From: Ruel C Bato, Jr.

Date: January 27, 2022

Subject: Merrill-Crowe Precipitate Acid Treatment Optimization Proposal

To: PROCESS PLANT MANAGER

I. OBJECTIVE

• To evaluate the current Merrill-Crowe precipitate acid treatment and provide an

improvement scheme to reduce or eliminate the production of “yellow pungent
odor” during refining of the Merrill-Crowe circuit dore product.

II. ISSUES WITH THE CURRENT OPERATION

1. Production of “Yellow Pungent Odor” during refining the Merrill-Crowe process

dore.
2. Heat-intensive operation due to heating of precipitate during acid treatment and
drying.
3. High ergonomic risk during washing due to manual tilting of 200 L drums.
4. Long drying hours (3-5 hours).

III. PROPOSAL SUMMARY

1. Double the washing time of the acid treated precipitate.

2. Utilize aeration instead of heating to reduce the impurities.
3. Fabrication of a tilting container for acid treatment and washing for easier handling.
4. Fabrication of a pressure filter to reduce the precipitate drying time.

Proposed Capacity (See Excel File for Details)

1. Tilting Tank Capacity: 1.1 m3 (Minimum Volume)
2. Pressure Filter Capacity: 551 L (Max Volume)
IV. CURRENT OPERATION

A. DESCRIPTION

Precipitate Harvest
The Gold Room acid treatment scheme starts after the harvest of precipitate from the
filter presses. The claimed precipitate is placed in 20 L pails to estimate the amount of acid
dosage. Sulfuric acid is used to treat the precipitate with a ratio of 3 L acid per pail of
precipitate.

Acid Treatment
After the harvest, the precipitate is placed in a heated pan with the addition of sulfuric
acid. The precipitate is mixed thoroughly with the acid while being heated by a burner for an
hour to reduce the impurities.

Washing
After acid treatment, the precipitate is placed in a 200 L plastic drum for washing. Raw
water is added to the drum until nearly full and is mixed thoroughly using a stirrer. The
precipitate is allowed to settle before decanting the drum by siphoning. This washing
process is repeated 6 times and is performed for an hour.

Drying
Drying the precipitate commenced after washing. The precipitate is again placed in the
heated pan and takes around 3-5 hours to fully dry the precipitate.

After drying, the precipitate is weighed to estimate the fluxes required for smelting.

B. ACID TREATMENT FLOWSHEET

 C. ACID TREATMENT TIMELINE

• A total of 7 hours Acid Treatment

Task Duration: Hours

1 2 3 4 5 6 7 8
Acid Treatment
Washing
Drying

V. PROPOSED ACID TREATMENT SCHEME

A. DESCRIPTION

Acid Treatment
After the harvest, the precipitate is placed in a “Tilting Container”. Sulfuric acid and
compressed air are introduced in the container. The precipitate is mixed thoroughly with the
acid while compressed air is also introduced. The process is performed for an hour to reduce
the impurities.

Washing
After acid treatment, water is added in the “Tilting Container” until nearly full and is
mixed thoroughly using a stirrer. The precipitate is allowed to settle before decanting the
container by tilting. This washing process is repeated 10-15 times and should be performed
for two hours.

Filtering
The washed precipitate is then filtered using a “Pressure Filter” to remove most of the
moisture (~80-90%). This process is expected to be completed in an hour.

Drying
Drying further the filtered precipitate for an hour to fully dry.

B. ACID TREATMENT FLOWSHEET

 C. ACID TREATMENT TIMELINE

• A total of 5 hours Acid Treatment

Task Duration: Hours
1 2 3 4 5 6 7 8
Acid Treatment
Washing
Pressure Filter
Drying

VI. IMAGES

A. Tilting Tank Guide