in fine carbons, which leads to gold loss.
 TAC cyanide analyzer
The TAC analyzer is an automatic titration unit that measures the cyanide concentration and pH
of the Slurry. A slurry sample from the splitter box is taken through a filtration sock and sent by
a peristaltic pump to the analyzer unit. The filtered sample is titrated with silver nitrate to
determine the free cyanide concentration. The cyanide concentration result, as determined by the
TAC, is used in a control loop to automatically adjust the cyanide addition rate to the circuit.

Figure 9: TAC cyanide analyzer

30
 CHAPTER FOUR

4.0 Thickener
Thickeners are large diameter conical bottom tanks that accelerate the settling of solids and
dewatering of tailings. As feed enters the thickener in the feed well, the solids start to settle
immediately. Solids collection is done by rotating rakes, which force the solids inward and down
to the bottom of the cone. Liquid overflow the top of the thickener tank into a launder. Coarse
particles settle at a high rate compared to very fine particles. Particle settling rates are increased
by the addition of flocculants.

Figure 10: The cross-section showing parts of thickener

At SBM, the overflow of the cyclone travels by gravity to the trash screens with panels of
aperture size 0.8 mm × 8.8 mm each. Trash is rejected while screen undersize flows to the
thickeners, The slurry reports thickener through the thickener hopper.

The thickener underflow reports pumping from the feed hopper direct to TSF dame as tailings.
The overflow material usually waters to the tank, which stores process water.

31
 Figure 11: SBM thickener

4.1 Control parameters of thickener

Controlling Underflow Density and Bed Mass by Underflow Pump Speed and Flocculants
Addition Rate.

When the thickener is operating properly and has an adequate bed mass, the underflow solids
density is high.

The solids density of the thickener underflow is a good indicator of the balance between the feed
and the discharge rates. A high density may be achieved by establishing a bed mass in the
thickener. This allows time for the Slurry to compact and for the excess water to percolate from
the bed.

As thickener underflow density increases to the absolute maximum, this usually means that the
load on the rakes from the bed mass is too high and that the thickener is approaching overload.

If the density is too high, the withdrawal rate of underflow slurry must be increased temporarily
to reduce the number of solids in the thickener.

Similarly, too low a density indicates that the pulp bed is too shallow and that the underflow
withdrawal rate must be reduced and the flocculant's addition rate must be increased. Under
optimum running conditions, the tonnage of solids removed from the thickener underflow must
be equal to that fed to the thickener.

Controlling Bed Level by Flocculants Addition Rate

32
If the bed level gets too high, the overflow from the thickener will have solid particles
overflowing with the clear water. To prevent this, the flocculants dosage to the thickener must be
increased to lower the bed level.

Controlling Thickener Rake Torque by Rake Level

A high rake drive torque indicates increasing pulp density or mechanical binding of the rake. If
the torque increase continues, a lift mechanism raises the rakes slowly while the drive motor
continues to turn them. As the rakes lift out of the sludge bed, the torque reduces. If the torque
continues to increase to a very high level even though the rakes are being raised, the rake drive
motor stops to prevent damage to the rakes.

33
 CHAPTER FIVE

5.1 ELUTION CIRCUIT

Elution involves removing the Gold from the activated Carbon by reversing the adsorption
process that occurs in the CIL circuit. Using high temperatures and pressures and treating the
Carbon with a concentrated caustic solution followed by elution with potable water, the gold
cyanide complex can be induced to desorb from the Carbon and return to the solution. The
desorption process is also referred to as 'stripping'.

In the CIL circuit, adsorption of Gold onto activated Carbon is most effective at low
temperatures, low cyanide concentrations, low pH and high gold concentration in solution
(although some of these conditions aren't practically achievable). By simply reversing these
conditions, elution (Desorption) of Gold from the Carbon occurs.

The main factor that makes Desorption or stripping a simple process is the fact that Gold will
only adsorb onto Carbon at low temperatures. If the temperature of a solution and carbon mixture
is increased, the Gold will readily desorb from the Carbon into the solution. Temperatures,
therefore the most important variable in the elution process and temperatures of 100-120°C are
necessary to achieve optimum elution performance.
Stages of elution circuit

 Acid wash
 Stripping
 Carbon regeneration

34
5.1.1 Acid Washing
Acid wash is a process that is done prior to elution for the purpose of removing the inorganic
foulants such as magnesium hydroxide (Mg (OH)2), calcium carbonate (CaCO3), iron cyanide
(Fe(CN)6) and silica (SiO2), but the adsorbed gold complex was unaffected. In the acid wash, the
precipitated/adsorbed salts are dissolved in hydrochloric acid (HCl) and then rinsed from the
Carbon. The HCl will readily be dissolved in most (70-90%) of the inorganic species. Acid wash
is useful in such a way that it increases the efficiency of the elution process as it increases the
surface area for the contact between the stripping solution and the porous carbon surface.
It also reduces the blinding of carbon pores by the salts of calcium and magnesium and increases
the carbon activity for the adsorption of Gold.

Acid washing is also critical in the AARL process to ensure elution efficiency. The acid modifies
the way in which the gold cyanide ions are adsorbed onto the Carbon in preparation for the
following pretreatment stage. Combined, the acid wash and pretreatment steps convert the Gold
cyanide ions from being strongly adsorbed to the Carbon to being weakly adsorbed elution stage.

5.1.1.1 Acid wash column

The acid wash column receives Carbon from Carbon in lich tank 01, which is loaded with
Carbon and the next step is Desorption. The loaded Carbons are transferred to remove the
adsorbed Gold. This stage of the acid wash is the first step, and it motivates the elution process
highly.

The loaded carbons from the recovery tank are carried with the help of a pump through the pipe
to the loaded carbon screen. This separates Carbon from Slurry. From this screen, the loaded
carbons flow through the pipe to the Acid wash column. When the loaded carbons are full in the
acid wash column, the Hydrochloric acid (1000 litres for a ratio of 3% HCL) and raw water are
added together to flush through the loaded Carbon.

Stages of acid wash: -

 Water fill and acid dosing

The water which is added is raw water, followed by acid; this acid (1000 litres) is dosed with a
flow rate of 3m3/hr. This process is done for 3600 seconds, after which the pump stops.

35
 Carbon transfer

When these stages are completed, then Carbon is transferred to the elution column.

5.2 Strip solution heater circuit

The strip solution heater circuit consists of a thermal oil heater and heat exchangers. The heater
circuit is used to raise the temperature of the stripping solution in order to improve the elution of
Gold from the Carbon and to increase the rate at which the Gold is eluted.

5.2.1 Elution column

The elution column is a stainless steel, insulated pressure vessel holding the same volume as the
acid wash hopper; it is designed to process two tonnes of Carbon per batch. The elution column
receives acid-washed Carbon, water, and strip solution.

The elution column is equipped with a pressure relief valve that discharges to the desorption area
sump. The elution column can also be drained to the sump via a drain valve in the strip solution
manifold at the base of the column.

36
 Figure 12: Elution column showing its parts

5.2.1.1 Operating sequence

The elution circuit is operated automatically by the control system. The trip solution (elution) is
heated prior to passing through the elution column. The Strip solution leaving the column is
located eluate, and it is cooled before passing through a dedicated electrowinning cell. The eluate
discharging the electrowinning cell is reheated and passed through the column again. This
sequence continues for 18 hours, and the flow rate is 8.6 m³ per hour.

The operator initiates the sequence and automatic sequence of operation as follows:

.Fill the column and prepare the strip solution

The elution column drain valve closes, the strip solution tank discharge valve and the recycle
strip solution valve open, and the strip solution pump starts. The solution is now being
recirculated through the column and back to the strip solution tank. When the elution column has
been filled with water, caustic and cyanide are added to the required concentrations in a strip
solution tank.

37
 . Preheat.

The elution pressure control valve, located after the trim heat exchanger, becomes operational to
control the circuit pressure to 200 kph. The thermal heater burner is started, and the thermal
heater oil circulating pump is started. The purpose of the heater, along with that of the primary
heat exchanger, is to provide the heat necessary to bring the solution to the preheat temperature
of 90'C

Figure 17: Heat exchangers

 Elution
Once the strip temperature is 90'C, the time elution cycle starts, and the strip solution is
advanced to the electrowinning cell. The flow can be adjusted by the variable-speed strip
solution pump. The operator starts the electrowinning rectifier, and Gold and silver are
removed from the pregnant solution. It is important that the flow remains constant at the 8.6
m³ per hour rate during this period. The oil heater is controlled during the elution period,
increasing the temperature of the strip solution to 120'C. The pressure in the elution circuit
continues to be controlled automatically at 200 kPa. A sample of the solution must be taken,
and pH checked to ensure it is above 13.

38
 Cool down.
The thermal oil heater is stopped automatically when the elution cycle timer has elapsed (18
hours). The column now has only fresh water, and the system is cool. The cooling down
process takes 30 minutes (1 bed-volume) to come to an end and 250 kPa. Then the barren
Carbon is in it and is ready to transfer. The carbons here are transferred to the regeneration
kiln.
 Carbon transfer

When the cool-down process is over, carbons are transferred to a spiral concentrator for
separation of grits and Carbon; then Carbon is transferred to the regeneration kiln hopper. From
the hopper, Carbon is fed to the Kiln for regeneration.

. Complete Transfer

The transfer is complete when the sequence timer expires (60 minutes). The operator can initiate
another transfer sequence if required; otherwise, the operator acknowledges that the transfer is
complete. The carbon discharge valve and the carbon transfer water valve close; then, the strip
solution pump stops. The strip solution tank discharge valve closes, and the elution column drain
valve opens.

5.2.1.2 Factors affecting the elution process

 Temperature

The operating temperature during the Elution cycle at Stamigold biharamulo mine (SBM) is
115-120oC for the split AARL elution system. Gold Desorption (or elution efficiency) reduces
with temperature. If lower temperatures are evident, the elution efficiency will be reduced. The
desired gold recovery could be achieved if the duration of the strip was increased, but this is a
fixed time. This means that the gold recovery is reduced, and the barren Carbon will have a high
gold concentration.

 Flow rate
High flow rates the in the elution cycle are important to draw out the gold cyanide from within
the carbon granules. Elution conditions are favourable for scale formation. Scale forms in areas
of greatest seeding, such as heat sources (heat exchange) and nozzles in pipes. Scale formation

39
will impede flow rate and reduce heat transfer, therefore negatively impacting elution. It is
important to use as pure water and chemicals as possible.

 Ionic strength
The fact that elution increases with increasing anion concentrators but decreases with increasing
cation concentrations means that the rate of elution passes through a maximum as the
concentration of the eluting salt (NaOH) is increased, i.e. too much elution salt will impede the
elution process. The presence of cations that form strong ion pairs with gold cyanide, such as
calcium, can have a negative impact on the elution of Gold if present in excess.

5.3 Spiral concentrator.

At Stamigold Plant, Carbon from the elution column is pumped to the spiral concentrator by the
force of water exerted by a pump. Material enters the spiral through the feed box located at the
top of a spiral together with added water. As material pass along the sluice surface, coarse grits
move slower near the Centre of the spiral while Carbon and water move at the outside trough of
the spiral and quickly reach the hopper. Grits pass through the tail splitter and are then collected
at the spiral discard bunker.
However, due to the poor efficiency of the spiral, Carbon and grit mixed and resulted in carbon
loss. Spiral separation efficiency can be improved by controlling and optimizing all operating
parameters of spiral concentrators, such as material flow rate, addition water flow rate and
adjustment of concentrate splitters.

5.4 Carbon regeneration

During the adsorption process, not only is soluble Gold adsorbed to the carbons, but the carbons
also can adsorb other unwanted material. These waste materials, called foulants, can be inorganic
or organic, and they both reduce the ability of carbons to adsorb soluble Gold during the
dissolution process.

5.4.1 Carbon Fouling

Carbon fouling is the build-up of organic and inorganic substances on Carbon, which
detrimentally affects gold adsorption. Fouling results in a decrease in the rate of and loading
capacity of gold adsorption onto Carbon and can also adversely affect the efficiency of
desorption (elution) processes.

40
5.4.1.1 Inorganic Foulants Removal
Most of the inorganic foulants were removed in the acid-washing stage of the elution cycle.

5.4.1.2 Organic Foulants Removal

Thermal reactivation was used to remove organic foulants example, diesel fuel, lubrication oils,
grease and fine vegetation, by subjecting the Carbon to temperatures in the order of 650-750°C
in a steam environment within a regenerative kiln. The high temperature burned off some of the
organic matter, whilst the reaction with the steam removed the rest. Steam also served to keep
the reactivation system oxygen-free (to prevent the Carbon from burning into ash) and was
involved in the chemical formation of active sites within the Carbon.

Importance of carbon reactivation and recycling

 Carbon reactivation enables the retention of the strength and activity of used Carbon and,
therefore, fits for another adsorption cycle.
 Reactivation and recycling of used Carbon reduced the amount of feeding new fresh
Carbon into the CIL circuit and therefore helped in operating cost minimization.

5.4.2 Regeneration kiln

A regeneration kiln is a horizontal kiln that essentially consists of a rotating steel drum through
which the Carbon passes. The drum itself is supported and driven by rollers installed at each end.
The drum normally rotates very slowly. Rakes and lifting panels are installed inside the drum to
continually "lift" the Carbon during its travel along the drum. This provides maximum heat
transfer to the Carbon, allowing efficient regeneration. Drum rotation, together with a slight
downward slope, causes Carbon to travel along the drum, where it discharges at the opposite end.

During activation, the following parameters are monitored;

 The temperature of the Kiln

 Carbon feed rate
 Quench water level

41
The temperature of the Kiln

The Kiln consists of three burners, 1, 2 and 3; these burners produce temperature to the burner
tube. The required temperature of the burners lay between 600-650°c, 700-750°c and 600-650
for burners 1, 2 and 3, respectively. When the temperature of burner one reaches 650°c, the
screw gate of the feed hopper opens and allows Carbon to enter the kiln tube for activation. The
burning process is conducted in the absence of oxygen gas. The aim of inhibiting oxygen gas is
to avoid combustion.

Carbon feed rate

The feed rate must be kept within the limit. Too high a feed rate will consume too high heat;
hence Carbon will not reach the required temperature. Too low a rate will result in overheating
of the Carbon.

Quench

Carbons from the kiln discharge nozzle fall into the quench hopper, and the hot Carbon is not
allowed to come into contact with atmosphere temperature. This is because, in contact with
Oxygen, it may result in combustion and localized cracking and turning to ash.

Figure 13:Quench tank at SBM

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4.5 Electrowinning
Electrowinning is a process used to recover metal Gold from concentrated solutions by applying
a voltage across electrodes immersed in a concentrated solution. The elute solution, normally
consisting of caustic soda, cyanide and water, circulates through the loaded Carbon, extracting
Gold and other metals. The loaded solution passes through an electrowinning cell where Gold
and other metals are attached to cathodes made up of steel wire by electrolysis. The solution
passes back through the loaded Carbon, extracting more Gold and other metals. This process
continues until Carbon has been stripped. The cathodes containing steel wire plated with Gold
and other metal are removed and placid in sulphuric acid. Sulphuric acid burns steel wire and
other metals and leaves gold sediment and a solution of acid and dissolved water. The sulphuric
acid and silver are drained off, after which gold sediment is washed several times. After water
washes are completed, Gold is dried and smelted.

When the elution process is completed, the pregnant solution is sent to the eluate tank. The
system converts the Gold from its solution form back into solid metal. The process is called
electrolysis.

5.5.1 Electrolysis of a gold solution

Electrons pass from the cathode to the anode through the solution completing the electric circuit
current causes the Gold to plate onto the steel wool cathode. The eluate acts as the conductor
between the cathode and the anode. The flow of current is due to the rectifier switch on.

Figure 20:ionization and gold cathode desorption

43
 o Cathode reaction gold deposition

Gold is electro-typically displaced from the alkaline solution cyanide solution and deposited on
the cathode surface according to the reaction.

Au(CN)2- + e- → Au + 2CN-

The steel wool has a high surface area, which means a large number of sites for the deposition
reaction to take place. This leads to higher efficiency and reduces the time for electrowinning.

o Anode reaction

The anodes or positive electrodes are made of stainless steel mesh. The anode does not collect
Gold but is necessary for the current to flow, completing the electrical circuit within the cell. It is
important that the eluate has a high pH, as the anode will corrode at less pH than 12. The only
reaction occurring at the anode is the oxidation of water to produce oxygen gas.

2H2O → O2 + 4H+ + 4e-

Steps during anodic reaction in solution: -

 Adsorption of cyanide on gold surface.

Au + CN-(aq) ⇌ AuCN-(s)

 Electrochemical extraction of an electron

Aucun-(s) ⇌ AuCN(s) + e-

 Combination of the adsorbed intermediate with another cyanide ion

Aucun(s) + CN- ⇌ Au(CN)2-(aq)

Where s refers to the surface adsorbed specie

 Overall cathode reaction

Au(CN)2- + e- ⇌ Au + 2CN-

44
The rate limiting condition appears when the diffusion rate of cyanide and Oxygen are equal,
then the slower diffusion rate of any species will provide the rate-limiting factor; the slow rate
has been related to the formation of the passive layer on the gold surface.

5.5.2 Calcination
Prior to smelting, the cathodes are first calcined in an oven at a temperature range of 350 - 450℃
. The purpose of calcining is to oxidize the steel wool and base metal impurities such as copper.
The oxide metal is then easily removed into the slag during the subsequent smelting process.
Without first calcining the cathodes, smelting would require a large quantity of flux and a larger
furnace heat input and would take a lot longer. Normally the calculation process takes place in
the calcination oven.

5.5.3 Smelting
Smelting is the final stage in the production of Gold. The purpose of smelting is to remove the
metallic and other impurities into the slag phase and produce gold bullion. The smelt temperature
is maintained for a period of time to ensure complete separation of the impurities into the slag.
The molten Gold and silver form an alloy that is heavier than the slag and hence sinks to the
bottom of the melting crucible. Smelting is achieved using the borax flux that acts to reduce the
melting point and viscosity of slag, which may get entrained in the presence of silica. The
temperature used is about 1150oC.

45
 CHAPTER SIX

6.2 Tailings storage facility

A Tailings storage facility (TSF) is a structure made up of one or more dams built for the
purposes of storing uneconomical ore (ground-up rock, sand and silt). Once tailings are placed in
a storage facility, the finely ground rock and water that together make up tailings will separate,
and the tailings that are solids will settle to the bottom. Water will accumulate at the surface to
form a tailings pond. Tailings ponds provide an important water source for mine operations,
especially for process plant operations. Tailings water is usually pumped back to the mill to be
reused in the milling process. Through this, mine water is recycled o significantly reducing the
amount of water that must be taken from the environment.

46
 CHAPTER SEVEN

7.0 Fire assay.

It is the industry standard process for obtaining analytical Gold and platinum group elements
( PGE) data from high-grade ore. Precious metals that can be Fire assayed in SBM are Gold and
silver. Fire assaying is used in the determination of Gold in all sample types.

7.1 Instruments that are used for fire assay in SBM Laboratory are

i/ crusher.

ii/ splitter

iii/ Crucible

iv/ Cupel

v/ Ball grinding

vi/ Fire finance

vii/ Beaker

Viii/ Test tube

ix/ AAS machine

7.1.1 Objective of Fire Assaying.

 Used in plant quality control
 It provided a number which represents the true value of precious metals in a given
amount of material.

7.2 Fire Assay Procedures

i/ The sample was reduced they are size to 2 mm by using the crusher, which can crush those
sample sampling places.

ii/ After crushing those samples, they can be reduced to 75 microns by using a ball mill.

47
iii/ 30g weighed from the Ball mill was mixed with Flux reagents which have 150g for each
sample

The functions of a Flux was

 To assist in melting the sample material

 To fuse the sample at a reasonable temperature
 To separate the slug materials and precious metals

The process of mixing the sample is done in a Crucible

Figure 14: Crucible

iv/ The mixture of sample and flux in a Crucible was taken to a Furnace which has a temperature
of 1000c - 1100c, where it can be fused to form a slurry.

Figure 15:Fire furnace

48
v/ A Crucible was removed from a Furnace after 1 hr in order to remove the Slurry to a mould
which is used to separate the slug and the Lead button, which have a large density than a slug.

Figure 16: mould

Figure 17: After separation of slug and lead botton

Vi/ A lead button it will be taken to a cupel which helps to remove all lead material formed in a
lead button after heating it to a Furnace which has a temperature of 1000°C to 1100°C for 1 hr.

49
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Gupta, A., & Yan, D. (2006). Mineral Processing Design and Operation: An Introduction. Perth
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