Electro-Winning Technology

Review

Scotia International of Nevada, Inc.

Electro-Winning Basics

 Nernst Equation
E = E0 – (RT/ln αM(n-1)+)
nF ln αMn+
 And the electro-deposition rate is shown as:

k = k0 exp (anF (E – E0)/RT)

Where E – E0 is the driving force or over-
potential
More Basics

 For Gold
Erev = -0.60 + 0.118 log αCN- + 0.059 log α Au(CN)2-

this ranges for -0.7v to -1.1v

Normal Operational Procedure is to Operate
at 2.7 to 4.5v. It is thought that high over-
potentials produces more “sludge” and
decreases the amount of “hard” plated
material.
The Various Generations of E-Cells

 First Generation Cells –

The first generation cells utilize an open flow
through the e-cell. The normal retention used
in the design is 60 minutes. These cells were
used for small refineries where a large
amount of floor space was not longer
required
Second Generation E-Cells

The next generation of cells utilized a

“labyrinth” path for the solution. The cathode
baskets were place in internal grooves the
connected to the bottom and sides of the
walls. This innovation forced all the solution
through the electrified cathodes, decreasing
short circuiting. This innovation allowed for
shorter retention times (30 minutes).
Third Generation E-Cells

This generation is also called a sludge cell.

This unit utilizes high current densities (larger
over-potentials) to produce non-adhering
precipitate (sludge). These cells have a
retention time of between 20 and 25 minutes
and are an open flow through design. These
cell have the advantage in large (over 1
million ounce) refineries, since they require
less floor space.
Fourth Generation E-Cells

The newest generation of cells combines the

advantages of the second and third
generation cells, utilizes advantages in better
metallurgically designed internals and a
realization that cell size variation can be
utilized to save floor space.
Fourth Generation (cont.)

The new generation utilizes the labyrinth path

along with a higher charge density. The cell
design decreases the retention time to about
15 minutes. The design realizes that using
overhead cranes has eliminated the need to
stay with the old 3’x3’ electrode design, so
floor space requirements are even further
decreased. These cells are ideal for large
refineries.
Fourth Generation (cont.)

In addition to baffling and cell size alteration,

this new generation utilizes the
understanding of the anode corrosion to bring
in an entirely different type of alloy usage for
the internals of the cells. This change allows
the high voltages that the client want to use
without the higher consumption rates
associated with the third generation cells.
Generation Advantages
First Least expensive system. Works well for small refineries
(less than 100,000 oz/yr). Utilizes lower volume of air
sweeping so there is less air treated for mercury
Second Requires less floor space and is less expensive to make
than the newer generations of e-cells. Uses similar
volumes to the the 1st generation cells, so less overall cell
volume is required, less air sweeping is needed
Third Produces more sludge by using higher
current densities. Requires less for space
than either the first or second generation cells.
Fourth Can be used to produce sludge if desired. Can be used at
normal or high current densities. Superior metallurgical
Design decrease the consumption of internals. Requires
the least floor space. Requires
less ventilation than the third generation
cells, Equivalent or lower cost than third
generation cells.
Disadvantages
Takes up too much floor space for
utilization in larger refineries. Does not
produce a large amount of sludge.
More expensive than first generation cells
Does not produce a large amount of
sludge.
Requires higher power consumption. Generates high
amount of bus heat and requires 5 to 10 times as much
air as the 1st or 2nd generation cells. High temperatures
at bus increases the potential for damage to the busbar
and the high potential for fire, interlocks are required
on the ventilation fan and the rectifiers.
Does require more ventilation volume, more power
consumption and costs more than 1st or 2nd
generation cells. There is more heat generated if used
in the sludging configuration and therefore requires
interlocking of the fan and rectifier.
 Typical 1st Generation Cell
+

Au

Au

_
Basic Design Calculations

Strip Solution Calculations:

Carbon has a density of 0.50 g/t, so a 3 tonne strip
@ 2 bv/hr requires 6 m3/hr or ~27 gpm. Since a
strip takes has approximately 8 hours of solution
flow, each strip will produce 48 m3 or ~12,700
gallons. For one strip per day, the e-cell flow would
be 2 m3/hr (9 gpm), two strips per day flow would be
4 m3/hr (18 gpm). Three strips per day (which
requires two strip vessels) would have an e-cell flow
of 6 m3/hr (27 gpm). Note: that the cell flow is
spread over a 24 hr period to save the additional
cost of e-cells.
E-Cell Design Calculations

For one strip per day system handling 3

tonnes per day, the e-cell size is:
1st Gen – 2 m3 or 75 ft3 cell
2nd Gen – 1 m3 or 38 ft3 cell
3rd Gen – 0.67 m3 or 24 ft3 cell*
4th Gen – 0.50 m3 or 19 ft3 cell*
* Not recommended for this application
Design Review

As can be seen from the calculations only a

first or second generation cell make sense to
specify. The more expensive sludging cells
are not cost effective.

In fact, the least expensive 1st Generation cell

fits the requirements best.
Second Example

If you wanted a electro-winning circuit for 1,400,000

ounce/year, you would have an e-cell flow of 40
m3/hr or 176 gpm based on two strips per day. The
e-cell capacity required, would be:
1st Gen – 1500 ft3 or 10 – 150 ft3 cells*
2nd Gen – 750 ft3 or 6 – 125 ft3 cells
3rd Gen – 500 ft3 or 4 – 125 ft3 cells (length 15’)
4th Gen – 400 ft3 or 4 – 100 ft3 cell (standard 13’
length or space saver 8’ length)
* Not recommended due to the high amount of floor space required
Discussion

As can be seen, there are numerous electro-

winning option that require the design engineer
to take the minimum refinery size into
consideration, the additional costs associated
with adding e-cell space to a refinery, the
refinery ceiling height, the amount of air that is
going to be treated, the operator’s work
schedule (5 days per week (normal schedule), 7
day/week (remote schedule) or some other
combination) and finally the client’s preference.