Functional Specification and

Control Philosophy for Asanko

Gold Mine Project

APPROVAL

Martin Barnard Process Engineer

Ryan Males Civil Project Engineer

 Functional Specification and Control
Philosophy for
ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

REVISION RECORD

Page Revision Description Date

1-13 A Issued For Approval 16/01/2015

REFERENCE DOCUMENTS

Document Number Document Name

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 Functional Specification and Control
Philosophy for
ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

Table of Contents

1 Introduction..................................................................................................................................
1.1 Documentation flow............................................................................................................
1.2 SCADA programming instructions.....................................................................................
1.2.1 Process interlocks.......................................................................................................5
1.2.2 Safety interlocks..........................................................................................................5
1.2.3 Maintenance mode......................................................................................................6
2 Intensive Leach Reactor (ILR)....................................................................................................
2.1 C8396-PID-0281................................................................................................................
2.1.1 DRA/Gekko Interface..................................................................................................7
2.1.2 pH Measurement.........................................................................................................9
2.1.3 Pressure Measurements...........................................................................................10
2.1.4 Gas Detection...........................................................................................................11
2.1.5 OTHER CYANIDE CODE SAFETIES.......................................................................12
2.1.6 SPILLAGE BUND LEVEL CONTROL.......................................................................12
3 APPENDIX A: GEKKO SYSTEMS PTY LTD - GRAVITY CIRCUIT PROCESS CONTROL
PHILOSOPHY....................................................................................................................................13

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 Functional Specification and Control
Philosophy for
ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

List of Tables

Table 1: DRA / Gekko Interface Interlocks.........................................................................................9

Table 2: pH measurement (AIT-1570).............................................................................................10
Table 3: HCN Detection (HCND-0512)............................................................................................11
Table 4: Ammonia Gas Detection (NHGD-0514).............................................................................11
Table 5: Safety Shower Interlock (ES-0510)....................................................................................12
Table 6: ILR Spillage Pump Control (PP-0504)...............................................................................13

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 Functional Specification and Control
Philosophy for
ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

1 Introduction

1.1 Documentation flow

Documentation flow of the project is as follows. (All these documents must be read in conjunction
with this document):

 Process Design Criteria

 PFD’s (Process Flow Diagrams) including Mass Balance
 P&ID’s (Process & Instrumentation Diagrams)
 Equipment list
 Functional Specification (this document)

1.2 SCADA programming instructions

Alarms on computer control system will only be for critical items and indicate the exact problem
(indicated in RED). Other alarms caused by main alarm must just be notes (indicated in
YELLOW). The alarm page must however include a record of all the alarms.

The control functions and modes are broken into the following sections:

1.2.1 Process interlocks

Process interlocks will be used to indicate that all process conditions when running in a specific
direction are healthy for safe operation of a drive in question. Process interlocks are only relevant
while the control mode is in interlock mode. The field start pushbuttons are disabled, but the field
stop pushbutton is enabled.

1.2.2 Safety interlocks

Safety interlocks will be used and will never be disabled in any mode and will stop the drive when
running. Safety interlocks are relevant in both control modes.

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Rev. A Date. 16.01.2015

1.2.3 Maintenance mode

Maintenance mode will be installed for maintenance purposes only. In maintenance mode all
process interlocks are disabled. All safety interlocks, maintenance interlocks and start-up
interlocks are enabled. When pressing the field start request button, an area siren will sound and
the drive will be enabled to start when the start window is active. After the motor has been running
in maintenance mode for a time exceeding the maintenance time set point, the control mode will
automatically change back to interlock mode. If the interlock of the drive is not healthy, the drive
will trip, preventing drives being run in maintenance mode for extended periods. The motor tag
indicator located next to the motor symbol will indicate that the motor is in maintenance mode by
changing its fill colour to yellow. While the motor is running, the operator can change the control
mode and provided that there is no fault within the newly selected mode the drive will keep on
running. The valve tag indicator located next to the valve symbol will indicate that the valve is in
maintenance mode by changing its fill colour to yellow. Valve positions can only be changed from
the SCADA when in maintenance mode. While in maintenance mode the operator has full control
functions from the field control stations.

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 Functional Specification and Control
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ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

2 Intensive Leach Reactor (ILR)

2.1 C8396-PID-0281

2.1.1 DRA/Gekko Interface

The Gekko ILR is an intensive cyanidation reactor for leaching high grade gold concentrates. The
system consists of a feed cone (TK-0496), solution cone (TK-0488), rolling reactor drum (RE-
0498), discharge- sump (TK-1570) and pump (PP-0502) for all recirculation and transfer duties.

The ILR is batch operated and consists of 9 steps, i.e. 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.

All of the ILR steps are covered in detail in the vendor control and operating philosophy, with a
short description as follows:

1) STEP 0 - IDLE

During this step, gravity concentrate is accumulated in the feed cone. Solids settle in the feed
cone and excess water will overflow via an overflow pipe. Loading will continue until a pre-defined
weight is reached (indicating a full cone), which will then trigger a final concentrate flushing
sequence and shut down of the Knelson Concentrators (the pre-defined weight will allow for
adequate space for the concentrate of the flushing sequences). The interlock will remain active
until step 1, loading solids, is completed. Upon completion of step 1 the interlock must be removed
and the Knelson concentrators can be started again.

The Knelson Concentrators concentrate flushing sequences will also be staggered so as not to
cause blockages in the feed cone or spillage therefrom.

2) STEP 1 - LOAD SOLIDS

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Rev. A Date. 16.01.2015

During the feed step, concentrate is loaded from the feed cone to the reactor drum. The DRA-
Gekko process interfaces during this step is interlocking the Knelson Concentrators not to perform
a concentrate flushing sequence.

1) STEP 2 - ADD REAGENTS

During this step Caustic, Oxygen and Cyanide are required at the Gekko interface. The solution
tank level (LT-0488B) will be used as a cyanide spillage prevention safety, stopping all potential
cyanide spillage. Solution tank level (LT-0488A) will be used for audible purposes for this
prevention.

2) STEP 3 - LEACH

During leaching, solution is circulated through the reactor drum and Oxygen is added while the
solution is circulated.

3) STEP 4 - CLARIFY

During clarification flocculant is added to settle out the solids, where after the solution is drained
out.

4) STEP 5 - CLARIFIED SOLUTION TRANSFER

During this step solution is transferred from the ILR unit to electrowinning.

5) STEP 6 & 7 - WASH BY MASS & BY TIME

During these steps the remaining solids are washed.

6) STEP 8 & 9 – EMPTY SOLIDS & DRAIN

During these steps the drum runs in reverse and the solids are ejected from the reactor drum into
the sump. The solids are pumped to the secondary mill discharge sump and water is added to
enable pumping of the solids.

Automated sample valves are present on all discharge lines to assist in metallurgical mass
balancing and accounting around the ILR.

An interlock list is provided in the vendor control and operating philosophy, Appendix A. The
following list is for interlocks which fall outside the Gekko battery limit and which describe a DRA-
Gekko interface.

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ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

Table 1: DRA / Gekko Interface Interlocks

Item Tag No. If Condition Resultant Action Interlock Type
Knelson
Concentrators:
Force final
Feed cone
concentrate flushing
maximum Process
WT-1566 WT-1566 > 19 sequence
weight Interlock
AND
reached
Stop Concentrators
GS-0474 = “Stop”
GS-0476 = “Stop”
Knelson
Concentrators:
Gekko
Hold Concentrators
sequence Gekko sequence step 1 Process
Gekko flushing sequence
step no. 1 activated Interlock
(Interlocks to remain
activated
active until step 1 is
complete)
Gekko sequence step 1
activated
AND

GS-0474 = “Running”
Hold Gekko
AND flushing sequence “Hold” Gekko Process
sequence Gekko
active sequence Interlock
step no. 1
OR
GS-0476 = “Running”
AND flushing sequence
active
Cyanide
Safety
Spillage LT-0488A LT-0488A > 95% XA-0488A = “On”
Interlock
Siren
XA-0512 = “On”
Emergency AND
E-Stop Safety
stop / man- “Activated” Shut down entire
Button’s Interlock
down siren Cyanide system as
described below
Shut down of entire Cyanide system in the plant:
Shut down Cyanide dosing pumps
PP-1222, PP-1224, PP-1218, PP-1220 = “STOP”
Shut down Elution pump
PP-0914 = “STOP”
Shut down Pregnant tank pumps
PP-1028, PP-1030, PP-1032, PP-1034, PP-1036 = “STOP”

2.1.2 pH Measurement

The pH in the solution cone, TK-0488, must be maintained above 10.5 and is controlled by the
vendor control philosophy. When the pH level drops below 10.2 a Low alarm will be activated,

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ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

Cyanide supply to the ILR unit must be shut off automatically and immediate corrective action is
required by the operating staff (addition of caustic to the tank - open Vendor valve XV-0488B).
When the pH level drops below 10 a Low Low alarm will be activated, the Cyanide supply to the
plant must be shut off automatically and the plant must be evacuated according to the specific
evacuation procedure.

Table 2: pH measurement (AIT-1570)

Description Item number Limits
Set Point pH AIT-1570 10.5
Controlled
pH AIT-1570 0-14
Variable
Manipulated
Siren XA-1570 ”On”/”Off”
Variable
Final Control Vendor Cyanide
XV-0488A “Open”/”Close”
Element 1 Supply Valve
Final Control Vendor Caustic
XV-0488B “Open”/”Close”
Element 2 Supply Valve
XV-1570B
Final Control Vendor Route
XV-0502D “Open”/”Close”
Element 3 Selection Valves
XV-0502I
Final Control Cyanide Dosing
PP-1218 “Start”/”Stop”
Element 4 Pump Drive
Action Table
Description Condition Action
Level HH Not used
Level H Not used
XA-1507 = “On” (Safety Interlock)
XV-0488A = “Close” (Safety Interlock)
XV-0488B = “Open” (Safety Interlock)
Level L AIT-0622 < 10.2
XV-1570B = “Open” (Safety Interlock)
XV-0502D = “Open” (Safety Interlock)
XV-0502I = “Open” (Safety Interlock)
XA-1507 = “On” (Safety Interlock)
XV-0488A = “Close” (Safety Interlock)
XV-0488B = “Open” (Safety Interlock)
Level LL AIT-0622 < 10 XV-1570B = “Open” (Safety Interlock)
XV-0502D = “Open” (Safety Interlock)
XV-0502I = “Open” (Safety Interlock)
NC-1218 = “Stop” (Safety Interlock)

2.1.3 Pressure Measurements

Pressure transmitters will be installed on the solid transfer to secondary mill discharge sump (PT-
0502A), ILR electrowinning (PT-0502B), and ILR rinse solution to CIL (PT-0502C). These
transmitters are for information purposes only and no control functions have been provided.

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ASANKO GOLD MINE PROJECT

Rev. A Date. 16.01.2015

2.1.4 Gas Detection

Hydrogen Cyanide and Ammonia gas detectors (HCND-0512 & NHGD-0514) are installed in the
ILR area.

When Hydrogen Cyanide (HCN) levels reach 7.5ppm a High alarm will be activated, Cyanide
supply to the ILR unit must be shut off automatically and immediate corrective action is required by
the operating staff. When HCN levels reach 10ppm a High High alarm must be activated, the
Cyanide supply to the plant must be shut off automatically and the plant must be evacuated
according to the specific evacuation procedure.

When Ammonia (NH) reaches a level of 25 ppm a High alarm will be activated, Cyanide supply to
the ILR unit must be shut off automatically and immediate corrective action is required by the
operating staff.

Table 3: HCN Detection (HCND-0512)

Description Item number Limits
Set Point HCN Level ppm HCND-0512 7.5ppm
Controlled
HCN Level ppm HCND-0512 0-15ppm
Variable
Manipulated
Siren XA-0512 ”On”/”Off”
Variable
Final Control Vendor Cyanide
XV-0488A “Open”/”Close”
Element 1 Supply Valve
Final Control Cyanide Dosing
PP-1218 “Start”/”Stop”
Element 2 Pump Drive
Action Table
Description Condition Action
XA-0512 = “On” (Safety Interlock)
HCND-0512 >
Level HH XV-0488A = “Close” (Safety Interlock)
10ppm
NC-1218 = “Stop” (Safety Interlock)
XA-0512 = “On” (Safety Interlock)
Level H HCND-0512 > SP
XV-0488A = “Close” (Safety Interlock)
Level L Not used
Level LL Not used

Table 4: Ammonia Gas Detection (NHGD-0514)

Description Item number Limits
Set Point NH level ppm NHGD-0514 25ppm
Controlled
NH level ppm NHGD-0514 0-50ppm
Variable
Manipulated
Siren XA-0514 ”On”/”Off”
Variable
Final Control Vendor Cyanide
XV-0488A “Open”/”Close”
Element Supply Valve

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Rev. A Date. 16.01.2015

Action Table
Description Condition Action
Level HH Not used x
XA-0514 = “On” (Safety Interlock)
Level H NHGD-0614 > SP
XV-0488A = “Close” (Safety Interlock)
Level L Not used
Level LL Not used

2.1.5 OTHER CYANIDE CODE SAFETIES

The following are additional safety measures put in-place for the Cyanide Code regulations and
cover the HAZOP items identified:

 Caustic solution can also be added to the spillage bund using a manual valve during condition
of Cyanide solution spillage as an additional operational safety. Extra care must be taken
when hose down water is used in the area. No controls or interlocks are provided for this
valve and must be operator controlled.

 Safety shower with eye wash and platform operated is installed inside the ILR cage and will be
painted luminous green, siren when in operation, have a potable water source 3.5-4.0BAR
pressure, have an isolation valve that’s locked-open, have a personnel decontamination hose
2m long x 20mm ID.

 A Haz-chem trailer will supplied with a fridge interlocked to temperature.

 Emergency and “man-down” stop buttons will be supplied with dedicated field sirens and
interlocked to Cyanide equipment.

Table 5: Safety Shower Interlock (ES-0510)

Item Tag No. If Condition Resultant Action Interlock Type
Safety Shower Safety
FS-0510 “Activated” XA-0510 = “On”
Alarm Interlock

2.1.6 SPILLAGE BUND LEVEL CONTROL

ILR solution as well as ILR sump overflow is routed to the spillage bund. A level transmitter (LT-
0504) is installed in the bunded area. The operator must start the ILR spillage pump (PP-0504)
when a high level is observed and when the low level is reached the ILR spillage pump will shut off
automatically.

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Rev. A Date. 16.01.2015

The operator must always ensure that the correct destination is selected for the spillage pump
discharge. This is done by opening and closing the manual isolation valves in the various
discharge routes. The discharge destinations, in order of preference, are:

 ILR solution tank (primary and default route that should be used as far as possible for all liquid
spills).

 Secondary mill discharge sump (when solids are present and all possible cyanide spills have
been neutralized and pumped to the solution tank).

Table 6: ILR Spillage Pump Control (PP-0504)

Description Item number Limits
Set Point Bund Level % LT-0504 20%
Controlled
Bund Level % LT-0504 0-100%
Variable
Final Control
Spillage Pump Drive PP-0504 ”On”/”Off”
Element 1
Action Table
Description Condition Action
Level HH Not used
Level H Not used
Level L LIT-0504 < 5% Stop Spillage Pump PP-0504 (NC-0504)
Level LL Not used

3 APPENDIX A: GEKKO SYSTEMS PTY LTD - GRAVITY CIRCUIT

PROCESS CONTROL PHILOSOPHY

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