Kibali Process Operating Manual

Process Operating
Manual
Table of Contents
Table of Contents...................................................................................................................ii
List of figures ........................................................................................................................ v
1. Introduction .................................................................................................................... 1
2. Crusher circuit ................................................................................................................ 3
2.1. Apron feeder ........................................................................................................... 4
2.2. Primary Crushers .................................................................................................... 4
2.2.1. Jaw Crusher .................................................................................................... 4
2.2.2. Hybrid Crusher................................................................................................. 5
2.2.3. Operating the primary crushers ........................................................................ 5
2.3. Secondary crushers (Cone) .................................................................................... 8
2.3.1. Operating the secondary crusher ..................................................................... 8
2.3.2. Factors affecting cone crusher operation ......................................................... 9
2.4. Conveyors ............................................................................................................ 10
2.4.1. Safety regarding the starting and stopping of conveyors ................................ 10
2.4.2. Housekeeping at conveyors ........................................................................... 11
2.4.3. Idler types ...................................................................................................... 12
2.4.4. Conveyor equipment ...................................................................................... 13
2.4.5. Belt splices .................................................................................................... 18
2.4.6. Idler Frame .................................................................................................... 19
3. Milling Section .............................................................................................................. 20
3.1. Mill ........................................................................................................................ 21
3.1.1. Factors affecting milling operation.................................................................. 22
3.2. Cyclone ................................................................................................................. 23
3.2.1. Factors affecting cyclone operation................................................................ 24
3.2.2. Cyclone operation .......................................................................................... 25
3.3. Knelson Gravity Concentrator ............................................................................... 27
3.3.1. Knelson operation .......................................................................................... 27
3.3.2. Factors affecting Knelson operation ............................................................... 28
3.4. Flash Floatation .................................................................................................... 29
4. Intensive Leach Reactor (ILR)...................................................................................... 29
4.1. Operator Duties .................................................................................................... 31
5. Floatation Section ........................................................................................................ 32
5.1. Floatation Cell ....................................................................................................... 33
Kibali Process Operating Manual Page ii

5.1.1. Flotation equipment ....................................................................................... 34
5.1.2. Floatation Reagents ....................................................................................... 36
5.1.3. Operating a Float cell ..................................................................................... 39
5.1.4. Operator float essentials ................................................................................ 41
5.1.5. Flotation troubleshooting ................................................................................ 42
6. Thickener Circuit .......................................................................................................... 46
6.1. Thickener .............................................................................................................. 47
6.1.1. Rake lifting mechanism .................................................................................. 49
6.1.2. Flocculant dosing ........................................................................................... 49
6.1.3. Operator control ............................................................................................. 50
7. Ultra-Fine Grinding Circuit ............................................................................................ 50
7.1. UFG Mill ................................................................................................................ 51
7.1.1. UFG Start-up procedure ................................................................................ 52
7.1.2. UFG bead loading procedure ......................................................................... 53
7.1.3. UFG shutdown procedure .............................................................................. 54
7.1.4. Operator control ............................................................................................. 54
8. Pump Cell Circuit ......................................................................................................... 55
8.1. Operator Duties .................................................................................................... 57
9. CIL Section .................................................................................................................. 57
9.1. Operator Duties .................................................................................................... 61
10. Leach and Detox Reagents ...................................................................................... 62
10.1. Oxidative pre-treatment ..................................................................................... 62
10.1.1. Factors affecting pre-oxidation ................................................................... 63
10.1.2. Aachen Reactor ......................................................................................... 64
10.1.3. Hydrogen Peroxide..................................................................................... 64
10.2. Lead Nitrate....................................................................................................... 65
10.3. Cyanide Leaching .............................................................................................. 65
10.3.1. Factors affecting leaching........................................................................... 66
10.3.2. Method for detecting free cyanide concentration ........................................ 67
10.4. Carbon Adsorption ............................................................................................ 68
10.4.1. Factors affecting carbon adsorption ........................................................... 69
10.4.2. Method of determining carbon concentration .............................................. 70
10.5. Ferric Chloride ................................................................................................... 71
11. Elution Circuit ........................................................................................................... 71
11.1. Acid washing ..................................................................................................... 73
Kibali Process Operating Manual Page iii

11.2. Elution ............................................................................................................... 74
11.2.1. Factors affecting elution ............................................................................. 74
11.3. Carbon Transfer ................................................................................................ 75
11.4. Oil Heaters ........................................................................................................ 75
11.5. Operator Duties ................................................................................................. 76
12. Carbon Regeneration Circuit .................................................................................... 76
12.1. Factors affecting carbon reactivation ................................................................. 77
12.2. Preparation of fresh carbon ............................................................................... 78
12.3. Operator Duties ................................................................................................. 79
13. Electrowinning and Gold Room ................................................................................ 79
13.1. Electrowinning ................................................................................................... 81
13.2. Calcining ........................................................................................................... 82
13.3. Smelting ............................................................................................................ 83
13.3.1. Fluxes ........................................................................................................ 83
14. Water Treatment Plant ............................................................................................. 84
14.1. Operator Duties ................................................................................................. 85
15. Control Room operation ........................................................................................... 86
Kibali Process Operating Manual Page iv

List of figures
Figure 1: Basic plant flow diagram ........................................................................................ 2

Figure 2: Crushing circuit ...................................................................................................... 3
Figure 3: Size reduction in a jaw crusher............................................................................... 4
Figure 4: Hybrid Crusher ....................................................................................................... 5
Figure 5: Empty apron feeder................................................................................................ 6
Figure 6: Particle breakage inside a cone crusher. ................................................................ 8
Figure 7: Poor housekeeping on conveyors ........................................................................ 11
Figure 8: Poor housekeeping damages idlers ..................................................................... 11
Figure 9: Tear in a conveyor belt ......................................................................................... 12
Figure 10: Impact idler ........................................................................................................ 12
Figure 11: Troughing idler ................................................................................................... 13
Figure 12: Self training idlers............................................................................................... 13
Figure 13: Tachometer on a conveyor ................................................................................. 14
Figure 14: Belt alignment switch ......................................................................................... 14
Figure 15: Pull wire switch on a conveyor belt ..................................................................... 15
Figure 16: Guards not in place at a take up pulley .............................................................. 15
Figure 17: Guards installed at a tail pulley........................................................................... 15
Figure 18: Take up pulley on a conveyor............................................................................. 16
Figure 19: Belt magnet installed on a conveyor ................................................................... 16
Figure 20: Example of metal found on a conveyor belt ........................................................ 17
Figure 21: Belt scale. .......................................................................................................... 17
Figure 22: Mechanical splice ............................................................................................... 18
Figure 23: Hot/Cold splice on a conveyor ............................................................................ 19
Figure 24: Damaged idler frame .......................................................................................... 19
Figure 25: Single Mill circuit ................................................................................................ 20
Figure 26: Cascading Mill .................................................................................................... 21
Figure 27: Cataracting mill .................................................................................................. 21
Figure 28: Cataracting and cascading mill (Combined motion) ............................................ 22
Figure 29: Schematic of a hydrocyclone operation (LENNTECH, 2012) .............................. 24
Figure 30: Types of cyclone underflow ................................................................................ 26
Figure 31: Example of a cyclone flaring .............................................................................. 26
Figure 32: Knelson gravity concentrator .............................................................................. 27
Figure 33: Intensive Leach Reactor (ILR) Circuit ................................................................. 30
Kibali Process Operating Manual Page v

Figure 34: ILR Mixing System ............................................................................................. 30
Figure 35: Floatation Section .............................................................................................. 32
Figure 36: Floatation Cell .................................................................................................... 33
Figure 37: Rotor and Stator ................................................................................................. 34
Figure 38: Float ball and level transmitter............................................................................ 34
Figure 39: Dart valve and E-Dart valve ............................................................................... 35
Figure 40: Blower ................................................................................................................ 35
Figure 41: Air control valve ................................................................................................. 36
Figure 42: Particle size versus recovery .............................................................................. 36
Figure 43: Collector reaction ............................................................................................... 37
Figure 44: Float operation ................................................................................................... 42
Figure 45: Flotation cell not frothing .................................................................................... 42
Figure 46: Flotation cell producing poor quality froth ........................................................... 43
Figure 47: Sudden drop of level in the flotation cell ............................................................. 44
Figure 48: Flotation cell sliming ........................................................................................... 45
Figure 49: Example of how a flotation cell should look like .................................................. 46
Figure 50: Thickener Section .............................................................................................. 47
Figure 51: Schematic diagram of a thickener ...................................................................... 48
Figure 52: Flocculation operation guidelines ....................................................................... 49
Figure 53: UFG Circuit ........................................................................................................ 51
Figure 54: UFG Mill ............................................................................................................. 51
Figure 55: UFG inside flow .................................................................................................. 52
Figure 56: Bead sump suction pipes ................................................................................... 53
Figure 57: Pump Cell Circuit ............................................................................................... 55
Figure 58: CIL Section ........................................................................................................ 58
Figure 59: Association of gold particles with other minerals. ............................................... 62
Figure 60: Aachen Reactor ................................................................................................. 64
Figure 61: Illustration of particle adsorption onto carbon ..................................................... 68
Figure 62: Elution Circuit ..................................................................................................... 72
Figure 63: Carbon Regeneration Circuit .............................................................................. 77
Figure 64: Gold Room Circuit .............................................................................................. 80
Figure 65: Water Treatment Plant ....................................................................................... 85
Kibali Process Operating Manual Page vi

1. Introduction
Kibali Gold Mine has two different types of ore i.e. the soft and easily recoverable oxide ore
and the hard, energy consuming sulphide ore. Most precious metals in the world are found
with sulphide containing ores with the most characteristically found with gold being: pyrite
[FeS2]; galena [PbS]; zincblende [ZnS]; arsenopyrite [FeAsS]; stibnite [Sb2S3]; pyrrhotite
[Fe(1-x)S]; and chalcopyrite [CuFeS2]. Sulphide ores are called refractory ores since it was
often treated by roasting off the sulphur and then leaching out the precious metals, but as
this is expensive and environmentally damaging the hydrometallurgical option is preferred.
The oxide ore was once sulphide as well but after years of erosion and oxidation of the top
layer of the minerals, a low sulphur (<2%) containing ore body was created. Similarly this is
done in the process to the refractory ore as well via oxidation with high concentrations of
ozone before the cyanidation process as the sulphur will consume the cyanide to form
thiocyanate ions [SCN-], which is reagent consuming therefore expensive.
The oxide ore is recovered through a standard: crushing, milling and CIL operation. Sulphide
ore requires more work to liberate the gold and the steps include: crushing; milling;
floatation; ultra-fine grinding (UFG); pump cells with two highly intensive oxidation steps
before leaching; and CIL to scavenge the remaining gold.
Both ore bodies contain alluvial gold to some extent, which means it is large enough to
recovery via a density (Au: 19.3 g/cm3) separating step which at Kibali is done with Knelson
gravity concentrators during the milling cycle.
Figure 1 illustrates a basic flow diagram of the plant. The oxide and sulphide streams are
built exactly the same with bypass streams too various equipment depending on the ore type
and requirements. The only difference is a Hybrid crusher being used for the oxide ore, as
this is more accommodative to the high fines and clay content in the ore, and a Jaw crusher
for the harder sulphide ore. The Hybrid crusher structure has been set up to change to a Jaw
crusher once the oxide ore is depleted.
It is the duty of all process and engineering personnel to familiarize themselves with the flow
of the plant as well as the equipment purposes to better understand what the operational
and maintenance requirements are. Knowing will also facilitate the understanding of all
upstream and downstream effects of your decisions and actions on how to operate a piece
of equipment.
Kibali Process Operating Manual Page 1

Clarifier
Secondary Process Water Dam

Crushing: Cyclones
Cone Crushers
Concentrate Tailings Thickener

Gravity
Flash Thickener FTSF
Concentrator
Primary Floatation
(Knelson)
Crushing:
Jaw (Sulphides)
Hybrid (Oxides) Milling
Rougher Floatation
Intensive Bypass ore directly

Leach to CIL if oxide ore
Reactor (ILR)
CTSF
Gold Room
CIL
Bullion Induction Furnace
Calcining Furnace
Elution Circuit
Ultra Fine Grinding (UFG)
(AARL)
Electrowinning Cells
Pump Cells
Figure 1: Basic plant flow diagram

2. Crusher circuit
The crushing circuit is the first step in size reduction of ore being fed from the mine
(Figure 2). The Run of Mine (ROM) ore is fed into a feed bin. An apron feeder feeds the
material from the feed bin into a primary crusher (Jaw for sulphide ore and Hybrid for oxide
ore) and onto a conveyor. The conveyor leads to a diversion chute, which can either go to
the mill feed conveyor for direct milling (oxides) or to the coarse ore stockpile for further
crushing (sulphides). The coarse ore stockpile feeds via an apron feeder to the Secondary
crushers feed bin, which uses a vibrating feeder to choke feed the cone crusher. The
secondary crushers’ product falls onto a conveyor feeding the fine ore stockpile. The fine ore
stockpile is fed to the mill feed conveyor with another apron feeder.
ROM ROM
Bin Bin
Apron Feeder Apron Feeder
Hybrid Crusher Jaw Crusher
Coarse Ore
Stockpile
Apron Feeder
Fine Ore
Stockpile
Vibrating
Feeder
Apron Feeders
Cone Crusher
To Mill To Mill
Figure 2: Crushing circuit

2.1. Apron feeder
An apron feeder consists of a slow moving metal conveyor belt drawing feed from the ROM
feed bin and transporting it towards the jaw crusher. An apron feeder provides good feed
control and the metal plate that the conveyor is made of is resistant to big rocks impacting on
the surface and abrasion. The feed bin level should always be managed in such a way that
the bin is never empty therefore the rocks from the ROM pad won’t fall directly onto the
apron feeder. This can cause the metal plates to bend and keep the apron feeder from
moving.
2.2. Primary Crushers
2.2.1. Jaw Crusher
A jaw crusher works by reducing the size of the entering ore particles by squeezing the
particles between a fixed jaw and a moving jaw (Figure 3). The moving jaw moves in an
eccentric motion so that it moves away and downwards from the fixed jaw to allow the ore to
move down the jaw crusher. The second motion of the jaw crusher moves upwards and
towards the fixed jaw. This squeezes the rock between the two jaws and causes the rock to
break into smaller particles. This process continues until the ore leaves the crusher.
Figure 3: Size reduction in a jaw crusher
The closed side setting or crusher gap is the minimum distance between the two jaws at the
closed position. The gap size of the primary crusher is normally determined by dropping a
lead weight attached to a rope into the crusher and then determining the diameter of the lead
weight after it has been crushed.

2.2.2. Hybrid Crusher
The hybrid crusher works by crushing the particles between two rotating rollers which have
teeth to grip, feed and crush the particles between the rollers (Figure 4). The crusher gap is
set by placing the stop blocks in a set position and pushing the loose roller against it via a
hydraulic system. If an uncrushable object such as a piece of steel is fed into the crusher,
the loose roller will be pushed open not to damage the crusher and the operator will have to
make certain it is pushed back into its closed setting.
Figure 4: Hybrid Crusher
2.2.3. Operating the primary crushers
Good operation at the primary crusher ensures constant throughput and enables the
operator to achieve the daily production target in the required time, which allows engineering
to do maintenance on the crusher and keep everything in working order.

The tasks required from the operators include:
 Ensuring a constant supply of ore from the mine to the crusher feed bin.
 Ensuring that mining doesn’t tip big rocks onto an empty apron feeder.
 To continually monitor the feed of the jaw crusher to ensure that big rocks do not
choke the feed chute.
 Inspecting the chutes.
 Housekeeping
 Communicating with the control room operator to ensure the smooth operation of the
primary crushing circuit.
 Ensuring that the gap size of the crusher is correct.
As an operator working on the primary crusher circuit you get to learn how the crusher
operates, sounds, feels and smells. When noticing something different on the crusher
circuit, go and investigate to see what caused the change and if it will result in downtime.
Ensuring a constant supply of ore from the mine to the crusher feed bin
The two primary crushers are designed to operate at a maximum feed rate of 700 tons per
hour each. To achieve this, there has to be a constant feed to the crusher. It is the duty of
the operator at the primary crushing circuit to communicate with the mining department to
ensure that this is done. If more loaders or trucks are needed to ensure a constant supply of
material from the mine, the operator must inform his supervisor or foreman of what is
required. The foreman will then contact the necessary people to make this arrangement.
Ensuring that mining doesn’t tip big rocks onto an empty apron feeder
If big rocks are tipped directly onto an empty apron feeder, the chances are good that a rock
can wedge between the apron feeder and the chute, or bend one of the apron feeder’s
plates which will cause long downtime.
Figure 5: Empty apron feeder

To continually monitor the feed of the jaw crusher to ensure that big rocks do not
choke the feed chute
Sometimes the ore delivered from the ROM pad is bigger than what the crusher is designed
for. If the big rocks are allowed to be discharged from the apron feeder to the crusher feed
chute, it will block the chute and cause downtime on the crusher. It is much quicker to
monitor the feed on the apron feeder and if a big rock is found to stop the feed and remove
the rock from the apron feeder with a crane.
Inspecting the chutes
Check the chutes regularly for damage/wear as well as any build-up of material. By finding a
worn spot before a big hole is created, saves time in the long run as preventative
maintenance is usually much quicker than unplanned maintenance. Removing build up
inside a chute is also much quicker than waiting for the chute to choke and then unchoking
it.
Housekeeping
Good housekeeping not only makes your section look good, it is also important from a safety
perspective. If your section is kept clean it reduces the amount of hazards as there are less
chances of tripping over something, or something falling on your head. Remember: “A place
for everything and everything in its place.”
Communicating with the control room operator to ensure the smooth operation of the
primary crushing circuit
It is good to always keep the control room operator up to date to ensure that he knows what
is going on in the field. The control room operator must also communicate to the operator in
the field what information he gets from the SCADA that is not according to normal operating
parameters.
Ensuring that the primary crusher gap size is correct
It is not the job of the operator to measure the gap size, but he must always ensure that
engineering measures the gap size as soon as big rocks appear on the coarse ore stockpile
feed conveyor. Check the gap size visually as well to see if it makes sense. Another way to
check if the gap size is correct is to stand next to the conveyor underneath the crusher and
looking at the rocks produced.

If the size looks as if it is smaller than 160mm then the crusher gap is fine. If the gap size is
too large, the secondary crushers’ throughput will suffer effectively reducing the amount of
feed that can be processed by the mills.
2.3. Secondary crushers (Cone)
A cone crusher breaks rock by squeezing the rock between the mantle and the concave
bowl liner. As rock enters the top of the Cone crusher, it becomes wedged and squeezed
between the mantle and the bowl liner or concave. Large pieces of ore are broken once, and
then fall to a lower position (because they are now smaller) where they are broken again.
This process continues until the pieces are small enough to fall through the narrow opening
at the bottom of the crusher.
Figure 6: Particle breakage inside a cone crusher.
2.3.1. Operating the secondary crusher
The secondary cone crushers are only utilized for the harder sulphide ore and can be
bypassed when oxide ore is being processed through the system. The cone crusher is
design to crush a maximum 700 tph.
Choke feeding is an important practice for the operation of a cone crusher. Choke feeding is
where the entire crushing chamber is buried in ore.

There are two reasons why choke feeding results in improved crushing performance:
 The rock particles will crush against themselves as well as against the steel crushing
surface (i.e. rock-on-rock contact as well as rock-on-steel).
 Because the crushing chamber is completely full, no near-sized rock particles can
pass through the OSS without being crushed (this does happen when the cone
crusher is dribble fed).
2.3.2. Factors affecting cone crusher operation
Gap size
The gap size or closed side setting (css) determines what maximum aperture your rock will
have coming out of the crusher. If larger rocks than required feed the cone crusher, the
crusher will have to work harder to reduce the rocks to the required size and the throughput
will suffer.
Liner wear
By monitoring the A dimension of the crusher, the liner life for each crusher can be
determined. If the liner is worn out, then the crusher will produce larger rocks that negatively
impacts production.
Faulty ASRI
The ASRI (Automatic setting regulation instrument) is the computer that monitors and
controls the crusher. It records your gap size, A dimension setting, power draw and fault/trip
history. If the crusher has a high power draw, the ASRI increases the gap size a little bit to
reduce the power and prevent the crusher from tripping. If the ASRI is faulty, then the
crusher will run in an erratic manner and throughput will be affected. The ASRI is also used
to do the metal to metal calibration on the cone crushers.
Choke feed
To increase the throughput of the cone crusher the cone crusher must be choke fed. When a
cone crusher is choke fed the rocks help to break each other along with the crushing
imparted by the liners, which also increases the lifetime of the liners.

2.4. Conveyors
Conveyor systems move materials from one point to another, over varying distances and
heights.
2.4.1. Safety regarding the starting and stopping of conveyors
Emergency Stops
Conveyors continue to move, even if a worker's clothing or body is caught in the machine.
Emergency stop devices are required at certain points in the conveyor system. Emergency
buttons or pull-cords are to be placed at the beginning and end of an entire conveyor
system, as well as at other strategic points along the conveyor. If a pull-cord is not stopping
the conveyor if it is activated, the conveyor must be locked out and first fixed before running
again. Report or be liable if not doing so.
Lock-Out Safety
Lockout and tag-out procedures must be put into place when a conveyor is shut down for
more than a short emergency stop. The conveyor start and stop mechanisms and the
electrical or other power source are required to have locking devices such as padlocks. In
addition, a tag with the identification of the person who turned off the system should be
attached next to every locking device. The identified person is the only one who is allowed to
unlock the system and turn the power and moving parts back on.
Other Safety Requirements
Workers should take safety precautions while a conveyor system is shut down. Never stand
or sit on a conveyor. Don't walk under an overhead conveyor. And avoid crawling around
and under a floor-level conveyor, including conveyors with or without side guards to keep
materials from falling off. For added protection, many facilities require that the conveyor must
be emptied before sounding a shut-off signal and shutting down the conveyor.
Conveyor Start-Up Safety
Before restarting a conveyor, certain safety procedures should be followed. Workers should
be near their stations if any material remains on the conveyor. However, workers should
stand back a few feet until the system is deemed to be working safely. Before the power
source is turned on and the conveyor system is put into operation, a loud warning horn

should sound. This will alert workers at the conveyor and those in the area in case of
problems in the system's operation, falling materials or other risks.
2.4.2. Housekeeping at conveyors
Good housekeeping must be exercised to keep the return rolls and snub pulleys clean.
Build-up of material on this equipment has a destructive effect upon the alignment of the
conveyor with the result that the belt may run against the structure and damage itself.
Figure 7: Poor housekeeping on conveyors
Figure 8: Poor housekeeping damages idlers

Figure 9: Tear in a conveyor belt
Damaged idlers should be replaced immediately and if damaged parts on the conveyor are
found, engineering needs to be alerted and inspection needs to be done to see what the
cause was.
There are many different things than can cause damage to the conveyor and the equipment
associated with it. The operator should always look out for any steel in the ore as they can
cause damage to the conveyor. Spillage at the take up pulleys or under the conveyor can
cause the belt to misalign and damage the structure, idlers or the belt itself. Damaged idlers
can also have the same effect on a conveyor belt.
2.4.3. Idler types
Each type of idlers has a specific function on the conveyor belt. Impact idlers cushion the
impact of falling ore onto the belt. This reduces the forces acting on the belt to help prevent
the conveyor from being damaged by falling objects. Self-training idlers keep the conveyor
aligned and prevent the belt from drifting. Troughing idlers give shape to the conveyor belt to
keep the belt from spilling its contents. Return idlers keep the returning side of the belt in
position.
Figure 10: Impact idler

Figure 11: Troughing idler
Figure 12: Self training idlers
2.4.4. Conveyor equipment
Each type of equipment used on a conveyor belt has a specific function to keep the belt
safely at the correct speed with the correct alignment and no damage to equipment.
Speed Switch
A speed switch is a device which continuously supervises the speed of the conveyor and
stops the conveyor as soon as speed of the belt drops below the normal working speed. The
belt loses speed due to the overloading of material. The speed switch also serves to detect if
the belt has snapped or tripped, as the speed will reduce to zero in those instances
Tachometer
The function of the tachometer is to determine the speed of the belt which the weightometer
uses to calculate the amount of tons passing on the belt.

Figure 13: Tachometer on a conveyor
Belt alignment switch
Belt alignment switches are installed along both sides of the belt and are positioned in such
a way that their operating handles get deflected by the edge of the swaying belt and initiate
warning/stopping signals indicating to the control room that the belt is out of its correct
alignment.
Figure 14: Belt alignment switch
Pull Wire
This is a very important safety device, which enables the supervisory personnel in
the vicinity of the belt to stop the concerned belt if any malfunctioning is noticed. As
per the usual practice, the Pull Cord switches are installed on one or both sides of
the conveyor, depending upon the provision for walking platform.

Figure 15: Pull wire switch on a conveyor belt
Guards
It is important to guard any moving equipment on a conveyor to prevent anybody entering

such areas as this is a risk to the operator’s safety. If a person’s clothing or body gets caught
between the conveyor and a pulley or idler, serious damage or death can be caused.
Figure 16: Guards not in place at a take up pulley
Figure 17: Guards installed at a tail pulley

Take up pulley and counterweight
The take up pulley and the counterweight is used to keep the correct tension on the belt to
prevent the belt from sagging. If the weight of the counterweight is too high, the belt will be
under tension, and there is a possibility of the belt snapping.
Figure 18: Take up pulley on a conveyor
Belt Magnet
The function of the belt magnet is to remove any tramp metal that can be found on a
conveyor belt. This is very important as the metal can damage your conveyors, crushers or
mill liners.
Figure 19: Belt magnet installed on a conveyor

Figure 20: Example of metal found on a conveyor belt
Belt scale
The belt scale is used to measure the amount of tonnes moving from one point to another in
the plant to ensure accurate accounting of the tonnes processed in each unit operation such
as the crushers or the mills.
Figure 21: Belt scale.
Maintaining belt scales
Proper and consistent maintenance on the conveyor and belt scale is essential for reliable
measurement operation. The scale should be routinely calibrated, the duration between
calibrations checks can be extended after the scale has proved reliable for a reasonable
period of time.

Routine inspections should be made of the scale area idlers, take-up, belt, speed sensor,
and scale to make certain they are in proper working order and that material build-up is not
hindering operation. Belt scales can be susceptible to problems caused by material build-up
because debris can collect in structural portions of the scale and prevent the material weight
from being sensed by the load cells. The additional material on the scale structure can also
give inaccurate readings.
2.4.5. Belt splices
A belt splice is used to join two pieces of a conveyor. There are three different types of
splices used on a conveyor belt.
Mechanical splice
A mechanical splice consists of clips attached to each side of the conveyor and keeping it
together. A mechanical splice is normally the quickest way to join a belt but is the least
desirable. If the belt clips are not made of stainless steel, it can trip the belt metal detectors
and have a negative effect on production. The clips can also catch on the idlers frames or
the idlers and tear the belt.
Figure 22: Mechanical splice
Hot splice/Cold splice
A hot/cold splice is used to glue different layers of the conveyor together thereby creating a
stringer splice between the two sections of the belt.

The main difference between a hot and a cold splice is the type of glue and the temperature
at which the glue is set. A cold splice is quicker than a hot splice but takes longer than a
mechanical splice.
Figure 23: Hot/Cold splice on a conveyor
2.4.6. Idler Frame
The idler frame keeps the idlers in their place to ensure smooth movement of the conveyor
belt.
Figure 24: Damaged idler frame

3. Milling Section
The goal of the milling section is to liberate the valuable minerals from the gangue by
grinding and exposing the mineral surface area. In the leaching circuit adequate exposed
surface area of the valuable mineral is required for oxidation and leaching purposes and in
the floatation circuit for recovery purposes. Figure 25 illustrates a single Mill circuit which has
been built in duplicate at Kibali.
The mill feed comes from the crushing section; thereafter it is grinded in the mill and falls out
onto a sizing screen. The sizing screen separates out the scats and steel balls from the
useable fine ore. The fine ore is pumped as slurry to the cyclones, which separates the finer
fraction, reporting to the overflow leading to the floatation section, and the coarser fraction to
the underflow. The cyclone underflow has three separate routes leading back to the mill for
regrinding and is called the recirculating load.
To Floatation
Section
Cyclone Cluster
Float Reagent
Addition
Flash Float
Knelson Gravity To Concentrate

Concentrator Thickener
Mill
To Intensive Leach
Reactor (ILR)
Scats
Stockpile
Figure 25: Single Mill circuit

The cyclone underflow can go directly back to the mill, over the Knelson feed screen, or to
the Flash Float feed box. Oversize of the Knelson feed screen reports back to the mill feed
conveyor, while the underflow can either go directly back to the mill or feed the Knelson
gravity concentrator. Gangue of the Knelson reports back to the mill and the alluvial gold
concentrate is sent straight to the intensive leach reactor (ILR). The flash float recovers the
gold associated with sulphides, which heads directly to the concentrate thickener while the
gangue reports back to the mill for regrinding.
3.1. Mill
A mill reduces the ore particle sizes by grinding it down. To reduce a particle from the feed
size of 80% -50mm for sulphide ore and primary crusher product for oxide ore (smaller than
160mm with 80% fines) down to the required particle size of 80% -75µm energy needs to be
imparted onto the ore. Energy is imparted by using steel balls as grinding media inside a
rotating mill. As the mill rotates the balls are picked up by the lifter bars and thrown onto the
slurry where it reduces the particle size by impact, which is called Cataracting (Figure 27).
Some of the balls also cascade down the ball charge which reduces the particle size by
abrasion and attrition, as shown in Figure 26.
Figure 26: Cascading Mill
Figure 27: Cataracting mill

Figure 28: Cataracting and cascading mill (Combined motion)
3.1.1. Factors affecting milling operation
Ball load
The amount of balls inside the mill has a large effect on the power draw of the mill. The
power draw of the mill is the amount of kW it uses per hour. The higher the power draw, the
more energy it uses and the higher the electricity required to obtain the power draw. To
determine the ball load inside the mill, the mill should be thoroughly flushed while grinding
out to ensure all the slurry is removed from the mill before stopping to obtain an accurate
reading of the ball charge.
Once inside the mill two measurements should be taken and the following formula used to
determine the ball load:

Feed rate
The mill feed rate is capped by the design maximum capacity of 450 dry tons per hour. The
ball charge, power draw, recirculation load and scats should be taken into account when
determining the optimum feed rate to achieve the desired grind of 80% -75µm. If the feed
rate is too low for a long period of time, then the mill will run empty and the grinding media
as well as the liner wear will increase.
Mill inlet water
The mill inlet water should be kept at the required set point. If the mill inlet water flow rate is
too high then the mill is being flushed out which will cause damage to your equipment as
well as hinder throughput. Your discharge sump level will stay high further reducing the
amount of tons you can process. If the mill inlet water is too low then the slurry will stick to
the grinding media inside the mill and result in a coarser grind and overloaded mill. Mill
discharge sump dilution water will not be enough to dilute the slurry adequately before it is
being pumped to the cyclones. This will cause inefficient separation resulting in a high
circulating load which hinders throughput. Make sure the settings are on auto to obtain
adequate water levels to process the ore at the correct densities. Common operating mill
grinding densities are around 1.8SG and cyclone feed densities should be controlled around
1.6SG.
3.2. Cyclone
A cyclone classifies different particles according to their density, shape and size. The
cyclone is fed from the mill discharge sump via mill discharge pumps to the distributor box
which ensures that all the cyclones get the same amount and type of feed. As the feed
moves from the inlet to the conical section the slurry start to spiral downwards in the cyclone.
The lighter or smaller particles move to the centre of the cyclone, while the heavier bigger
particles move away from the centre of the cyclone. This is the classification process in the
cyclone. As the lighter particles move to the centre, it gets transported upward by an air core
created by the pressure in the cyclone and exits the cyclone via the vortex finder. The
bigger, heavier particles move to the bottom of the cyclone and exits via the spigot/apex.

Figure 29: Schematic of a hydrocyclone operation (LENNTECH, 2012)
3.2.1. Factors affecting cyclone operation
The goal of the cyclone is to separate all the small particles smaller than 75µm from the
bigger particles. The smaller particles report to the overflow of the cyclone and the bigger
particles report to the underflow and ultimately back to the mill. There are several factors
affecting the classification in a cyclone:
Feed density
A higher feed density (percentage solids) means there are more particles in the feed that
has to be classified. The lighter particles get hindered on their way to the centre of the
cyclone which causes some of it to report to the underflow. The lower your percentage
solids, the higher flow rates need to be processed and can reduce the efficiency and
capacity of downstream equipment.
Feed pressure
When the cyclone pressure is too low some of the fine particles reports to the underflow, as
the pressure in the air core is too low to transport them upwards. When the pressure is too
high, coarse particles are pulled to the centre of the cyclone and transported upwards via the
air core. The pressure in the cyclone is normally regulated by opening and closing cyclones
in the cluster, too maintain the pressure between 80-100kPa.

Vortex finder size
Increasing the size of the vortex finder allows the cyclones to have a greater throughput, but
at the cost of having a coarser overflow. As the size of the vortex finder increases, the air
core in the cyclone increases as well. This causes some coarse particles with a lower
density to move upwards towards the vortex finder of the cyclone. The vortex finder should
be sized in such a way that the required throughput and particle size is achieved in the
cyclone overflow.
Spigot/Apex size
Increasing the size of the spigot increases the grind. There is an optimum point, where if the
spigot is too big more fine particles will report back to the mill, leading to over grinding.
Resulting in higher costs since your liner wear and steel ball consumption increases. The
throughput capacity of the mill will drop as the recirculating load increases as well.
3.2.2. Cyclone operation
During the operation of a cyclone the operator should check the following:
 Feed density to the cyclone to be taken at the mill discharge sump.
 Feed flow rate to the cyclone.
 Cyclone pressure.
 Overflow density to be taken at the linear screen.
 Determine if a cyclone has choked by looking at the oversize on the linear screen.
 Determine if there are any leaks on the cyclone.
 Check if the underflow has any build up. If there is build up, clean it.
 During maintenance periods measure the diameter of every vortex finder and spigot
and replace any worn ones.
 Monitor the shape of the cyclone underflow. This will give you an indication of how
the cyclone is running.

Figure 30: Types of cyclone underflow
A. The cyclone is flaring. This means that the underflow density is too low which causes
fine particles to go back to the mill. Closing a cyclone to increase the pressure will
help to reduce the flaring of the underflow. If the cyclones are flaring and new spigots
were installed, the spigot size is too big.
Figure 31: Example of a cyclone flaring
B. Correct cyclone underflow discharge. The cyclone underflow is between flaring and
roping.
C. The cyclone is roping which can be caused by the pressure in the cyclone being too
high. If the cyclone is roping, then the overflow will be coarser than in B. to reduce
the roping, open another cyclone which will cause the pressure to drop. If the cyclone
is roping continuously after new spigots were installed then the spigot size is too
small.

3.3. Knelson Gravity Concentrator
The Knelson gravity concentrator separates out the more dens alluvial gold from the less
dens gangue via density separations. It works on the same principles as a cyclone as it
separates on size as well as density. Therefore screening is necessary before feed enters
the Knelson as screening will force it to only separate on density. The Knelson is better than
a cyclone in the fact that it is a batch operated system, meaning it will continually
concentrate the more dens particles during operations and separate it out from the gangue,
where after the concentrate is dropped to the ILR for further processing.
Figure 32: Knelson gravity concentrator
3.3.1. Knelson operation
Illustrated in Figure 32 are the inner workings of the Knelson gravity concentrator.
Fluidization water flows into the water cavity through the rotor shaft. Pressure forces water
through the fluidization holes into the concentrating rings. Feed slurry enters unit and is
distributed from the deflector pad, while centrifugal forces drives the slurry outward to the
cone wall. Starting from the bottom the solids fill each ring and once the rings reach capacity
a concentrating bed is formed. After a set amount of time the feed is cut off to the unit and
the flush cycle begins. The motor will stop and all the concentrate will be flushed to the ILR
unit. Once the concentrate is flushed the whole sequence will restart to collect more alluvial
gold.

The operator should do daily inspections on the following:
 Engineering does the daily greasing of the bearings.

 Visually inspect the machine for:
o Unusual or excessive vibration
o Water leaks
o Slurry spillages
 Open filter drain for 3 seconds and check for solids or discoloration.
 Check that the fluidizing water pressure and filter differential pressures are indicating
normally.
Weekly checks for the operator include:
 Check the feed screen for blinding, holes and correct spray water.
 Remove Knelson lid and observe operation, especially the ramp down, flush and
start-up sequence (It is possible to instantly asses the health of the system by
observing the sequences).
 Lock-out the Knelson:
o Make sure the 3mm slit holes are clear.
o Feel the inside of the rings of the concentrator cone for scale build-up and
polyurethane wear.
o Inspect deflector pad and cone for wear.
 Remove filter screen and clean, ensure proper reassembly.
3.3.2. Factors affecting Knelson operation
Fluidising holes
If the fluidising holes are not kept clean, the water will not pass through and as a result the
concentrate bed will compact. If the concentrate bed compacts no new concentrate can be
captured resulting in zero recovery of gold.
Bowl sealing
If the bowl flange, bolts or cone hub leaks, the fluidising water will not have sufficient
pressure to push through the fluidising holes. As a result the concentrate bed will compact
leading to zero recovery. However do not cover up the silt holes as these will help remove

any built silt that is centrifuged onto the cone walls. If the silt is not removed the machine will
go out of balance.
Fluidization water
Normal concentrating flow rates are between 52 to 76 m3/hr; while a normal flushing flow
rate is 10 to 20% higher. A normal concentrating operating pressure range is 7 to 21 kPa
and filter differential pressure 28 to 56 kPa.
Improper shutdown
Improper shutdown will cause recovery loss and/or equipment damage. Reducing the
fluidization water too low while the cone is rotating will cause the fluidization holes to plug.
While shutting down with too high fluidization flow will result in concentrate losses.
3.4. Flash Floatation
The goal of the flotation cells is to separate the sulphide particles from the rest of the ore.
This sulphide rich concentrate will be treated in a separate section than the rest of the ore.
This will improve the overall operation and recovery of the plant.
A portion of the cyclone underflow is fed to the flash flotation rougher cell and enters via the
feed box. The float reagents, i.e. frother, promoter, activator and collector, are also fed into
the feed box. The froth or concentrate is sent to the concentrate thickener, while the
underflow of the cell is fed back into the mill for regrinding. The floatation operation is
discussed further in the Floatation section.
4. Intensive Leach Reactor (ILR)
The Gekko ILR is an intensive cyanidation reactor for leaching high grade gold concentrates.
The system consists of an ILR feed cone, solution cone, rolling reactor drum, sump for the
reactor discharge, pump for all recirculation and transfer duties, flocculant mixing tank and a
flocculant pump (Figure 33).
Gravity concentrator concentrates is gravity fed into the reaction drum from the feed cone.
During a batch, leach solution is added to the reactor drum while it rotates at slow speed (1-
2rpm) to achieve thorough mixing of the solids and leach solution (Figure 34). Solution
overflows from the reactor drum into the discharge sump from where it is pumped to the
appropriate destination depending on the sequence step.

From Knelson 1/2
Concentrate
Solution
Feed Cone
Cone
Water
Cyanide
Rins Solution
to CIL ILR Caustic
Preg Solution
Oxygen
to Preg Tank
Peroxide
Solids to Mill 1/2
Discharge Flocculent
Figure 33: Intensive Leach Reactor (ILR) Circuit
Figure 34: ILR Mixing System
Intensive cyanidation leaching is carried out at cyanide levels ranging between 5000 to
50000 ppm with DO levels exceeding 15 ppm. A batch is processed in 9 steps: Loading,
addition of reagents, leaching, clarification, solution transfer, wash, rinse, emptying of solids
and drainage.
Both the feed and solution vessel weights are monitored. The weights are compared to
various set-points during the process to control the progression of solids and solution
through the batch sequence. On completion of a batch leach, the pregnant leach solution is
pumped to the ILR electrowinning pregnant solution tank.

The reagents used in the ILR process are: sodium hydroxide (NaOH) for pH control and
conductivity modification, Sodium Cyanide (NaCN) for metal dissolution, Oxygen gas to
provide an oxidant for the dissolution reaction and a suitable flocculant for clarifying pregnant
leach solution prior to discharge. The reagents properties in the leach process are discussed
in section 9.
At the end of the process, solids are removed from the reactor drum by reversing the rotation
direction of the drum. The solids is discharged into the ILR sump and pumped either to Mill
no. 1 or 2 discharge
Water is added for the purpose of leach solution make up and to assist with tailings solids
discharge. Automated sample valves are present on all discharge lines to assist in
metallurgical mass balancing and accounting around the ILR.
ILR recovery can be improved by the following:
 Increase the recirculation rate of the solution.

 Use of fresh reagents and high oxygen levels are very important at the start of a
batch.
 Increase the DO levels in the reactor.
 Change drum speed until optimal mixing is achieved.
 Problem elements can be eliminated by adding additional reagents, for example:
o Lime to precipitate As
o Phosphate to precipitate lead.
4.1. Operator Duties
The operator should do the following at the ILR section:
 Monitor ILR sequence and make sure the system is functioning normally.
 Monitor reagent addition and ensure adequate reagent levels within the circuit to
complete a leach cycle.
 Take samples during each step to monitor the circuit.
 Mix Flocculent for the ILR.
 General housekeeping and inspections for maintenance purposes.

5. Floatation Section
Floatation is a process in which valuable minerals are recovered by separating hydrophobic

particles (physically repels from water) from hydrophilic particles. Reagents are added which
selectively combines with the valuable minerals to make it hydrophobic, while air is added to
create surface area for the hydrophobic particles to cling to and float to the top of the cell
and overflow into a launder. The gangue which remains hydrophilic will leave the cell via the
tails. The precious metals at Kibali are mainly associated with various sulphide minerals,
which will chemically be used to combine with the reagents that will make it hydrophobic.
The floatation section, displayed in Figure 35, is fed from the milling section’s cyclone
overflow over a linear screen. The linear screen removes all oversize material, which mostly
comprise of wood chips that fall onto a dewatering screen. The underflow of the linear
screen falls into a route selection box, which can either go to: the calibration tank; Rougher
cells if sulphide ore is being fed; or directly to the tails tank if oxide ore is fed.
From Cyclone
Overflow
Blower
Linear Screen Dewatering Screen
Collector
Cell #1
Cell #2
Cell #3
Activator To Tails
Cell #4
Thickener
Cell #5
Cell #6
Promoter Tailings
Tank
Frother
Concentrate To CIL
Tank
Calibration To Concentrate
Tank Thickener
Figure 35: Floatation Section

In the Rougher bank feed well; collector, activator and frother is dosed. Collector, activator
and promoter can also be dosed in Cell #3 if necessary. A blower adds air into every cell.
The roughers separate out the concentrate from the gangue, with the gangue running
through to the tails tank and the concentrate to the concentrate tank. The tailings tank can
either be pumped to the tailings thickener if sulphide ore is being fed or it can go directly to
the CIL if oxide ore is being fed. The concentrate is sent directly to the concentrate
thickener.
5.1. Floatation Cell
A floatation cell separates out minerals on the chemical properties it possesses. Reagents
are added to selectively change the properties of the valuable mineral in order for it to
separate out. The valuable minerals are changed to become hydrophobic (physically repels
water) in order for it to stick to the air that is added to the tank and float to the surface. Two
layers of material are created, namely a froth layer and a slurry layer. The froth layer
carrying the valuable minerals overflows into a launder, while the slurry layer, containing the
gangue minerals, flows out at the bottom (Figure 36).
Figure 36: Floatation Cell

5.1.1. Flotation equipment
Rotor and Stator
The rotor and stator are used to mix the slurry, reagents and air (Figure 37).
Figure 37: Rotor and Stator
Float ball
The float ball is used in conjunction with a level transmitter to determine the pulp level in the
rougher cell. As illustrated in Figure 38, the float ball has a shaft and striker plate which the
level transmitter uses to read the level.
Figure 38: Float ball and level transmitter

Dart valves
Either a dart valve or e-dart valve is used to control the level in the rougher cell. Usually two
dart valves are used simultaneously, one fast acting and one slow acting, to accurately
control the pulp level in the cell. Figure 39 shows a dart valve and E-dart valve respectively.
Figure 39: Dart valve and E-Dart valve
Air control valve
The amount of air that enters the cell is a very important method of controlling the amount of
froth that is generated as well as the size of the bubbles. Air flow is generated by the blowers
(Figure 40), while the control valves (Figure 41) regulate the flow to each cell and the
remainder is blown off back into the atmosphere.
Figure 40: Blower

Figure 41: Air control valve
5.1.2. Floatation Reagents
Floatation reagents selectively modify the properties of minerals. In gold floatation the
valuable metals are associated with sulphide minerals, similar to platinum floatation.
Therefore reagents associated with modifying sulphide minerals are used. In contrast to
platinum floatation, gold floatation focusses on recovery rather than grade, which means
promoters rather than depressants are used.
For the reagents to effectively work the valuable mineral surface area must be exposed.
Therefore the ore is ground down to 80% -75µm as it is the best median between cost and
recovery. Figure 42 illustrates a graph between size fraction and recovery.
Figure 42: Particle size versus recovery

Collector (PAX)
A collector is defined as an organic chemical of which the chemical structure is divided into a
polar and a non-polar group. The non-polar group is associated with the hydrophobic portion
that repels water and the polar group the solidophilic portion which attaches itself to the
sulphide mineral, illustrated in Figure 43.
Air
Bubble
Hydrophobic chain
Polar group
Mineral
Figure 43: Collector reaction
Under dosing of the collector will result in less recovery of the mineral, but too much collector
will force the collector to start attaching to the gangue minerals, reducing the grade.
Although gold floatation focusses more on recovery than grade, overdosing will have
adverse effects on the rest of the circuit and can also drop recovery of the sulphide minerals
as it will have to fight for space on the air bubbles.
Activator (CuSO4)
Copper sulphate is widely used as an activator for sphalerite, pyrite, pyrrhotite and other
sulphide minerals. The use of copper sulphate as an activator in gold floatation has various
benefits:
 Copper sulphate attaches to the sulphide mineral surface which causes the collector
to attach to the sulphide particle much easier resulting in increased recovery.
 Cyanide acts as a depressant for most sulphide minerals and copper sulphate reacts
with the cyanide to form copper cyanide, neutralizing the depressant effect.
 Pyrite does not float in a highly alkaline pH environment, but reacts with xanthate and
floats readily in a near neutral or acid pH range. The reducing effects of copper
sulphate solution may help reduce the pH and increase floatation efficiency.

Too little activator will cause the recovery to drop, while too much activator will cause
unwanted particles to float resulting in decreased concentrate grade. High reagent dosage
also results in high recovery costs.
Frother
Frothers are heteropolar surface-active compounds containing a polar group and a

hydrocarbon radical, capable of adsorbing in the water-air interface. A frother’s bonds are so
strong it creates conditions for froth formation, with the molecules arranging in the air-water
interface and stabilising the surface area.
The frother is added to stabilise the air-water interface in order for the collector to repel itself
from the water into that interface. Because of density differences the air bubbles will float to
the top and overflow into the launders, separating the concentrate from the gangue.
Frother dosing is important for the following reasons:
 Too little will cause unstable froth and reduce recovery.

 Too much will:
o Create too stable froth that is hard to breakdown and will cause downstream
difficulties.
o Increase the gangue particles entrained and carried over to the concentrate.
Promoter
A promoter is more selective than xanthates against iron sulphides in alkaline circuits up to a
pH of 12. Because the promoter acts in the same way as a xanthate it also helps to stabilise
the air-water film, increasing froth strength.
Dosing promoter in the circuit is not always necessary; it will depend on the ore type and
characteristics as well as the quality of the process water that is used. Only use when
recovery in the system is not up to standard, since overdosing will cause too stable a froth
that creates difficulties downstream.

5.1.3. Operating a Float cell
In a flotation cell, there is almost always a trade-off between recovery and concentrate
grade. As soon as the recovery increases, the concentrate grade will decrease and vice
versa. It is the duty of the operator to ensure that the flotation section is operated so that the
flotation section produces the optimum concentrate grade at the highest recovery possible.
Pulp Density
Flotation occurs better at a lower density, but cannot be floated at too low density as the
residence time in the cell is decreased and the recovery drops. If the density in the cell is too
high, the viscosity of the pulp increases which causes air hold up in the cell. This causes the
air bubbles to merge and become bigger bubbles. This decreases the coarse particle
recovery in the cell.
Air addition rate
The rate at which air is added to a cell determines the amount, size and shape of the
bubbles in the cell. This is important as the air bubbles can be considered as the carrier that
transports the sulphide particles to the froth zone. Increasing the air rate causes an increase
in the amount of froth that goes into the launder. If the air flow rate in the cell is too high, the
speed of the bubbles is too fast and that causes the bubbles to burst when it reaches the
surface of the cell.
As the air rate is increased, the amount of water overflowing into your launder also
increases. The amount of water recovered has an effect on your grade, as the water entrains
particles without selectivity, so gangue particles reports with the water to the concentrate.
If the blower is running and there is no air going through the flow meter, then it is possible
that the rotor shaft has choked up and that no air can go through into the cell. To un-choke
the rotor shaft, remove the v-belt guard and unscrew the top of the rotor shaft. Insert a hose
to remove build-up.
If this does not solve the problem, material is built up between the rotor and the stator and
needs to be cleaned to enable air to leave the rotor shaft.

Froth depth
The depth of the froth in the flotation cell determines whether the grade or recovery will be
favoured. The higher the froth depth the grade will increase but the recovery will decrease. If
the froth depth is lower, the recovery will increase and the grade decrease.
Feed rate to the flotation cell
To ensure that the flotation cell runs optimally, the flow rate into each flash float cell should
be managed accordingly. If the flow rate into the cell is too high (more than 190m3/h), the
residence time in the cell decreases and the air gets sucked into the underflow which causes
an unstable cell with insufficient air to operate correctly. If the flow rate in the cell is too low,
then the cell will have difficulty maintaining the required level as well as the mass pull will
decrease and the circuit will operate under target.
Start-up of Rougher bank
• Start rougher tails pump and select desired direction to pump tails.
• Ensure that the concentrate pump is ready to run and in automatic.
• Start reagent pumps in automatic and ensure correct dosing set points are entered.
• Ensure that all level control and air control valves are in automatic on the PID
controllers.
• Start air blowers and ensure that the blow off valve is in automatic.
• Open feed valve to flotation section.
• Start-up Rotors as the cells start getting level (every subsequent cell in a different
direction).
• Wait until all the cells have level in them and start adjusting the air and level set
points via the control room.
Shutdown of Rougher bank
• Close feed valve to flotation circuit.

• Stop all the reagent pumps.
• Give all the flotation cells a low level set point of +- 20 to 30%.
• If the low level set point is reached close all the level control valves manually, starting
with the first cell working your way down the bank until all level control valves are
closed manually.
• Starting with the last cell open level control valves manually 30%.

• Wait until the cell is empty and stop the rotor.
• Continue working up the float bank to the first cell emptying them one by one and
stopping the rotors.
• When following these steps keep the tailings tank in mind and ensure it does not
overflow.
• When all the cells are empty and the rotors are stopped then stop the air blowers.
Ensuring that the air points do not choke up.
• It is very important when stopping the flotation to ensure that the blowers do not run
with pulp still in the cell while the level control valves are closed and no feed is
coming in. The energy that is generated by the air the pulp and the rotor becomes
extremely hot and can cause severe damage to the cell and its components.
5.1.4. Operator float essentials
• Always try to maintain a stable feed rate. If the feed is not stable levels the cells will
not be able to control properly and some cells might slime and others might not float.
• Never pull too fast or too slow on the cells. If a cell is pulling too fast it will slime
which will cause the gangue to go to your concentrate and grade will decrease. Also
don’t pull too slow otherwise recoveries will drop. It is always better to run your level
set point a bit lower and increase the air. Pull the whole bank in a way that the
concentrate pumps can keep up.
• When running a float bank, pull your first few cells a bit harder to get the sulphides
out quickly. At the last few cells the sulphides in the pulp will be less so the cells don’t
need to pull too hard.
• Always maintain correct dosing rates from reagent pumps. There is a lot of negative
impacts over and under dosing has on a float bank (see reagent descriptions).
• Housekeeping and maintenance is very important. Keep concentrate launders and
float ball shafts clean. Inspection on rotors, stators as well as level control valve darts
must be done regularly.
• Always start reagents about 10 minutes before you put feed through the circuit so
that by the time the pulp is introduced you can start floating. Stop reagents when the
circuit is not getting feed.
• Always check that given set points of air and level matches the actual value, if not
investigate.

Figure 44: Float operation
5.1.5. Flotation troubleshooting
In the flotation section, there are many different operational variables and thus many things
can cause a variation from normal operating procedures. This section serves as a guide to
help identify the problem but is by no means a complete guide to solve any problem
experienced on the flotation section
Example 1 – No froth in the flotation cell
Figure 45: Flotation cell not frothing

Factors that could contribute to the problem:
1. Mechanical failure
 Blower tripped (Causing the froth to collapse)
 Air valve not functioning properly
 Agitator tripped (No agitation in flotation cell)
 High density in the flotation cell (Air bypassing to the underflow)
2. Reagents
 Reagent pumps tripped / pump failure
 Dosing tanks ran empty
 Pipe line choked
 Ore changed and need a change in reagent dosing
3. Flotation cell choked
 If the cell cannot drain properly it causes instability in the cell and no froth can
form.
Example 2 – Poor quality froth
Figure 46: Flotation cell producing poor quality froth

Factors that could have caused the problem:
1. Dosing of PAX and CuSO4

 Reagent dosing is not correct. Measure the reagent flow rate and adjust the
pump speed accordingly.
 Reagent dosing tank could was empty. Ensure transfer pumps are running
and mixing is in progress at the reagent mixing area to ensure that there are
always sufficient reagents available.
 No reagent addition. Ensure dosing pumps are running and in good working
order
 If there is still no reagent addition inspect the dosing line for leaks or
blockages. If no leaks are found, inspect the pump and if a problem is
suspected, make a call out to a fitter to solve the problem.
4. Air flow
 Reduce air flow to cell
 Air valve not functioning (Stuck on an open position)
5. No floatable particles in the ore.
 When it is determined that all the reagents are correct, it is possible that there
are no floatable particles in the ore.
6. Not enough feed going into the cell.
 Confirm from the flow meter in the field and the control room if the cell is
getting enough feed.
Example 3 – Sudden drop of level in the cell
Figure 47: Sudden drop of level in the flotation cell

1. Level control valve stuck on an open position – Investigate in the field if the level and
feed control valve in the field is not stuck in an open or closed position.
2. Feed valve close (No feed coming in to the flotation cell) –Confirm in the field and in
the control room if the feed valve is open and the correct flow rate is going to the
flotation cell.
Example 4 – Flotation cell sliming
Figure 48: Flotation cell sliming
1. Choked cell
2. Faulty level indication (Level control valve in closed position)
3. Faulty level control valve
4. Over feeding (Flow rate in to cell to high)
5. Over dosage on reagents (Pax and frother)
6. Air flow too high in the cell.
Example 5 – What the froth should look like in a flotation cell.
Below is an example of how a flotation cell should look like. There are a lot of factors
influencing a flotation cell, but the operating variables must be manipulated so that the float
can look like this.

Figure 49: Example of how a flotation cell should look like
6. Thickener Circuit
The thickener section is illustrated in Figure 50. The rougher bank concentrate enters the
concentrate thickener with a mixture of lime and flocculent as necessary. The solids settles
out in the bottom of the thickener where it can either be recirculated back into the thickener
to build up density or transferred to the UFG section for further processing. The concentrate
thickeners water overflow falls into a communal feed box that feeds the clarifier.
Rougher bank Tails enters the section and can either go to the cyclone cluster or directly to
the FTSF tailings disposal tank. The cyclone underflow also goes to the FTSF tailings
disposal tank while the overflow feeds the tailings thickener to recover the water and
separate out the last fines. CTSF return water and rapid fill from the raw water dam can also
enter the tailings thickener. Tailings thickener underflow can either be recirculated to the
thickener to build density or transferred to the FTSF tailings tank.
Tailings thickener overflow, concentrate thickener overflow, process water dam water,
flocculent, copper sulphate and ferric chloride feed the clarifier. The last fines and metals in
the system are settled out in the clarifier. Clarifier water is used for process water, spray
water and hose down water. Clarifier underflow can be circulated to build density and be
transferred to the CTSF tailings tank.

Process Water
To CIL Tails
Spray Water Tank
Hosedown
Water
CTSF Return
Water
From Rougher
Tails
Process Water
Dam
Cyclone
Lime Raw Water Cluster
Clarifier
Dam
Flocculent FeCl3
From Rougher To FTSF

Concentrate
FTSF
Tailings
Tank
Concentrate Tailings
Thickener Thickener
To UFG
Figure 50: Thickener Section
6.1. Thickener
A Thickener (Figure 51) is a large vessel with the main purpose of separating out solids and
liquids. The separation is achieved with the aid of flocculent to settle out the suspended
solids to the bottom of the vessel with the clear water overflowing into a weir and ultimately
back into the plant as process water. The two main reasons for the separation are to recover
water from the circuit to re-use in a closed loop and to densify the solids for further
processing downstream.
Over a long enough period of time, all the solid particles will settle to the bottom with the aid
of gravity. For this to happen, a very large thickener and a very long residence time will be
required. To speed up the process and reduce the size of the thickener, flocculant is added
to the thickener which causes the solid particles to bind together. Particles with a large SG or
of a large size will settle faster than particles with a low SG or small particle size.
Flocculant is a chemical added to the thickener to increase the rate of solids settling. The
flocculant causes the solid particles to bind to each other increasing the mass of each
agglomerated particle. Flocculant addition is the most important factor in the operation of a
thickener. Dosing too little flocculant will cause the overflow of the thickener to be cloudy
which negatively affects your process water as well as all the unit processes that makes use
of process water.

Overdosing flocculant increases your reagent consumption which increases your costs and
can also cause a large amount of solids settling very quickly on top of your thickener rake.
This will cause the rake to get stuck and the thickener will need to be drained and washed
out to free up the rakes.
The most important thing to remember about a thickener is that what comes in must go out.
If the amount of solids coming into the thickener over a long period of time is more than what
comes out of a thickener, there is accumulation in the thickener and the build-up will cause
problems in the long run.
Figure 51: Schematic diagram of a thickener
A thickener is not simply a “pass through” unit process and must be operated efficiently to
ensure that the rest of the plant is run correctly. The overflow of the thickener must be clear
to ensure that the liquid going to the clarifier does not contain any solids. If the liquid
contains solids, then the pipes will be worn much quicker and the solids in the process water
can also block up equipment such as spray nozzles. The underflow should be at the correct
density to the UFG’s to ensure adequate grinding occurs with proper liberation of the mineral
surface area.

6.1.1. Rake lifting mechanism
Under normal operating conditions, a thickener very rarely runs at steady state and
accumulation of solids occurs. To accommodate a certain amount of build-up in the
thickener the thickener is designed with a hydraulic rake lifting mechanism to move the rakes
up and down as the thickener fills up. The lifting mechanism may be set to raise the rakes
automatically when a specific torque level is encountered, continuing to lift until the torque
returns to normal or until the maximum lift height is reached. Generally, corrective action
must be taken to eliminate the cause of the upset. Once the torque returns to normal, the
rake’s mechanism is lowered slowly to 'plough' gradually through the excess accumulated
solids until these are removed from the tank.
Care should be taken to ensure that the solids in the thickener does not keep on increasing
as this can cause the rakes to become stuck. This will require the thickener to be partially or
completely drained to loosen the rakes.
6.1.2. Flocculant dosing
The correct dosing of flocculant is the most important factor in managing the thickener.
When a thickener is not operating as it is supposed to, the chances are that some aspect of
the flocculant dosing is not correct such as the wrong strength, incorrect flow rate, not dosing
etc.
Figure 52: Flocculation operation guidelines

6.1.3. Operator control
The thickener operator can monitor the following variables relating to the thickener:
 Bed pressure – When the bed pressure increases, it is a sign that there is
accumulation inside the thickener and the underflow pump should be sped up.
 Feed - Talk to the control room and inspect at incomings sources to determine the
feed rate, density and particle size of the feed entering the thickener.
 Thickener underflow – Determine the thickener underflow density and obtain the
thickener underflow flow rate from the control room. Determine if it is sufficient to
keep the thickener running correctly as well as ensuring the correct densities is sent
to the UFG’s.
 Thickener torque – Obtain the thickener torque from the control room or on top of the
thickener and determine if it is within acceptable limits.
 Flocculant dosing – Always ensure that the flocculant pumps are running by
confirming with the control room operator as well as checking in the field. Go to the
flocculant dosing point and see if the flocculant is dosing or not. It is also a good idea
to feel the flocculant with your hand. If it feels slightly sticky and more viscous than
water then the flocculant is dosing.
7. Ultra-Fine Grinding Circuit
The role of the Ultra-Fine Grind (UFG) mill circuit is to reduce the particle size of the sulphide
minerals concentrated from the floatation circuit, which will increase the surface area of each
particle. Increased surface area results in easier and faster oxidation of the sulphides in
order to reduce reagent consumption and ultimately increase recovery of gold.
The UFG circuit (Figure 53) is fed from the concentrate thickener underflow over a sizing
screen to remove any foreign material. The feed is split into two feed tanks, one feeds UFG
one and two and the other feeds UFG three and four. All the UFG’s can be bypassed if
necessary directly to the product screen and sump, which can either feed to the pump cell
circuit or the CIL circuit as necessary. The UFG’s grinding media (beads) are in a closed
loop with each individual UFG mill and can also be bypassed to a bead recovery screen.

To Pump Cell
From Concentrate
Thickener Underflow To CIL
UFG Bead
Product Recovery
Dilution Water
UFG UFG UFG UFG

#4 #3 #2 #1
Feed Tanks
Bead Bead Bead Bead

Sump Sump Sump Sump
Figure 53: UFG Circuit
7.1. UFG Mill
The UFG mills treat feed slurry at 1.4 SG and 80% passing 106µm, grinding it down to a
target grind of 80% passing 20µm. The mill consists of a shaft with perforated discs rotating
the grinding media and slurry, adding the energy necessary to grind down the feed slurry.
The slurry enters at the bottom of the mill and has to pass through the grinding media and
discs before it overflows over the mill through grinding media retaining screen panels
(Figure 54 and 55).
Figure 54: UFG Mill

Figure 55: UFG inside flow
7.1.1. UFG Start-up procedure
 Start product screen and product pump ensure gland service valve is open on the
selected pump.
 Start-up UFG trash removal screen.
 Ensure that all drain valves on selected line is closed and that all equipment is
healthy.
 Make sure that the mill overflow (discharge) valve is open.
 Open gland service water on feed pump.
 Open all three flushing water valves on suction and discharge ends of the feed pump.
 Start the feed pump in auto while keeping the suction valve closed.
 Open the feed valve to the mill and wait for mill to fill up with water.
 Start the mill motor on a set point of 8 Hz (60 rpm).
 Fill the mill with beads with the bead loading procedure.
 Gradually increase the mill motor up to 30 Hz (220 rpm).
 Open the suction valve for the feed pump and close all the flushing water.
 The mill is now in full operation.

7.1.2. UFG bead loading procedure
 Once the mill is full of water and the motor running at 60 rpm, the mill is ready for
bead loading.
 Close the left side suction valve (bead suction) and open the right side suction valve
(water suction) (Figure 56).
 Start the bead pump at 30Hz.
 Once the bead pump is pumping the water up to the mill the bead suction valve can
be fully opened (left valve).
 Now close the water suction (right side valve) slowly until the operator hears the
beads pumping (keep in mind the level of the bead sump and top up with water as
necessary).
 The water suction should be closed more every time the sound of the beads stop
until it is fully closed.
 Once the water suction is fully closed the operator can stop topping up the bead
sump with water and pull it empty.
 Once the sump is empty the water top up valve must be opened up again for a short
while to flush the line.
 After the line has flushed and the bead sump is empty the bead pump can be
stopped and the mill start-up procedure followed further.
Bead
Suction Water
Suction
Figure 56: Bead sump suction pipes

7.1.3. UFG shutdown procedure
 Open all three flushing valves on the feed pump suction and discharge ends.
 Close the suction valve on the feed pump.
 Flush the mill for 20 minutes, the operator in the field must confirm that the discharge
of the mill is clean before stopping the mill.
 Stop the mill motor.
 Stop the feed pump and close gland service water.
 The mill feed valve will close automatically as soon as the pump stops.
 Open all the drain valves on the line that was running.
 Close all three the flushing water valves.
 The mill is now out of operation
7.1.4. Operator control
It is the duty of the operator in charge of the UFG area to ensure the following:
 Achieving the required targets with regards to throughput, grind and density.
 Good housekeeping in the UFG area.
 Screen panels inside the mill as well as on top of the discharge sump are kept clean.
 The inlet pressure on the mill must be between 100 and 200 kPa, if it is higher the
feed line is most probably choked.
 Min feed flow = 20 m3/h, Max feed flow = 35 m3/h
 Mill running RPM = 220 at 30 HZ
 Amps on mill should be between 400 Amps to 500 Amps (change according to grind
results from Melvin analyser and bottle roll leach test work). Load beads in circuit to
increase the Amps
 Always ensure that the mill feed valve is closes when the feed pump stops.
 Make sure that the mill is properly flushed before stopping to prevent chokes.
 Inspect the bead load in the mill and inspect the grinding plates

8. Pump Cell Circuit
The pump cell circuit (Figure 57) is the hydrometallurgical solution to treating the refractory
gold, which is locked-up in the sulphide material. Slurry from the Ultra-Fine Grinding (UFG)
circuit is pumped to a sampling feed box prior to being sampled and gravity fed to the
Pumpcell circuit pre-oxidation tank.
The Pumpcell pre-oxidation circuit consists of two agitated tanks operated in series. Each
tank is fitted with four Aachen REA450 reactors, through which slurry is circulated and
contacted with Oxygen. The slurry is circulated with Aachen reactor pumps, of which there is
one for every two Aachen reactors, each with its own dedicated high pressure gland service
water supply. Introduction of Oxygen with the use of these high shear reactors is aimed at
increasing the dissolved Oxygen level which enhances leach kinetics and carbon loading.
Both pre-oxidation tanks have three Oxygen spargers at the bottom of the tanks through
which Oxygen is injected, further increasing dissolved Oxygen levels.
Slurry
From UFG Oxygen
Peroxide
Lime
Cyanide
Lead Nitrate
Carbon
Diesel
Diesel
Pre-Ox 1
To CIL
Pre-Ox 2 Pump Cell

Tails
To Loaded
Carbon Screen
Pre-Leach
Figure 57: Pump Cell Circuit

Pre-oxidation in tank no. 1 is done at natural pH while pre-oxidation in tank no. 2 is done at a
Leach pH of 10.5. The pH is adjusted by addition of Lime, which is normally only added to
tank no. 2, but can also be added to tank no. 1 if required. Lead Nitrate (optional) can also
be dosed in both pre-oxidation tanks to enhance leach kinetics. Hydrogen Peroxide is also
available for dosing in both tanks as a back-up oxidant if Oxygen is not available. The
product stream from pre-oxidation tank no. 2 overflows to an agitated pre-leach tank, fitted
with one Aachen REA400 reactor with a dedicated Aachen reactor pump. Slurry is circulated
through the Aachen reactor for a final Oxidation stage. The tank is also equipped with three
Oxygen spargers at the bottom of the tank. Cyanide is added to start the leaching process,
Lime is added to maintain the leach pH and Hydrogen Peroxide can also be dosed if
required. A diesel dosing facility will also be supplied to dose into the pre-leach tank and is
aimed at reducing the effect of “preg robbing” (carbonaceous material) in the slurry.
The pre-oxidation tanks and the pre-leach tank can each be bypassed in case a tank needs
to be taken off-line for maintenance. Tank no. 1 can be bypassed and the feed routed
directly to tank no. 2. Tank no. 2 can be bypassed and the product from tank no. 1 can be
fed directly to the pre-leach tank. If the pre-leach tank is to be bypassed, pre-oxidation tank
no. 2 will become the pre-leach tank and Cyanide will be dosed in tank no. 2.
The pre-leach product stream overflows to the first of six 100m3 Kemix Pumpcell tanks
operated in series. The Pumpcell tanks are operated in a carousel mode, with counter
current flow of carbon relative to slurry. Slurry is moved between tanks with MPS(P) screens
which transfer slurry to the next sequential tank, but screens out Carbon which remains in
the tank. The Carbon in a Pumpcell circuit always remains in the same tank but the position
of the tank in the circuit is changed. For example: Day no.1, tank no. 1 is used as the first
tank, with sequential tanks no.2 to 6 operating in series. Day no.2, tank no. 1 is isolated and
the entire content of the tank is pumped to the elution circuit. Tank no. 1 is then re-
introduced to the circuit as the last tank and receives a fresh batch of carbon. Tank no. 2
then becomes the first tank in the circuit and the procedure is repeated each day.
The Pumpcell circuit is operated at a carbon concentration of 50g/l with a single tank being
taken offline for loaded carbon transfer every 24 hours. This results in a loaded carbon batch
size of 5 tons per day. The Pumpcell circuit is to be operated so as to achieve carbon
loading of 7670 g/t with a desired gold recovery of 84%.

It is the operator’s duties at the pump cell circuit to:
 Ensure correct DO levels are achieved in the Pre-Ox and Pre-Leach tanks by using
the Aachens, air spargers or hydrogen peroxide or a combination thereof.
 pH control is monitored closely and lime added accordingly.
 Correct cyanide levels are achieved in the Pre-Leach tank.
 Pumpcell tanks are rotated daily, with the current first deposit tank being pumped to
the loaded carbon screen and the remaining tanks moved up, i.e. second tank
becoming the first up to the last tank becoming the second last and the tank that was
emptied refilled with fresh or re-activated carbon and made the last tank.
 Correct carbon concentration levels are in the Pumpcell tanks.
 Lead nitrate is added accordingly.
 Diesel is added in the correct amount at the Pre-Leach tanks, once the metallurgist
has verified with test work that it is necessary.
 Housekeeping is done continuously around the section.
9. CIL Section
The Carbon in Leach (CIL) circuit (Figure 58) is used to leach out gold from the easily
recoverable oxide ore or act as a scavenger for the remaining gold from the Pumpcell circuit.
Oxide material from Mill no. 1 or 2, bypassing the flotation cells, is pumped to the CIL pre-
oxidation tank. The feed enters the pre-oxidation tank through a mixing box and can be
bypassed to CIL tank no. 1 if the pre-oxidation tank is off-line. An Aachen reactor pump
circulates the slurry in the tank through 2 Aachen reactors which contacts the slurry with
Oxygen under high shear conditions. The Aachen reactor pump is supplied with high
pressure gland service water. Oxygen is also injected at the bottom of the tank through 3
Oxygen spargers. Introduction of Oxygen with the use of high shear reactors and spargers is
aimed at increasing the dissolved Oxygen level which enhances leach kinetics and Carbon
loading.
Lime is added to the pre-oxidation tank to increase the slurry pH to the required leach pH
level before Cyanide is added. The leach pH level must be maintained at 10.5 or higher.
Lead Nitrate is also added to enhance leaching kinetics.

Slurry Ferric
From Rougher Oxygen Acid
Tails #1
Peroxide
From Rougher Lime

Tails #2
Cyanide
Lead Nitrate
From Pumpcell
Tails Carbon
To Loaded
Carbon
Pre-Oxidation CIL#2 CIL#4 CIL#6 Detox #2 Detox #4
Dewatering Screen
CIL#1 CIL#3 CIL#5 Detox #1 Detox #3

To CTSF
To Loaded
Carbon CTSF
Tailings
Tank
Figure 58: CIL Section

Hydrogen peroxide can be dosed as an Oxygen replacement if Oxygen is unavailable and
can also be used as a top-up oxidant if required.
The slurry overflows from the pre-oxidation tank into a launder and flows by gravity to CIL
tank no.1. CIL tank no. 1 can be bypassed and the slurry routed to CIL tank no. 2 if the tank
is off-line for maintenance.
Slurry and activated Carbon flows counter current to each other through CIL tank no. 1 to 6.
Slurry from the pre-oxidation tank flows by gravity to CIL tank no. 1. Pumpcell tailings also
reports to CIL tank no. 1 after passing through the Pumpcell tailings samplers. The slurry in
tank no. 1 is routed to tank no. 2, and thereafter each subsequent tank, using MPS(P)
interstage screens. These screens run continuously and “pump” the slurry from its tank into
an overflow launder from where it flows to the next tank. The MPS(P) screens only transfers
the slurry while retaining the Carbon in the tank.
Fresh / Regen Carbon is added to tank no. 6 (12 tons) and is pumped from each tank to the
preceding tank in the sequence using Carbon transfer pumps. Carbon can be added to tank
no. 5 as well, if tank no. 6 is off-line for maintenance. 12 tons of Carbon is transferred daily
from each tank and the operator must base the transfer time (time the pumps will be
running) on the Carbon concentration in each tank.
The Carbon concentration is determined by manual sampling. Carbon and slurry is

transferred by a Carbon transfer pump from tank no. 1 to the loaded Carbon screen at the
top of the elution columns where the Carbon is screened out for elution. The loaded Carbon
screen is used for Carbon form both CIL and Pumpcells, but has a split deck, ensuring that
the Carbon from both sources is kept entirely separated. The screened out slurry is returned
to CIL tank no. 1, but can also be bypassed to tank no. 2.
The following reagents are dosed in the CIL tanks:
 Oxygen is added to the CIL tanks via three spargers in the bottom of each tank to
enhance leach kinetics and Carbon loading.
 Cyanide is dosed in tank no 1 to effect Gold leaching. Cyanide is usually dosed in
tank no. 1 but can also be dosed in tank no. 2 if tank no. 1 is off line for maintenance.
 Lime can be dosed in CIL tank no. 1 – 4.
 Lead Nitrate can be dosed in tank no. 1 to enhance leach kinetics.
 Hydrogen Peroxide can be dosed in each CIL tank to serve as replacement oxidizer
when Oxygen is not available.

Four Detox tanks, each with two Aachen REA450 reactors, are used for Cyanide
destruction. Cyanide must be destroyed to below 20 ppm WAD before CIL tailings can be
disposed of in the lined tailings dam according to DRC legislation. The Detox facility
achieves this by creating highly oxygenated slurry with the Aachen reactors and Oxidizing
the Cyanide to Cyanate in the presence of activated Carbon catalyst.
CIL tailings from the final CIL tank reports to detox tank no. 1. Two MPS(P) interstage
screens are used to screen out Carbon and move the slurry from the tank into an overflow
launder. Approximately 60% of the slurry transferred to the launder is routed to an Aachen
reactor pump via a still-well from where it is pumped through 2 Aachen reactors and returned
to the bottom of the detox tank. The Aachen reactor pump is supplied with high pressure
gland service water. Oxygen is injected into the slurry under high shear conditions at the
Aachen reactors in order to oxidize the remaining Cyanide in the slurry to Cyanate.
Oxygen is also injected at the bottom of the tank through three Oxygen spargers to further
enhance dissolved Oxygen levels. The remainder of the slurry in the overflow launder flows
by gravity to detox tank no. 2 where the process is repeated. Each of the detox tanks has
two MPS(P) screens installed, but all the tanks will not necessarily be loaded with Carbon.
Each detox tank can be bypassed if maintenance is required on the tank. Tailings from the
final detox tank overflows by gravity to CIL tailings disposal.
The following reagents are dosed in each detox tank:
 Oxygen as described above.

 Ferric Chloride is dosed in each detox tank for Arsenic destruction and to further
assist in oxidizing Cyanide.
 Copper Sulphate can be dosed in each tank to precipitate Iron bound Cyanide
species.
 Un-neutralized spent acid from elution is added to each tank to achieve a pH of 8 to
9, above which it is difficult to oxidize Cyanide.
 33% HCl can be dosed if spent acid is not available.
 Hydrogen Peroxide can be dosed in each detox tank to serve as replacement
oxidizer when Oxygen is not available. It can also be used as a top-up oxidant if
required.

The pulp in the Detox circuit is contacted with activated Carbon which serves as a catalyst
for the oxidation of Cyanide to Cyanate. The Carbon concentration in the detox circuit should
be maintained at 50g/l and activated Carbon can be manually added to each detox tank via
the carbon loading process in regen. Fresh / regenerated Carbon can be added to each tank
individually as required, but normally Carbon will only be present in detox tanks no. 2 and 4.
Carbon is moved from tank no. 4 and 2 directly to the loaded carbon screen using Carbon
transfer pumps installed in each tank.
When required, the detox system also has the flexibility to be used as CIL tanks, in which
case the Carbon can be moved from each tank to the preceding tank in the system. The
Carbon can also be routed from each tank directly to the loaded Carbon screen. 12 tons of
Carbon is transferred once every 5 days from detox tanks no. 2 & 4 to the loaded Carbon
screen. The operator must base the transfer time (time the pumps will be running) on the
Carbon concentration in each tank (determined by sampling).
It is the operator’s duties at the CIL section to:
 Ensure correct DO levels are achieved in the tanks by using the Aachens, air
spargers or hydrogen peroxide or a combination thereof.
 pH control is monitored closely and lime added accordingly.
 Correct cyanide levels are achieved in the first CIL tank.
 Carbon is moved on a daily schedule up-stream to ensure recovery is optimal and
fouling on carbon is minimal.
 Interstage screens are cleaned on a regular basis.
 Correct carbon concentration levels are maintained in the tanks.
 Lead nitrate is added accordingly.
 Detox system is monitored closely with minimal cyanide reporting to the CTSF.
 Housekeeping is done continuously around the section.

10. Leach and Detox Reagents
In the Pumpcell and CIL section gold is leached out of the ore and adsorbed onto carbon for
further processing. The gold is leached out with cyanide and oxygen and requires sufficient
surface area to do so. Modifying and assisting agents are also used to accelerate the leach
process and/or reduce further reagent consumption while increasing overall recovery. As
cyanide is a health and environmental risk, it is detoxed before leaving the plant to be
deposited in the CTSF. Acid is also added in the detox process to neutralize the water and
create favourable conditions to rehabilitate the water for re-introduction to the environment.
10.1. Oxidative pre-treatment
The goal of oxidative pre-treatment (pre-oxidation) is to remove or alter certain elements in

the ore so that the leaching of precious metals such as gold and silver can be improved.
The pre oxidation of the slurry before leaching is done for the following reasons:
 Gold is locked in reactive minerals such as sulphides and cannot be liberated, even
by fine grinding.
Figure 59: Association of gold particles with other minerals.

 To reduce the amount of reagents being consumed by the gangue particles such as
sulphides.
 To form a layer around carbonaceous materials in the feed to prevent gold being
adsorbed onto these particles or to destroy the carbonaceous particles completely.
Without the presence of high amounts of oxygen, most sulphide particles decompose very
slowly in slurry. In order to increase the rate at which the sulphide particles decompose,
reagents such as air, oxygen or hydrogen peroxide can be added to the slurry.
Oxidation of the slurry is normally done at the pH at which the leaching circuit is operated to
reduce the amount of pH altering reagents such as lime. The oxidation of the slurry is not
very dependent on the pH.
10.1.1. Factors affecting pre-oxidation
The three parameters that have the biggest influence on the oxidation of sulphides are:
 Dissolved oxygen concentration.

 Temperature.
 Degree of mixing.
Dissolved oxygen concentration – The oxygen needs to dissolve in the slurry to increase
your dissolved oxygen content. The low solubility of oxygen in water under atmospheric
conditions limits the rate at which the slurry can be oxidized. To increase the solubility the
partial pressure of oxygen in the gas phase needs to be increased. The use of relatively pure
oxygen instead of air increases the partial pressure by a factor of approximately 5.
Temperature – An increase in temperature decreases the amount of dissolved oxygen in

the slurry. To change the temperature of the slurry is normally not economically justifiable so
the oxidation step is done at atmospheric temperature.
Degree of mixing – Increasing the agitation rate as well as a properly designed mixing tank
increases the rate of oxidation of the slurry.
From the above three variables it can be seen that the dissolved oxygen concentration is the
only real variable that can be adjusted by the operator. The amount of dissolved oxygen
required in the pre-oxidation step of the leaching circuit depends on the ore being treated.

Hydrogen peroxide can also be used as an oxidizing reagent, but is normally more
expensive than oxygen and the chemical reactions occurring in the tanks are usually less
favourable than the reactions when oxygen is pumped into the system.
If oxygen is just pumped into the tank, high amounts of reagents will be necessary to
achieve the required dissolved oxygen concentration. To increase the effectiveness of
oxygen dissolution into the slurry, Aachen reactors are used.
10.1.2. Aachen Reactor
Figure 60: Aachen Reactor
The oxygen is pumped into the system perpendicularly to the flow of the slurry. The diffuser
assembly is manufactured in such a way that very fine oxygen bubbles are produced and
injected into the slurry. These fine bubbles then dissolve into the slurry due to effects of
pressure and the mixing characteristics of the slurry.
Slurry is pumped from the bottom of the tank by dedicated pumps and circulates through the
Aachen reactors back into the bottom of the tank. This circulation of slurry through the
Aachen reactors increases your dissolved oxygen content in the tank.
The amount of dissolved oxygen present is usually measured by probes in the tank, but can
also be measured using handheld oxygen meters.
10.1.3. Hydrogen Peroxide
Hydrogen peroxide is used to some extent to increase the DO level and assist the leaching
process. If enough peroxide is added it oxidizes free-cyanide to cyanate as follows:

Since peroxide does not introduce any foreign ions into the process like other detoxing
methods, it is used as a detoxing reagent and the kinetics of oxidation are sufficiently fast
that effective oxidation can be achieved in a few minutes. Hydrogen peroxide is a very costly
reagent and is needed in very high quantities to reduce free cyanide content that it is not
economical to use as the sole detoxing reagent. Fe(II) cyanide can also be precipitated as
an insoluble salt in the presence of peroxide and copper or zinc salts.
10.2. Lead Nitrate
Sulphide ions are reagent consuming and retard any leaching effects as 1% sulphur
consumes 15.3 kg/t NaCN. The adverse effect of sulphide ions can be countered by the
addition of small amounts of a soluble lead salt, such as lead nitrate. Lead nitrate assists in
the passivation of reactive sulphide mineral surfaces and forms insoluble hydroxide and lead
sulphide which is precipitated and may be oxidized to sulphate generating Pb2 for further
reaction with sulphide.
Lead ions can also increase gold leaching rates, as pure gold dissolves much slower than
gold alloyed with other metals. The trace amounts of lead depolarize gold surfaces and
prevent or reduce the passivation effect, thereby accelerating gold leaching rates. Although
the addition of lead ions to achieve concentrations of 1 to 10 mg/L have been found to be
beneficial, lead concentrations in excess of 20 mg/L have been found to retard gold
dissolution.
10.3. Cyanide Leaching
In gold extraction, leaching is the method at which a mineral such as gold or silver is
dissolved into a liquid. For gold to dissolve into a solution, two different reagents are
required, namely cyanide and oxygen.
Potassium cyanide dissolves into water to form potassium and free cyanide ions. When the
free cyanide comes into contact with the water it forms hydrogen cyanide (HCN). Hydrogen
cyanide is not completely stable in water and depending on the pH the HCN will convert
back to free cyanide ions or vaporize as a gas into the atmosphere. In the leaching process
free cyanide is much more effective than HCN to dissolve gold. To ensure that the
concentration of HCN in the slurry is as low as possible which means that most of your
cyanide in the slurry will occur as free cyanide ions, the pH of the slurry should be high. At a
pH of 10.2 over 90% of the cyanide occurs as free cyanide ions.

Another reason why the pH of the slurry should be kept high (Above a pH of 10) is that at a
lower pH the HCN vaporizes easily and causes a loss of cyanide concentration in the slurry.
HCN gas is deadly and is monitored with HCN gas monitors at dosing and detoxing positions
in the circuit.
10.3.1. Factors affecting leaching
The major factors affecting the rate at which gold dissolves are as follows:
 Cyanide concentration.
 Oxygen concentration.
 Temperature.
 pH.
 Grinding.
 Degree of agitation.
 Slurry density.
 Residence time.
Cyanide and oxygen concentration - Gold reacts with oxygen and cyanide to form a
chemical that can be absorbed onto activated carbon to remove the dissolved gold from the
slurry. Thus the concentration of cyanide and oxygen must be enough to leach as much gold
as possible.
Temperature – At increasing temperatures up to 85°C the rate at which gold dissolves

increases. At temperatures of above 85°C the amount of oxygen that can dissolve in the
slurry decreases dramatically and reduces the rate at which gold dissolves. Modifying the
temperature in the circuit is too costly and operation is done at ambient temperature.
pH – Gold can be successfully leached at a pH as low as 9.0, but the amount of HCN gas
that escapes the system is too high to be economically feasible. To ensure that the
maximum amount of HCN reduces to free cyanide ions, the pH is kept above 10.2. The pH
should always be at the required level before cyanide is added to the system as this will help
prevent cyanide leaving the system as HCN gas. Lime is normally used to control the pH in a
leaching circuit.

Grinding – The rate at which gold is dissolved is dependent on the amount of gold surface
area exposed after grinding. The rate at which gold is dissolved generally increases with
decreasing particle size. The cost of grinding finer must be weighed against the increase in
the rate of gold dissolution to determine the optimum grind for an ore. Normally 80% passing
75µm is adequate for CIL and 80% passing 20 µm for Pumpcell.
Degree of agitation – The rate at which gold dissolves increases with increasing agitation.
The degree of agitation is mostly influenced by the design of the tank. To ensure the degree
of agitation is as high as possible, the agitator and baffles in the tank must be regularly
inspected for wear.
Slurry density – The rate at which gold is dissolved increases with a decreasing density in
the cell. At increasing density the residence time of each particle increases in the cell. Higher
density in a cell also decreases the amount of reagents consumed. Normally leaching is
done between 35% to 50% solids.
Residence time – An increase in residence time for each particle greatly increases the
probability that the particle can be leached if enough reagents are available in the system.
The residence time in the cells can be controlled by the density of the slurry and the amount
of tanks that is online. Regular checks should also be done to see if there is not a build-up of
particles in a tank (Sanding).
10.3.2. Method for detecting free cyanide concentration
In order to determine the amount of cyanide in solution present in each tank, the operator
must use the following procedure:
 Filter about 200ml of slurry though a paper filter/ funnel into a 100ml beaker
 Collect 30-40ml of clear leach solution/ filtrate
 Measure exactly 10ml of filtrate into a clean and dry 100ml titration flask
 Add 3 drops of Rhodaine/ Phenolphthalein indicator
 Ensure the burette with silver nitrate is zeroed
 Place the titration flask under the burette on top of a white background
 Carefully open the burette and silver nitrate drop by drop into the solution.
 Stopping after each drop, swirl the titration flask and check any slight colour change in
the titration flask contents

 Look for the appearance of the lightest pink colour in the flask and close the burette at
that moment.
 Calculate the volume of silver nitrate by change in burette volume
 Vt = Volume of silver nitrate titre to get to end point (ml)

 Ct = Molar concentration of silver nitrate (typically 0.01M)
 CNppm = 26 x (Vt x Ct)
 = 26 x Vt (for a titre concentration of 0.01M)
10.4. Carbon Adsorption
Carbon is used in the leaching circuit to concentrate the gold bearing solution to a higher
grade so that gold can be extracted more efficiently by methods such as elution and electro
winning.
Adsorption is the process of adhesion of gold in solution onto a surface. The gold that is in
the solution in the leaching tanks attach to the carbon particles. Activated carbon is material
with a lot of microscopically small holes inside. This property is the reason that the activated
carbon has a large surface area and thus a lot of space for the gold to attach to the carbon.
Figure 61: Illustration of particle adsorption onto carbon

10.4.1. Factors affecting carbon adsorption
Factors affecting Adsorption:
 Type of carbon
 Carbon particle size
 Mixing efficiency
 Slurry density
 Temperature
 Gold concentration in solution
 Cyanide concentration
 pH
 Carbon fouling
 Competing species
Type of carbon – Carbons can be produced from different materials such as wood, coal and
coconuts. Depending on the type of material used the physical and chemical properties of
the carbon can differ. Carbon that has a higher capacity is more brittle while carbon with a
lower capacity is often stronger and losses due to attrition are less.
Carbon particle size – The rate at which gold is adsorbed onto the carbon increases with a
decrease in particle size. Carbon has to be of a size so that the inter stage screening can be
used effectively. Screening of carbon usually occurs at 0.6 – 0.8 mm. Finer carbon is more
susceptible to attrition losses and the amount of carbon that cannot be screened and goes to
the tailings increases.
Mixing efficiency – The agitation of the cell should be designed so that the carbon stays
suspended in the slurry and doesn’t settle or float as this will negatively affect the rate at
which the gold adsorbs onto the carbon. The higher the agitation, the higher the rate at
which gold adsorbs onto the carbon.
Slurry density – The higher the density in the cell, the lower the rate will be at which gold
will adsorb onto the carbon. A higher density also increases the retention time since it
reduces the effective volume that needs to pass through the circuit.
Temperature – The amount of adsorbed gold that each particle can take decreases as the
temperature increases.

Gold concentrate in solution - The rate of gold adsorption increase with gold in solution,
therefore activated carbon is fed in a counter current manner to the slurry. The counter
current flow ensures barren carbon at lower concentrations of gold at the tails end and
loaded carbon at the higher concentration of solution at the feed end.
Cyanide concentration – The higher the free cyanide concentration in the slurry, the slower
the adsorption rate of gold onto carbon will be.
pH – A decrease in pH leads to a small increase in carbon adsorption. The loss of cyanide

through vaporization outweighs the small increase in carbons adsorption that is gained by
lowering the pH. pH control is also necessary as HCN gas is deadly.
Carbon fouling - Fine particles in the slurry can physically blind the carbon which causes no
gold to adsorb onto the carbon. Certain chemical reactions can also cause precipitation onto
the carbon which blinds the carbon, such as a very high concentration of lime.
Competing species – Poisons which are generally organic impurities, can often compete
with gold for adsorption.
10.4.2. Method of determining carbon concentration
To determine the amount of carbon in the cell, the following method can be used:
Calculate carbon concentration Cc (g/l) as follows:
 Take a 1-litre slurry sample from the tank.

 Do not sample near the inter-stage screen - a biased result is often obtained there.
 Pour the sample into a bucket or container with a fine 600 µm mesh at the bottom.
 Wash the slurry through the mesh with water, retaining the carbon.
 Using a plastic funnel, carefully wash the clean carbon into a 200 ml measuring cylinder.
 Read off the volume of settled carbon Vc (ml).
Vc(ml )
Cc( g / l ) 
4
 Take another 1-litre sample from the opposite side of the tank and repeat the above
washing procedure to verify.

10.5. Ferric Chloride
Cyanide species naturally degrade over time which reduces the toxicity of cyanide. Various
mechanisms are responsible for the degradation while ore as well as environment
characteristics determine the rate at which it degrades. The degradation mechanisms
include: volatilization, oxidation, adsorption onto other minerals, hydrolysis, biodegradation
and precipitation.
Free cyanide can be converted to the less toxic Fe(II) cyanide complex by the addition of an
excess of a suitable soluble Fe(II) salt within the pH range 7.5 to 10.5. Weak metal cyanide
complexes (i.e. copper, zinc, and nickel) are partially decomposed in the presence of excess
iron and forms insoluble double salt cyanide species, such as Cu2Fe(CN)6.
Chlorine is also used for cyanide destruction. The active reagent for chlorine oxidation for
free and complexed cyanide is the hypochlorite ion, which is produced when chlorine
dissolves in water. Free cyanide reacts rapidly with hypochlorite (OCl) in aqueous solution to
form cyanogen chloride, otherwise known as tear gas. At a high pH (10 to 11), cyanogen
chloride is readily hydrolysed to cyanate and chloride ions. Effective oxidation of cyanide can
be achieved within 10 to 15 min. The residual active chlorine concentration is still toxically
high when the toxic cyanide has been destroyed and needs to be dechlorinated with
hydrogen peroxide.
11. Elution Circuit
The process of elution (Figure 62) is the reverse of adsorption. Where the gold molecules
attached to the carbon particles to concentrate the gold to a smaller volume, in elution the
gold has to be removed from the carbon.
The CIL and Pumpcell carbon are to be batch treated in the elution circuit separately through
two identical circuits. The duplicate 12t AARL columns will share a common heater facility
capable of running both columns simultaneously. The CIL carbon is to be treated in 12 ton
batches once every 24hours, while carbon from the Pumpcell circuit will be treated in 10ton
batches every 48 hours.

From CIL
Water
From Pumpcell
Carbon
Oil
Cyanide
Acid Wash
Caustic Tank
To CIL
Acid
To CIL
To Pregnant Tank
Elution
Column
Elution
Solution
Secondary
Heat Exchanger
To Carbon Regen
Primary
Heat Exchanger
Expansion
Tank
De-aerator
Tank
Heater
Figure 62: Elution Circuit
Loaded carbon is collected in an elution circuit acid wash tank. In the acid wash every batch
of carbon is treated to remove carbonated material by circulating a 3% HCl through the
carbon by dilution of concentrate HCl from a dedicated acid wash tank. The acid wash tank
has an overflow weir to also facilitate elutriation of loaded carbon prior to the acid wash step
with strainers for carbon holding. The elutriation process removes trash from the carbon
such as wood chip and plastics which might otherwise interfere with the flow through the
strainers during elution. Acid wash solution is pumped to the Detox circuit where it is used
instead of fresh / concentrated acid and will be neutralized by the process before being
pumped to tailings.

Carbon that has been acid washed is then loaded into a 12t AARL elution column by gravity.
The carbon is pre-treated with a pre-treatment solution containing 1% NaCN and 3% NaOH
from a dedicated solution tank. This solution is pre-heated to 125°C by recirculating the
solution through the elution column, primary heat exchanger and the electric oil heater and
back to the solution tank at a flow rate of 2BV/h for a period of 110minutes followed by a pre-
soak using the same solution at a flow rate of 2BV/h for a period of 60minutes. Eluate
produced during these two steps are then pumped to the elution electrowinning circuit feed
tank / pregnant solution tank.
Gold is then eluted from the carbon using ambient elution water only from the same solution
tank, pre-heated via a recovery heat exchanger and controlled at 125°C with the primary
heat exchanger and the electric oil heater. This water is pumped at a rate of 2BV/h through
the column for a period of 150minutes. Eluate produced during the elution cycle is then
pumped to the elution electrowinning circuit feed tank / pregnant solution tank.
On completion of the elution cycle a rinse cycle will follow by pumping ambient elution water
from the same solution tank, pre-heated via a recovery heat exchanger and controlled at
125°C with the primary heat exchanger and the electric oil heater. This water is pumped at a
rate of 2BV/h through the column for a period of 125minutes. Eluate produced during the
rinse cycle is then pumped to the elution electrowinning circuit feed tank / pregnant solution
tank.
On completion of the rinse cycle a cooling cycle will follow by pumping ambient raw water
from the same solution tank. This water is pumped at a rate of 2BV/h through the column for
a period of 25minutes. The raw water used during this step will report to the CIL circuit.
Eluted carbon is removed from the column and report to the carbon regeneration kiln.
11.1. Acid washing
The slurry first goes to an acid wash tank to remove inorganic particles that have
blinded/fouled the activated carbon. The inorganic foulants are removed before elution as
this will increase the efficiency at which precious metals is dissolved from the carbon and
increase the carbon regeneration efficiency. This step does not dissolve the gold that is
attached to the carbon. Fouling particles that have precipitated on the activated carbon are
dissolved by the acid. The acid normally used is hydrochloric acid (HCl). The acid can be re-
used a few times before it has to be neutralized by caustic soda. The acid washed carbon is
then transferred to the elution column for the removal of gold from the carbon.

11.2. Elution
The function of the elution column is to produce a small volume of high-grade gold
concentrate in solution suitable for recovery by electro winning as well as a step in carbon
recycling to reuse it in the leaching circuit. Carbon is typically reused between 100-400
adsorption-elution cycles, depending on the quality of the carbon.
11.2.1. Factors affecting elution
Factors affecting the elution are as follows:
 Temperature and pressure

 pH
 Solution flow rate
Temperature and pressure – Temperature is the most important factor in the elution of
gold, as an increase in temperature shows a great increase in the elution rate. To achieve
temperatures higher than 100°C and keep the elution liquids from boiling, the elution column
is operated under pressure around 350kPa.
Cyanide concentration – An increase in cyanide concentration increases the rate at which

gold is removed from carbon as the cyanide ions displaces the gold from the carbon.
pH – Caustic is added to the elution column as it acts in a similar manner to free cyanide
ions by displacing the gold from the carbon. The caustic regulates the pH as well, as the pH
must be kept high to reduce the amount of HCN lost in a gaseous form.
Solution flow rate – The solution flow rate is normally expressed as carbon bed volumes
per hour (BV/h). The concentration of gold on the carbon after elution generally decreases
as the bed volumes increase.

11.3. Carbon Transfer
To transfer carbon from the elution column to the kiln feed bin the operator should follow the
following sequence:
 Column temperature must be below 50⁰C and the solution pump stopped.
 Ensure all manual valves are in the correct position:
o Discharge line valve leading to the tank open and bypass valve closed.
o Flushing water at bottom of column is open.
o Column discharge valve on top of column must be closed.
 Auto flushing valve can now be opened, the solution pump started and the field
operator must verify the discharge at the sieve bend.
 Once the discharge has been verified the following valves should be stroked
simultaneously:
o Carbon dump valve should be opened.
o Vent valve on column should be opened.
o Flushing valve should be closed.
 The solution flow must remain above 45m3/hr, if not the last mentioned valves must
be switched back with only the flushing valve open to force the line clean of carbon.
 This process should be repeated until all the carbon has been transferred.
 The solution pump can now be switched off, all manual valve switched back in
position and the column drained of water.
 The column is now ready for the next elution.
11.4. Oil Heaters
Whenever new oil is added into the oil system the naturally accumulated moisture should be
boiled out of the system. Since water boils at 100⁰C and the oil system is not under
pressure, it should be heated slowly from 80⁰C. The temperature should be increased by
increments of 3⁰C after the system has stabilised. The process should be repeated until all
the moisture is out of the system and the oil is at 140⁰C, where after the oil can be heated to
the normal operating temperature of 215⁰C.

It is the operator’s duties at the Elution circuit to:
 Ensure acid wash is done on the carbon before elution.

 All pump strainers and candle filters are cleaned on a regular basis.
o Pump strainers needs to be cleaned when the pump cannot deliver sufficient
flow.
o Candle filters needs cleaning when the pressure differential exceeds the
normal operating pressure differential of 100kPa.
 The GSW of the solution pump are always running as the excess heat can damage
the pump even when not running.
 Samples are taken of every step in the elution cycle between each bed volume
pumped.
 Oil heaters and pumps are started and stopped in the field for each elution cycle.
 The water capturing tank at the oil heaters is emptied after each elution to verify that
no tubes in the heat exchanger are damaged.
 Follow the carbon transfer procedure and ensure all the carbon is transferred to the
desired location.
 General housekeeping
12. Carbon Regeneration Circuit
Activated carbon within the process fouls over time, which needs to be removed from the
carbon to sustain recoveries. Carbon fouling occurs due to the following mechanisms:
 Undesirable organic or inorganic species are adsorbed onto the carbon surface,
taking up active sites which would otherwise be available for gold adsorption.
 Inorganic salts are precipitated onto the carbon surface, blocking active sites.
 Solid particles or precipitates are physically trapped in carbon pores, restricting
access to gold-bearing solution.
To remove any particles from the activated carbon that has not been removed during acid
washing and elution, the activated carbon must undergo heat treatment. Therefore the
carbon is reactivated in a rotary kiln at the carbon regeneration circuit (Figure 63).

From Elution
Columns
Kiln Feed
Tank
Fresh
Carbon
To Pumpcell Carbon
Tank
Fines To CIL Tails
To CIL Carbon
Tank
Figure 63: Carbon Regeneration Circuit
After the carbon has been separated from the Eluate, it is pumped to a storage tank as the
carbon regeneration is a batch process. The carbon is fed from the holding tank via the
screw feeder to the rotary kiln at a rate of 1000kg/h dry solids. The rotary kiln heats the
carbon up to a temperature of approximately 750°C. When the reactivated carbon exits the
rotary kiln, it is quenched with water in a quench pan before being fed to a classification
screen.
Fresh carbon as well as reactivated carbon is fed to a small vibrating screen to remove any
undersize carbon that will have a detrimental effect on the leaching circuit as they pass
through the inter stage screens and report to the tailings. Carbon sizing screen undersize
(carbon fines) is pumped to the cyanide tailings disposal circuit, while the oversize is
pumped to the CIL, Detox and Pumpcell circuits.
12.1. Factors affecting carbon reactivation
The factors affecting carbon regeneration are as follows:
 Temperature
 Residence time
 Initial moisture content of carbon
 Quenching of carbon

Temperature – If the temperature is too low the removal of any foreign particles on the
carbon will be incomplete as it requires a high temperature to be removed from the carbon. If
the temperature is too high then the activation of the carbon will decrease and the hardness
of the carbon increases, making it very brittle.
Residence time – if the residence time in the kiln is too low, then the removal of foreign
particles from the carbon will be incomplete.
Initial moisture content of carbon – in the Eluted carbon storage tank, strainers are fitted
to remove excess moisture. Any excess moisture not removed by the strainers will be
removed by the wedge wire screens in the screw feeder. The carbon should have moisture
to speed up the activation process, but too much moisture will reduce the activity of the
carbon.
Quenching of carbon – The reactivated carbon is immediately quenched after it is

discharged from the rotary kiln in an enclosed vessel, since hot carbon is very reactive with
oxygen and needs to be cooled to avoid damaging the carbon.
12.2. Preparation of fresh carbon
Despite being manufactured to particular size specifications, fresh carbon always contains
small quantities of fine carbon as well as carbon having sharp points and edges and flat
plate-like particles. These types of particles are unsuitable for the leaching process.
Type of particle Reason why not suitable for adsorption

Fine particles Will adsorb gold and pass through the inter
stage screens and report to the tailings
Particles having sharp points or edges These particles are easily broken and end up
as fine carbon particles
Flat plate-like particles These particles are small enough to get
through the apertures of an inter stage
screen
To ensure that these particles from a fresh batch of carbon are not introduced to the
leaching circuit, the fresh carbon is dumped on a classifying screen where the undersize is
removed and pumped to the carbon safety screen (linear screen) before the tailings.

The operator at the carbon regen circuit needs to do the following:
 Inspect kiln seals on a daily basis.

 Inspect grease levels at support rollers.
 Ensure quenching water, sizing screen and associated pumps are running before
starting the kiln and remains running until all the carbon has stopped discharging
after shutdown.
 Inspect and clean screen panels on the sizing screen.
 Ensure the carbon transfer pump does not choke with carbon, as it will destroy the
impeller and pump casing.
 General housekeeping.
13. Electrowinning and Gold Room
Electrowinning and smelting is the last step in the recovery of gold (Figure 64). Pregnant
solution from the ILR circuit is sampled and collected in the ILR pregnant solution tank. This
solution is then circulated through a single electrowinning cell and steady head tank. Gold is
deposited on the cathodes as sludge and the solution circulated until the desired barren gold
concentration is achieved or 18 hours has elapsed.
Pregnant solution from the CIL elution circuit is sampled and collected in the CIL elution
pregnant solution tank. This solution is then circulated through the electrowinning circuit
consisting of six cells operated in parallel and steady head tank. Gold is deposited on the
cathodes as sludge and the solution circulated until the desired barren gold concentration is
achieved or 18 hours has elapsed.
Pregnant solution from the Pumpcell elution circuit is sampled and collected in the Pumpcell
elution pregnant solution tank. This solution is then circulated through the electrowinning
circuit consisting of six cells operated in parallel and steady head tank. Gold is deposited on
the cathodes as sludge and the solution circulated until the desired barren gold
concentration is achieved or 18 hours has elapsed.
After completion of the above mentioned electrowinning batches, barren solution is sampled
and stored in two barren solution tanks which can either be pumped to the elution circuit for
re-use or to the CIL circuit for disposal.

Loaded cathodes will be periodically removed from the cells, the gold sludge will be washed
off using a high pressure washer and the washed solution will then be decanted. Two
separate washing facilities have been allowed for, for accounting purposes. The gold sludge
will then be calcined in two electric calcination furnaces. The calcined sludge will then be
mixed with fluxes and loaded into an induction smelting furnace. During smelting, metal
oxides will form slag and once the furnace crucible contents are poured into cascading
moulds, gold will solidify at the bottom while slag separates easily from the gold. The gold
bullion bar(s) will be cleaned, labelled assayed and prepared for shipping. Slag will be
manually crushed and pulverised and together with de-canted and waste water from the gold
room, recycled to the concentrate thickener by a dedicated pumping facility.
Electrowinning
From Pumpcell From CIL Elution
Elution
Pregnant Pregnant
Tank #1 Tank #2
To Concentrate
Cathode Wash Thickener
From ILR
Pregnant
Tank #3
Barren Barren
Tank #1 Tank #2
Bullion
Induction
Furnace
To Elution To CIL
Calcining
Furnace
Figure 64: Gold Room Circuit

13.1. Electrowinning
Electrowinning is the process of plating out high-grade gold solutions onto cathodes by
means of adding a voltage over electrodes immersed in the solution.
Electrowinning is dependent on the following:
 Electrolyte hydrodynamics
 Temperature
 Cathode surface area
 Cell voltage
 Cell current efficiency
 Solution conductivity
 pH
 Solution flow rate
Electrolyte hydrodynamics – The degree of mixing has a large effect on the mass
transport of solution species and consequently the gold deposition rate. The flow rate and
design of the cells are the only variables since no mechanical agitation is used.
Temperature – Higher solution temperature has the following advantages:
 Diffusion coefficient of Au(I) cyanide is increased – increasing the deposition rate.

 Solution conductivity is increased – improve cell current efficiency.
 Solubility of oxygen is decreased, reducing the amount of oxygen available for
reduction at the cathode – improve cell current efficiency.
The effect of higher temperature is still quite small compared to; gold concentration, degree
of mixing and cathode surface area.
Cathode surface area – The electrowinning efficiency is maximized, within reason, by

maximizing the cathode surface area through the use of three-dimensional electrodes such
as steel wool. Additionally the gold deposited onto the cathode further increases the surface
area, increasing the rate of water and oxygen reduction at the cathode.
Cell Voltage – Deposition of metal starts between -0.7 and -1.1V. At this low relatively low
cathodic over-potential a dens, solid product forms on the cathode while at higher cathodic
over-potential delivers a fluffy, porous deposit, which may end up as sludge on the cell floor.

In industrial cell systems the voltages are in the order of 2 to 4V, which compensates for
solution losses and side reaction.
Cell current efficiency – Gold deposition rate increases with increasing current, up to a
point where the maximum current efficiency is reached. Cell currents are typically in the
range of 30 to 100 amp/m2, with varying efficiencies dependant on the cell configuration,
gold concentration, electrolyte composition, as well as hydrodynamic properties of the
electrolyte.
Solution Conductivity – Solution conductivity determines the ohmic potential drop across
the cell, with higher conductivity resulting in lower electrical loss in solution. Cells are
operated typically in the order of 2 S/m electrolyte conductivities. Conductivity of the solution
can be increased if necessary by a suitable electrolyte, such as sodium hydroxide.
Electrowinning of solutions containing less than 10 g/t Au is extremely limited due to current
densities achievable.
pH – pH is important for solution conductivity as well as electrode stability. Stainless steel

anodes and cathodes corrode below a pH of 12.5. The corroded metal can cause side
reactions which reduces cell efficiency.
Cyanide concentration – Increasing cyanide concentration needs higher voltages over the
cell to ensure efficient operation.
Solution flow rate – Higher flow rates through the cell promote solid gold deposition on the
cathode while a slower flow rate promotes the formation of powder or sludge.
13.2. Calcining
Roasting or Calcining is the process of converting base metals to its respective oxides by
heat treatment, such as zinc, iron, lead and copper. The oxide impurities are subsequently
easily removed into a slag during smelting. Oxidation is most effective at temperatures
ranging from 600 to 700⁰C with the base metals oxidizing in 12 to 18 hours. Slow roasting
conditions are generally most efficient to oxidize the metals. The oxidation reaction is usually
limited by the mass transport of oxygen to the metal surfaces, and adequate flow of
oxygen/air must be provided in all regions of the material. Thin layers of material on the
calciner trays are preferred, around 40 to 80mm thick.

13.3. Smelting
The purpose of smelting is to remove base metals and other impurities form high-grade
concentrates to produce a gold-silver bullion/dorè containing typically >95% precious metals.
The smelting product is suitable for direct sale and/or further refining.
The smelting process utilizes slag-forming fluxes to remove the impurities at temperatures
exceeding all the metal melting points, typically between 1200 and 1400⁰C. The mixture is
maintained at the maximum temperature for approximately 1.5 hours to ensure complete
separation of impurities into the slag. The molten gold and silver alloy is heavier than the
slag and sinks to the bottom of the smelting vessel, as well as the moulds when poured.
13.3.1. Fluxes
Silica has a high melting point (1723⁰C) which forms a highly viscous slag that may entrain
the precious metals. The addition of sodium and boron oxides (Borax) reduces both the
melting point (800⁰C) and viscosity of the slag. The amount of silica-sodium borate flux
added with the charge is dependent on the initial quantity of base metals and other
impurities in the charge. Acidity of the slag is gradually reduced as the base metals react
with flux materials. Once the reaction is complete, the slag should be neutral, or slightly
acidic, to protect the furnace lining or crucible from basic (alkaline) corrosion. Other
chemicals may be added to the flux for various reasons, such as:
 Calcium fluoride (fluorspar), which reduces slag viscosity by the substitution of

fluoride ions into the silica lattice.
 Sodium carbonate, which improves slag clarity and decreases viscosity, thereby
reducing precious metals entrainment.
 Oxidizing agents, such as sodium nitrate (nitre) and manganese dioxide (pyrolusite),
assist in the oxidation of unoxidized species, such as base metals.
Fluorite and soda ash may cause foaming and/or increased precious metal volatilization
losses, dependant on temperature and charge composition, and care must be taken when
adding such modified fluxes in smelting systems.

In the table below is a common mixture of fluxes in varying circumstances:
14. Water Treatment Plant
The water treatment plant filters and purifies the raw water in three stages to service
separate sections of the plant (Figure 65); i.e. filtered water for dust suppression and fire
water, potable water for safety showers and lavatories, elution water for the elution circuit.
Raw water is supplied from the raw water dam feeding the settler tanks. Flocculant (to
agglomerate the particles) and chlorine (to disinfect) is dosed in with the water feeding the
settling tanks. The settlers have a stirrer to mix in the reagents and an air recirculation pump
to ensure the settling of solids is achieved efficiently as possible. A auto purge valve drains
out any settled out solids every 10 minutes. The overflow of the settling tanks can only be
used further in the process once the water clarity is at 10 NTU (measured in field by the
operator).
The clarified water is pumped through sand filters, which removes the last remaining solids
until the clarity is under 5 NTU, to the filtered water distribution tank. The filtered water tank
distributes the water to the fire water system, dust suppression system and is pumped
through activated carbon filters to the potable water tank. Chlorine is added again at the
potable water tank to make the water drinkable.

The potable water tank is distributed into the potable water ring main as well as pumped
through ion exchange columns to the elution water tank. The ion exchange columns remove
calcium and magnesium and effectively soften the water for the elution circuit. Chlorine can
also be added to the elution water tank to preserve the water. The elution water tank is
distributed to the two elution solution tanks at the elution circuit.
From Raw Water

Dam Sodium Hypocloride
Flocculant
Settlers
Sand Filters
Carbon Filter
Filtered
Water
Brine
Elution
Water
To Fire Water Tanks
and Dust suppresion
Potable
tanks
Water
To Elution Circuit
To Potable Water
Ringmain
Figure 65: Water Treatment Plant
The water treatment plant operator’s duties include:
 Inspecting all equipment every day to ensure it is in working order.

 All the water tanks are continuously filled and ready for use in the plant.
 Flocculant and hypochloride is mixed and ready for use.
 Settler discharge clarity is below 10 NTU before it is used further in the process.
 General housekeeping

15. Control Room operation
The main function of the control room operators is to monitor and control all the different
operations in the plant and see that it happens according to the parameters set by
management in a safe and cost effective way.
At the start of shift a control room operator must use the SCADA and go through every
section to check if the plant is running correctly, including asses the following:
 If equipment is not running, why is the equipment not running?

 What is being done to get the equipment in good running condition?
 How long it is going to take to get the equipment running?
 If necessary inform the engineering foreman and process supervisor so that they can
arrange for further assistance to resolve the issue quickly and reduce downtime.
 Determine if the plant is running to the set parameters.
Next duty is to check for any alarm conditions or processes that are not running according to
the plant parameters, if so the control room operator has to:
 Inform the foreman that his section is not operating according to the required parameters
 Suggest solutions to solve this.
 Make changes to the SCADA in consultation with the foreman or section supervisor to
get the section back to the set parameters.
If everything is back online and running like it is supposed to, the control room operator can
start with housekeeping in the control room as it is his responsibility to keep his work area
safe and healthy, which includes:
 Neatly storing away files and books and loose papers lying around.
 Remove trash and objects that don't belong in the control room.
 Dust of tables, computers, cupboards and windowsill. This is very important to remove
as much dust as possible to avoid damage to the computers as this can cause gold
production stoppage.
 Check that all cables are neatly stored away in trucking as this can cause serious injury
due to trip and fall or electric shock.
 Inspect fire extinguisher and first aid box.

The control room operator can then check the notice boards for any new safety flashes,
instructions or important information that he must relay to the shift foreman or supervisors.
Throughout the remainder of the shift he must continue to closely monitor everything on the
SCADA to ensure that production targets are met, which includes:
 Feed rates and weight on belt scales, bin levels, sump levels, and statistics on the drives
such as the power draw to insure equipment can't get damaged.
 Densities, levels, grind or shift composite, cyclone pressures at the milling to measure
the performance of the plant.
 Reagent levels to make sure that there is no unnecessary stoppages.
 pH Levels, flows, water levels, oxygen and instrument air.
If any is out of parameter the control room operator must inform the relevant personal
immediately to avoid production loss. He can also check for alarm conditions (such as low
flows, alignment, slip switch, temperature transmitters, vibration, etc.) and inform operators
in the field to correct this.
Keep log of everything that is happening as it can help you analyse the performance and
makes problem solving easier, write a report book to report the day's events and plant
performance as it could help the next shift improve.
If problems do occur, always ask yourself why? Take a step back and look at upstream and
downstream flows to see what might have caused the problem as this could also give you a
solution to the problem. Always remember, "A trend is your friend to the end", if you can't
find the reason for a problem, pull up trends of the process and see what information you
can gather. This will give you valuable info and could make problem solving easier.
Learn your plant parameters and procedures e.g. call-out, plant start-up and shutdown and
know them by heart. Always keep safety in mind. Follow this guideline and you can operate
and control the plant safely and efficiently.

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Process Operating

Kibali Process Operating Manual Page ii

Kibali Process Operating Manual Page iii

Kibali Process Operating Manual Page iv

Figure 1: Basic plant flow diagram ........................................................................................ 2

Kibali Process Operating Manual Page v

Kibali Process Operating Manual Page vi

Kibali Process Operating Manual Page 1

Secondary Process Water Dam

Concentrate Tailings Thickener

Intensive Bypass ore directly

Bullion Induction Furnace

Figure 1: Basic plant flow diagram

Apron Feeder Apron Feeder

Hybrid Crusher Jaw Crusher

Figure 2: Crushing circuit

Kibali Process Operating Manual Page 3

2.2. Primary Crushers

2.2.1. Jaw Crusher

Figure 3: Size reduction in a jaw crusher

Kibali Process Operating Manual Page 4

Figure 4: Hybrid Crusher

2.2.3. Operating the primary crushers

Kibali Process Operating Manual Page 5

Figure 5: Empty apron feeder

Kibali Process Operating Manual Page 6

Inspecting the chutes

Ensuring that the primary crusher gap size is correct

Kibali Process Operating Manual Page 7

2.3. Secondary crushers (Cone)

Figure 6: Particle breakage inside a cone crusher.

2.3.1. Operating the secondary crusher

Kibali Process Operating Manual Page 8

2.3.2. Factors affecting cone crusher operation

Kibali Process Operating Manual Page 9

2.4.1. Safety regarding the starting and stopping of conveyors

Other Safety Requirements

Conveyor Start-Up Safety

Kibali Process Operating Manual Page 10

2.4.2. Housekeeping at conveyors

Figure 7: Poor housekeeping on conveyors

Figure 8: Poor housekeeping damages idlers

Kibali Process Operating Manual Page 11

2.4.3. Idler types

Figure 10: Impact idler

Kibali Process Operating Manual Page 12

Figure 12: Self training idlers

2.4.4. Conveyor equipment

Kibali Process Operating Manual Page 13

Belt alignment switch

Figure 14: Belt alignment switch

Kibali Process Operating Manual Page 14

It is important to guard any moving equipment on a conveyor to prevent anybody entering

Figure 16: Guards not in place at a take up pulley

Figure 17: Guards installed at a tail pulley

Kibali Process Operating Manual Page 15

Figure 18: Take up pulley on a conveyor

Figure 19: Belt magnet installed on a conveyor

Kibali Process Operating Manual Page 16

Figure 21: Belt scale.

Maintaining belt scales

Kibali Process Operating Manual Page 17

2.4.5. Belt splices

Figure 22: Mechanical splice