MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA

OPERATING MANUAL

1.0 INTRODUCTION

The Mirah Plant is a Gold, Silver and Copper recovery plant incorporating the
following:
 Crushing
 Milling
 Classification
 Leaching
 Adsorption
 Elution
 Electrowinning
 Smelting
 Cyanide Recovery
 Tailings Disposal
 Reagent Mixing/Supply Services

It is designed for a nominal throughput rate of 700,000 tonnes per annum of soft ore,
or 650,000 TPA of hard ore.

The Plant Operating Manual is written as guide to operators and other personnel of
the plant in order to successfully operate the plant facilities. The manual should be
used in conjunction with other information not included but supplied separately to the
Client. This includes vendor’s manuals, engineering drawings, PLC programs, etc.

The manual is divided into three volumes. Volume 1 has the three main Sections
being: Plant Description, Plant Operating Procedures and Maintenance. Each of
these is then divided into smaller specific plant areas or equipment types to enables
quick reference to each Section. Volume 1 contains information in general that has
been prepared specifically for this manual. Volume 2 and 3 contain information that
was prepared during the design of the plant and facilities. Volume 2 contains design
documents and Volume 3 design drawings and information relating to the drawings.

708608642.docx 1
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

2.0 PLANT DESCRIPTION

2.1 Overview

The Mirah gold ore treatment plant consists of the following major process areas:

 Area 15 - Crushing
 Area 25 - Milling
 Area 40 - Leaching/Adsorption
 Area 45 - Gold Recovery
 Area 46 - Reagents
 Area 48 - Cyanide Recovery
 Area 50 - Services – Water
 Area 51 - Services – Power
 Area 53 - Services – Air and Diesel

This Section describes the process route, equipment and operation of all equipment.

2.2 Design Summary

The plant is designed for a nominal throughput of 700,000 tap. Due to variations in
ore hardness the SAG mill has been sized to treat the hardest component of the
Lebar and Kuning ores – Kuning hard ore at a rate of 650,000 TPA. Milling capacities
for the softer ores (i.e.: Lebar hard and soft and Kuning soft ore) will be 700,000 tap.

The required leach residence time for the Lebar ore is lower than required for the
Kuning ores. The leach circuit has been designed for 33.5 hours residence time for
Lebar hard ore at 700,000 tpa. At the lower throughput of 650,000 tpa for Kuning ore,
the leach residence time is 36.1 hours.

All of the equipment selected is designed at a capacity of 700,000 tpa.

2.3 Comminution

Reference Drawing: 4272-00-F-001 Crushing and Milling

Coarse ore can be either directly tipped or fed by front end loader into a 100 t
capacity ROM bin 15BIN01. A grizzly (15SCS01) with a spacing of 500 mm has been
provided to reject excessively coarse rocks which may block the coarse ore bin,
apron feeder or jaw crusher. This aperture is variable. Ore is withdrawn from the
coarse ore bin by a 1200 mm wide x 6500 mm long apron feeder, 15FDA01, fitted
with a variable speed hydraulic drive. Ore discharging from the apron feeder drops
into a single toggle jaw crusher (15CRJ01) and then onto the mill feed conveyor
(15CVR01). The mill feed conveyor delivers ore into the SAG mill (25MLS01).

The Mirah comminution circuit consists of an open circuit 850 mm x 1100 mm (34” x
44”) single toggle jaw crusher 15CRJ01, powered by a 110 kW motor and a 4.7 m
diameter x 7.8 m long fixed speed grate discharge SAG mill, 25MLS01, powered by a
2500 kW drive and rotating at 76% critical speed. The mill operates in closed circuit
with a bank of 5 x 300 mm hydrocyclone classifiers, 25CYC01/05.

708608642.docx 2
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

The design size reductions are as follows:

ROM ore feed mm max < 750

Jaw crusher product size, mm P80 = 110
Leach feed sizing, micron P80 = 75

The mill has been sized to grind Kuning hard ore from a feed size of F 80=110 mm to a
product size of P80=75 microns at a throughput of 650,000 tpa. The ball charge
required to achieve this is 11% by volume @28% mill load. The motor has been
sized to accommodate a ball charge of 12% by volume @ a mill load of 35%.

Mill feed rate is measured by a single idler weightometer, 15WIB01, calibrated for a
tonnage range of 0 to 100 t/h. A control loop will automatically adjust the feed rate of
the primary apron feeder, 15FDA01, to maintain a consistent feed rate to the milling
circuit.

Quicklime is added to the mill feed conveyor, 15CVR01, from a 6 t lime hopper,
46BIN04, using a variable speed belt feeder, 46FDB01. This is to modify the slurry
pH to 10.0-10.5 to minimise the consumption of cyanide and the generation of highly
toxic hydrogen cyanide gas (HCN) in the atmosphere above the leach and adsorption
tanks and around the carbon safety screen. The belt feeder speed is adjusted
manually.

Dust suppression facilities are provided for the ROM bin, 15BIN01, using a spray bar
over the bin. A dust extraction system (15DEX01) is provided for the mill feed
conveyor, 15CVR01, and the primary jaw crusher, 15CRJ01.

PLC sequences are provided for starting and stopping the crusher, apron feeder,
lime feeder and mill feed conveyor. The sequences are initiated via a group start
push button (see Section 4.1).

A spillage pump, 25PPS01, is provided to remove spillage from under the mill and
cyclone tower.

Ball charging is conducted using the ball kibble, 25KBL01, and the kibble hoist,
25HST01, located beside the mill feed conveyor and the SAG mill. Balls are hoisted
up to above the ball charging chute, 25CHU17, where they are fed into the mill.

2.4 Classification and Screening

Reference Drawing: 4272-00-F-001 Crushing and Milling

The SAG mill discharge passes through a 12 mm aperture trammel to remove mill
scats. The undersize is pumped by either of two 8 x 6 centrifugal pumps,
25PPC01/02, with 110 kW drives to the classification cyclones (25CYC01/05). A
common variable speed drive, 25VSD01, and sump level probes are provided for
control of the level in the mill discharge sump in order to stabilize the feed to the
cyclones. Trommel oversize reports to a scats bin.

The cyclone cluster consists of a bank of 5 x 300 mm hydrocyclones.

708608642.docx 3
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

Cyclone underflow, at approximately 70% solids, gravitates to the SAG mill feed
chute while cyclone overflow at a design density of 40% solids gravitates to a 1200
mm x 3600 mm, 0.6 mm aperture vibrating trash screen, 25SCV01. Plastic, oversize
rock, wood, blasting wire and other trash in the slurry is removed by the trash screen
before it enters the cyanide leach circuit. The trash screen undersize discharges to
the leach tank or can be diverted to the 1st adsorption tank.

2.5 Leach and Adsorption

Reference Drawing: 4272-00-F-002 Leach and CIL

The cyanide leach and carbon adsorption circuit consists of seven tanks arranged as
one leach, 40TNK01, and six adsorption tanks, 40TNK02/07. Total leach and
adsorption time is approximately 33.5 hours, for softer ores and 36.1 hours for
Kuning hard ore based on an average slurry density of 40% solids.

Sodium cyanide solution can be added to either the leach or 1st adsorption tank.

Test work indicates that relatively high cyanide concentrations (approximately 0.1%)
will be required for optimum silver recovery. Although this will result in higher residual
cyanide levels in the CIL tailings, the cyanide will be recovered in the cyanide
recovery facility.

A continuous launder with a slope of 1.5º is used for slurry transfer. The leach tank
has a diameter of 12.5 m. All the six adsorption tanks have a diameter of 9.5 m.
Design tank volumes are as follows:

Utilised Utilised
Tank Duty Height Volume
m m³
40TNK01 L1 12.1 1,473
40TNK02 A1 10.3 730
40TNK03 A2 10.0 709
40TNK04 A3 9.7 688
40TNK05 A4 9.4 667
40TNK06 A5 9.1 645
40TNK07 A6 8.8 624
Total Volume 5,536

A system of plugs and slide-gates is provided for bypassing individual tanks for
maintenance purposes. More than one tank may be bypassed, but this is not
recommended, as precious metal recovery may be adversely affected.

The leach tank is fitted with a 55 kW mechanical agitator (40AGT01) and each of the
adsorption tanks is fitted with a 45 kW mechanical agitator, 40AGT02/07. Each
agitator consists of dual down pumping impellers.

Oxygen is necessary for the leaching of gold by cyanide. Although metallurgical test
work did not indicate Lebar and Kuning ores to have a significant oxygen demand,
aeration sparging is provided in both the leach tank and the first two adsorption
tanks. The design aeration rate is 1.5 Nm³/t ore per hour. This is equivalent to a flow

708608642.docx 4
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

rate at 48 Nm³/h of air per tank. All the agitators are supplied with rotary couplings for
air sparging and the air flow rate to each tank is measured by a rota meter.

A meter will be provided in tank 40TNK01 for monitoring slurry pH. pH is maintained
at 10.0-10.5 to minimise cyanide consumption and prevent high concentrations of
toxic hydrogen cyanide gas (HCN) in the leach, adsorption and tails screen areas.
This is controlled by changing the addition of lime to the mill (see Section 2.3).

Provision has been made for a future leach tank if more residence time is required.

Carbon is moved counter current to the pulp flow at a design rate of 10 tpd. Transfer
pumps, 40PPS15/19, are provided in 40TNK03 to 07 for movement of carbon from
vessels A6 to A1 (40TNK07 to 02) and a loaded carbon pump, 40PPS02, is provided
in tank A1(40TNK02) for transfer of carbon to the 1.2 m x 2.4 m vibrating loaded
carbon screen, 40SCV03, ahead of the carbon elution column. The loaded carbon
screen has an aperture of 0.8 mm.

Carbon is moved ‘batch wise’ from tank to tank over a 12 hour period. When carbon
is being transferred the volumetric concentration of carbon in the tanks should be
monitored to ensure the required carbon profile is maintained in each tank. The
design concentration of carbon is 15 g/l.

Mechanically swept carbon retention screens, 40SCC02/07, are provided in the

adsorption tanks. Davit hoists, 40HST02/07, are provided for lifting the screens from
the tanks for maintenance purposes. All screen components in contact with slurry are
fabricated from stainless steel and the screen is fabricated from 0.7 mm x 7.0 mm
slotted stainless steel mesh.

The leach and adsorption circuit is largely manually controlled. There are few
interlocks with other areas of the plant, and none which will trip the mill feed, crushing
and conveying system. Some of the more significant control features are listed below

 Agitators are started and stopped manually at field pushbutton stations;

drive status and motor current is monitored through the plant control
system
 Carbon advance is controlled manually by the leach area operator, based
on field observations of carbon concentrations in the adsorption tanks
 The loaded carbon transfer pump, 40PPS02, is started manually but will
stop automatically when the elution column feed hopper is full of carbon
and a high level switch is actuated
 Leach air flow rates are controlled manually. A rota meter is provided for
measurement of air addition to each leach tank
 Leach and adsorption tank bypassing and drainage require a series of
manual operations. No automatic facilities are provided

A carbon safety screen, 40SCV04, is provided on the tail of the adsorption train to
remove any carbon which may escape from the circuit. The screen is a 1.2 m x 3.6 m
vibratory screen with 0.6 mm polyurethane deck. Any carbon oversize is kept for later
treatment to prevent gold losses.

Operational procedures for this area are described in more detail in Section 3.4.

708608642.docx 5
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

The spillage pump, 40PPS03, is provided for the leach and adsorption area for the
clean-up of slurry in the bunded area.

2.6 Gold Recovery

Reference Drawings: 4272-00-F-003 Elution

4272-00-F-005 Gold Recovery

The gold recovery area comprises facilities for carbon elution, carbon regeneration,
electrowinning, bullion smelting and handling and the provision of the reagents
necessary for the carbon elution process.

Elution of gold and silver from the loaded carbon is achieved using a modified Anglo
American Research Laboratory (AARL) method, (a split elution). The major
advantage of a split elution is an improvement in electrowinning efficiency. Loaded
carbon is transferred from the first adsorption tank, 40TNK02, to the elution column,
feed hopper 45BIN03, via the loaded carbon screen, 40SCV03. The recovery area is
designed to treat two 5 tonnes batches of carbon loaded to 9,000 g/t Au + Ag a day,
i.e. A total of 10 tonnes of loaded carbon per day.

Since Regeneration is not required on all the carbon, 5 tonnes of eluted carbon per
day is regenerated in a horizontal carbon regeneration kiln, 45KLN01, and returned
to the last adsorption tank, 40TNK07, and 5 tonnes of eluted carbon per day is
returned from the elution column directly to the last adsorption tank, bypassing
carbon regeneration.

PLC sequences are provided for carrying out several of the gold recovery activities.
These sequences are initiated via the CITECT operator interface computer.
Sequences include:

 AARL carbon elution

 Transfer of spent electrolyte to cyanide mixing or leaching
 Transfer of carbon to regeneration or directly to the last adsorption tank

The regeneration kiln is controlled from a separate PLC control panel located
adjacent to the kiln.

Operations such as electrowinning, cathode handling and bullion smelting are

manually controlled and operated, with some remote monitoring and interlocking
provided for system protection.

Operational procedures for this area are described in more detail in Section 3.5 to
3.7.

2.6.1 Loaded Carbon Recovery

Slurry containing loaded carbon is drawn from the first adsorption tank, 40TNK02, by
a submersible slurry pump, 40PPS03. The slurry discharges onto a 1.2 m x 2.0 m
vibrating loaded carbon screen, (40SCV03) fitted with 0.8 mm aperture
polypropylene screen panels. The slurry passes through the screen and discharges
back to the first or second adsorption tank. The carbon passes over the screen and is
washed by water sprays.

708608642.docx 6
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

The washed carbon discharges into the screen oversize chute, from which it falls into
the elution column feed hopper, 45BIN03, and is transferred into the elution column
(45ELU01) as required. Excess water in the carbon drains from the elution column
onto the floor below the column then drains to the CIL area sump pump.

2.6.2 Elution

The elution column, 45ELU01, is a rubber lined pressure vessel with torispherical
ends. The effective volume of the elution column is nominally 12.2 m³, allowing for
the containment of 5.0 tonnes of carbon along with some excess volume which
prevents overfilling and allows for solution disengagement. The column and
associated piping is lagged and clad to minimise heat losses.

At the base of the column is the elution column distributor, 45DBR06. The various
solutions used in the elution process enter the column via an inlet manifold. The
column distributor allows water to drain from the column while the column is being
filled with carbon and allows the various solutions to be injected and distributed into
the column during the elution process.

Solution heating for the elution process is achieved by a closed circuit heating
system. This comprises an 1800 kW diesel fired heater, heat exchangers and a
thermal oil circulation pump.

Thermal oil, a high flash point heat transfer fluid, is circulated through the heater
system, 45HTR01, and the primary heat exchange, 45HEX01, by the thermal oil
pump, 45PPC07. Heat is transferred from the thermal oil to the elution feed solution.
The gold is eluted from the carbon at a temperature of 110º C. The primary heat
exchanger is of the plate and frame type.

Waste heat is recovered from the hot solution discharging from the elution column by
a reclaim heat exchanger, 45HEX02, which is also of the plate and frame type. The
recovered heat is transferred to fresh incoming solution prior to final heating of the
solution in the primary heat exchanger.

The elution process is based on the Anglo American Research Laboratories (AARL)
system, using a five step cycle to firstly remove contaminants then elute the gold
from the carbon. These steps include:

Step 1 Acid injection to remove calcium, magnesium, copper, zinc, silica and
some organics from the carbon

Step 2 Hot water rinse to complete the removal of acid and preheat the carbon
bed

Step 3 Caustic-cyanide pre-soak to chemically prepare the carbon for gold

elution

Step 4 Hot water elution to desorb or elute gold from the carbon into a
concentrated volume from which the gold can be recovered by electrode
position

Step 5 Water cooling to terminate the elution process and cool the carbon
sufficiently to allow safe transfer out of the elution column

708608642.docx 7
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

As the elution is a split elution procedure, during step 4 lean elute is first pumped
through the column from the lean elute tank, 45TNK34, and exits the column to either
of the electrolyte tank, 45TNK08/09. During the second half of step 4, fresh elution
water from 45TNK10 is pumped through the column then back to the lean eluate
tank, 45TNK34, in preparation for the next elution cycle.

The carbon elution process is fully automated. The elution sequence is initiated from
the CITECT operator interface computer.

The gold rich electrolyte or eluate at approximately 70º C is stored in one of two
electrolyte tanks, 45TNK08/09. Each tank feeds a separate electrowinning circuit.
The use of two electrowinning streams allows electrowinning to be conducted
simultaneously to elution. The gold rich liquor is pumped to three electrolytic cells,
48EWC01/03, in parallel, each containing 10 stainless steel cathodes. The gold and
silver is deposited electrolytically onto the cathode.

Various clean-up pumps are provided for spillages in the elution area. The elution
area sump pump, 45PPS07, covers the elution area. All spillages report to the first
adsorption tank, 40TNK02. An electrolyte sump pump, 45PPS08, is provided to direct
spillage from either electrolyte tank to the first adsorption tank, 40TNK02, or either
electrolyte tank, 45TNK08/09. This is manually set.

An extraction fan, 45FAN01, provided for the electrowinning cells to remove harmful
gases including hydrogen and ammonia from the cells to atmosphere. This fan
should always run while the cells are in operation.

Provision for two additional future cells has been made in the design.

2.6.3 Bullion Processing

On a periodic basis the gold sludge is washed from the cathodes with a high
pressure water spray (45PPC41) either in the cells or on a work table. All slimes from
the cells or the table are fed into the slime filter feed sump, 45SMP04. A pump,
45PPC40, feeds the sludge through a plate and frame filter, 45FTP01 and filtrate is
recirculated back to the sump. Overflow from the sump as well as any other spillage
in the area is pumped by the gold room clean-up pump, 45PPS09, to the electrolyte
spillage pump, 45PPS08, for removal.

Filtered sludge cake is then dried in a drying furnace, 45FRN01, at 150º C. The dried
cake is mixed with fluxing agents and placed in the smelting furnace, 45FRN02.
Bullion is poured into moulds. The ingots are removed from the mould, cleaned up,
weighted, stamped and stored in a safe ready for despatch from the site. The slag is
allowed to cool, before being stored for filter retreatment.

2.6.4 Elution Chemicals

The caustic cyanide pre-soak solution added in Stage 3 of the elution cycle consists
of 2% caustic soda and 2% sodium cyanide. Sodium hydroxide is fed to the caustic
cyanide tank, 45TNK17, from the caustic storage tank, 46TNK22 using the caustic
header tank, 46TNK19. Sodium cyanide is also fed to the caustic cyanide tank from
the cyanide storage tank, 46TNK14, from a header tank, 46TNK17.

Details of reagents are discussed in Section 2.11.

708608642.docx 8
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

2.6.5. Eluted Carbon Transfer

Transfer of eluted carbon from the elution column, 45ELU01, is performed

hydraulically. Carbon can be transferred to either the regeneration kiln feed storage
hopper, 45BIN02, via a Dutch State Mines (DSM) dewatering screen, 45SCS08, or
sent directly to the last adsorption tank, 45TNK07. Carbon is transferred under
pressure supplied by water.

The carbon transport process is controlled by a PLC sequences initiated from the
CITECT operator interface computer.

2.6.6. Carbon Regeneration

Five tonnes per day of eluted carbon is transferred to the regeneration kiln feed
storage hopper, 45BIN02, from the elution column. The carbon is hydraulically
transferred from the elution column to a dewatering screen fitted with a 0.7 mm
wedge wire screen panel. From the screen the carbon falls into a bin with sufficient
volume to accommodate 5 tonnes of carbon. A second screen in the base of the
storage hopper effects further dewatering of the carbon.

From the storage hopper the carbon is conveyed by a screw feeder into the
regeneration kiln, 45KLN01, where it is maintained at a temperature of 650 - 700º C
for a period of 20 minutes to burn-off organic foulants absorbed on the carbon and to
reactivate the surface of the carbon to restore its ability to absorb gold from the
leached slurry.

From the kiln the carbon discharges to a quench tank and is conveyed by a screw
feeder, 48FDS02, to the vibrating carbon sizing screen, 45SCV02. From the screen
carbon discharges to the last adsorption tank, 40TNK07, to repeat the gold
adsorption – elution – regeneration cycle.

The carbon regeneration process is controlled from a separate PLC located adjacent
to the kiln. Important variables including regeneration temperature, fault alarm and
system run/stopped status is displayed on the CITECT operator interface computer.

2.7 Cyanide Recovery

Reference Drawings: 4274-00-F-006 Cyanide Adsorption

4274-00-F-007 Resin Elution
4274-00-F-00 Cyanide Recovery System

The cyanide recovery area comprises an adsorption and elution circuit using
Vitrokele™ resin as the adsorbent. CIP tailings slurry is contacted with the resin in four
agitated adsorption stages. During adsorption any metal complexed or free cyanides
are loaded onto the resin.

Vitrokele Process Chemistry

Vitrokele is supplied as a sulphated resin and is conditioned prior to use dependent

on whether the aim is to recover metal or cyanide or both.

708608642.docx 9
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

Cyanide removal is of primary concern the Vitrokele is first conditioned by contact

with a copper sulphate solution followed by treatment with sulphuric acid. The copper
ion remains attached to the resin and is free to bind with free cyanide from the
solution being treated.

Conditioning R-SO42- + CU(CN)43-  R-Cu(CN)43- + SO42-

R-CU(CN)43-+ 3/2H2SO4  R-CuCN- + 3HCN + 3/2SO42-

Adsorption R-CU- + 4CN-  R-Cu(CN)43-

Elution/ R-Cu(CN)43- + 3/2 H2SO4  R-CuCN- + 3HCN + 3/2SO42-
Regeneration

Cyanide Scrubbing HCN + NaOH  NaCN + H2O

Cyanide is stripped from the resin by sulphuric acid and is recovered by neutralising
with sodium hydroxide. No additional regeneration of the Vitrokele resin is necessary
as the copper remains on the resin ready to bind with more cyanide.

For the recovery of metals, no conditioning is required. The resin is contacted with
the process stream to be treated and the adsorbed metals are eluted with zinc
tetracyanide. Regeneration of the resin is performed by contacting with sulphuric
acid.

The adsorption, elution and regeneration proceeds according to the following general
reactions:

Adsorption R-SO42- + Me(CN)43-  R-Me(CN)43- + SO42-

Elution R-Me(CN)43- + NaCN  R-CN + Me(CN)43-

or R-ME(CN)43- + Zn(CN)42-  R-Zn(CN)42-+ Me(CN)43-

Regeneration R-CN + H2SO4  R-SO42- + HCN

or R-Zn(CN)42- + 2H2SO4  R-SO42- + 4HCN + ZnSO4

Because of the nature of the ore type, it is anticipated that though most of the
cyanide exiting the CIP plant will be free cyanide, there is indication that some WAD
cyanide will be present as copper. These WAD cyanides or copper metal complexes,
will load onto the resin and soon over saturate the resin with copper. As the cyanide
levels in tails must be minimised it is important to periodically remove some of the
metals off the resin i.e. metals elution. A metal elution is a fairly rapid procedure
which uses sodium cyanide as the eluant.

Additionally, the resin will scavenge any remaining silver and gold from solution. If
not removed, this would build up a loading on the resin and inadvertently reduce the
loadings of cyanide on the resin. Additionally, both gold and silver are not removed
by sodium cyanide elution. A stronger eluant, zinc tetra cyanide, and a much longer
time (up to 36 hours) is required in this process. Since the level of gold and silver
loadings are low, the elution’s only need to be performed on a periodic basis.

The following tables summarises the design capacity of the circuit:

708608642.docx 10
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

Free Cyanide Copper Silver Gold

pp, NaCN ppm Cu ppm Ag ppm Au
Cyanide Adsorption Feed 750 40 21.5 neg
Cyanide Adsorption Tails <5 <1 0.1 neg
Resin Loadings – kg/t 113 60 10 neg

Cyanide Copper/Metal Silver/Gold

Elution Elution Elution
Operation Basis Continuous Batch Batch
Feed Rate (aver 24h 0.98 (0.09)?
basis)
Eluant H2SO4 NaCN Na2Zn(CN)4
Batch Time (h) N/A 4 36
Batch Frequency (No/Day) N/A 3 1 in 3

Copper is removed from solution as solid copper cyanide using acid precipitation and
filtration. Gold and silver are recovered in an electrowinning cell. Cyanide in strip
solution is recovered by a stripping and scrubbing circuit.

2.7.1 Cyanide Adsorption

CIP tailing slurry is fed to the first of four agitated adsorption tanks, 48TNK25/28. The
nominal slurry residence time in each adsorption tank is 45 minutes, with a total
residence time of 3 h (based on 700,000 tpa throughput).

The resin is retained in the adsorption tank by a mechanically swept retention screen
(interstage screen), 48SC08/11. The pulp and resin are both kept in suspension by
7.5 kW mechanical agitators, 48AGT12/15. These are dual axial flow impellers.

Slurry flows under gravity through each of the tanks. Launders are provided with
bypass to allow tanks to be taken offline for maintenance. The slurry exits the circuit
and is screened by the resin safety screen, 48SCV05, so as to prevent resin leaving
the circuit. This is a 1.2 m x 3.6 m vibrating screen with 0.6 mm aperture. Once
screened, the slurry gravitates to the tailings sump before being pumped to the
tailings dam.

As resin loads with cyanide and metals, the resin is advanced by continuous air lifting
of slurry and contained resin, counter current to the main slurry flow. At the head of
the circuit, slurry containing loaded resin is air lifted across a vibrating loaded resin
wash screen, 48SCV06.

The loaded resin is separated from the slurry and washed before being transported
by water to either the metal or cyanide elution columns using a splitter box,
48BOX01. The box is manually switched between cyanide and metal elutions. A
positioner reports the position of the box to the CITECT interface. A total of 24 t/d of
resin is advanced.

The adsorption circuit is designed to load the resin to 60 kg/t of free cyanides (as
CN-) and 60 kg/t of metal complex cyanides including copper and silver. Elution for
free cyanide base metal complexed cyanides and precious metal complexed
cyanides requires separate procedures. Hence the resin is transported to either the
metals (48COL02) or cyanide (48COL01) elution columns.

708608642.docx 11
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

2.7.2 Cyanide Elution

Cyanide elution involvers the continuous elution of loaded resin in the cyanide elution
column, 48COL01.

Resin is laundered from the loaded resin screen, 48SCV06, to the resin dewatering
screen, 48SCS02. Resin is transferred at an average rate of 0.98 t/h. The operating
flow will be less for the majority of time, with occasional surges coming from the
screen during pressure transfers from either the metal or silver elution columns,
48COL02/05.

The dewatering screen, 48SCS02, is an inclined screen with 0.6 mm aperture. The
screen removes the transport water which gravitates to the final adsorption tank,
48TNK28. Resin overflow from the screen drops into the cyanide elution column,
48COL01. The column contains a dry bed of resin above a slightly fluidised bed, a
screened overflow and two distributors. The resin moves evenly through the bed into
the elution air lift, 48ALT05, where it is transported to the last adsorption tank,
48TNK28. At the outlet to this tank, an air disengagement chamber separates the air
which can contain hydrogen cyanide, HCN, a highly toxic gas.

Warning: The cyanide elution procedure generates HCN, a highly toxic gas.
Care must be taken when working in the area particularly while the
elution column is in operation.

Sulphuric acid from the sulphuric acid dilution tank, 48TNK30, is dosed into the
column through the second distributor (mid way up the column). The acid enters at
10% w/v concentration and is quickly diluted to 5% w/v. It slowly seeps up through
the bed eluting cyanide from the resin. This cyanide is present as dissolved HCN gas
in the solution. Acid is consumed in this reaction.

The spent acid overflows through the screen at the top of the column. This screen is
wedge wire piping to enable even collection of spent acid off the column. This then
gravitates into the stripper feed tank, 48TNK39. The pH of the overflow is measured
and is used to control the addition of acid into the column through a flow meter and
variable speed drives on the sulphuric acid eluant pumps, 48PPC22/23. The pH is
kept as high as possible to ensure complete use of acid. This however, must be done
in conjunction with maintaining reasonable elution efficiencies. A pH between 1.5 and
2.0 is used.

Water is added into the first distributor at the base of the column. This water acts to
wash remaining acid from the resin as well as maintain a constant up flow in the
column. The up flow relates to the total flow of both acid and water into the column.

The air lift uses water injection to fluidise the resin and air is to transport the resin to
the last adsorption tank, 48TNK28. The water injection set to minimise water exiting
the column from the water wash, while maintaining enough flow to get resin up the air
lift.

When surges come through into the column, the level of the dry bed rises. This bed
height is measured using an ultrasonic level indicator. The height is used to control
the flow rate of air to the air lifts. On an increase in height the air will increase to
remove resin at a faster rate.

708608642.docx 12
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

2.7.3. Metals Elution

Metals elution involves the removal of copper and other base metals (excluding silver
and gold) from the resin. This needs to be done on a periodic basis to prevent over
saturation of copper on the resin. If copper leakage from tails occurs, resin needs to
be chute more frequently.

High strength sodium cyanide is required to elute the resin. Cyanide is prepared in
the metal eluant tank 48TNK33, to 10% w/v strength. The elution procedure requires
three steps:

Step 1 Recycled eluant is pumped from the recycle tank, 48TNK38, through the
elution column, 48COL02, to the precipitation tank, 48TNK35.

Step 2 Metal eluant is pumped from the metal eluant tank, 48TNK33, through the
elution column, 48COL02, to the recycle eluant tank, 48TNK38.

Step 3 Water is used to wash remaining cyanide from the column. Water washes
are returned to the second cyanide adsorption stage, 48TNK26.

2.7.4. Copper Precipitation

Each metal elution cycle results in a batch of eluate in the precipitation tank,
48TNK35. Copper is precipitated as copper cyanide (CuCN) by the addition of 98%,
sulphuric acid to solution. The reaction occurs at a pH of 2.0 and acid addition is
controlled to this pH.

To achieve precipitation, the filter feed pump, 48PPC45, pumps the copper eluate to
the precipitation filter. Concentrated sulphuric acid is injected in-line just before an in-
line mixer, 48MXR01. Sulphuric acid addition is controlled by a variable stroke drive
on an electronically actuated diaphragm acid feed pump, 48PPD05, and is ratiod to
the filter feed flow rate and controlled to pH 2.0.

Warning: The mixing of these fluids generates heat and HCN, a highly toxic
gas. Care must be taken when working in the area particularly
while the precipitation process is occurring.

The now precipitated solids and liquid are pumped through a pulse tube filter,
48FTP09. The filtrate is transferred to the stripper feed tank, 48TNK39. Once the
entire contents of the precipitation tank, 48TNK35, have been precipitated and
filtered, the filter then goes into a wash cycle. The wash cycle involves water flush
followed by an air flush to remove any remaining toxic material in the filter cake. The
filter is drained and water washes go to the stripper feed surge tank, 48TNK39, and
air flushes go to the cyanide stripping column, 48COL04.

A discharge cycle is performed after filter performance drops below normal filtration
rates. The discharge cycle involves water washing, air washing, draining and then
discharging using an air burst to blow cake off the candles. Discharged cake goes
into a bin under the filter. This bin is then removed manually to be stored and
disposed of.
2.7.5. Silver Elution and Recovery

708608642.docx 13
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

As sodium cyanide eluant is not a strong enough to remove precious metals in metal
elutions, a second elution procedure is employed. This uses zinc tetracyanide
Na2Zn(CN)4 as the eluant.

Before a silver elution, a metal elution is performed on a batch of resin. With all
copper removed, resin is transferred under pressure from the metal elution column,
48COL02, to the silver elution column, 48COL03. The pressure transfer uses water
to transport the resin.

Eluant is prepared in the gold eluant tank, 48TNK36. In a fresh batch, the required
quantity of sodium cyanide as solution is added to the tank. Zinc sulphate, as a
powder, is then added by hand into the tank. Water is then used to make the tank up
to full volume. The agitator, 48AGT19, is then switched on for a period to achieve
mixing of the solution. Zinc sulphate will slowly dissolve and the solution will become
essentially clear. The agitator is then turned off during elution.

A heater, 48HTR02, is used to bring the eluant up to a constant temperature of 40 -

50º C. The system must not be raised above 50º C due to the negative effect this will
have on the resin and its properties.

Silver elutions include two steps.

Step 1 Recirculation of the eluant through the silver elution column, the
electrowinning cell, 48EWC07 and back into the gold eluant tank,
48TNK36. This step operates for approximately 36 hours.

Step 2 A water wash is applied to remove any remaining cyanide solution. Water
washes are disposed of in the second adsorption tank, 48TNK26.

On completion of the elution, resin is transferred from the silver elution column to the
loaded resin screen, 48SCV06. This is done by pressure transfer with water.

Electrowinning of gold and silver occurs in the same fashion as the main plant (see
Section 2.6). The cell is located in the gold room.

2.7.6. Cyanide Stripping and Scrubbing

Cyanide stripping is used to remove toxic hydrogen cyanide, HCN, from various
streams which are created in the resin elution processes. Scrubbing involves
absorbing the gas from the air stream using caustic soda. Both are performed in
packed towers using polypropylene packing to increase the liquid/gas contact area
for the transfer to occur.

Liquors to be stripped are fed into the stripper feed surge tank, 48TNK39. These are
pumped into the stripper using variable speed drives pumps, 48PPC47/48, to the
spray bar at the top of the stripping column, 48COL04.

These liquors are then discharged from the stripping column to tailings using the
stripping column pumps, 48PPC41/42.

Air is drawn through both columns using the cyanide recovery fan, 48FAN02. This air
is drawn from the atmosphere at the stripping column and the vents of various
vessels and tanks which contain toxic material. The air is discharged to atmosphere
from a 15 m high stack after exiting the scrubbing column.

708608642.docx 14
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

The scrubbing column, 48COL05, uses the cyanide scrubbing column pump,
48PPC43/44, to recirculate solution to the distributor at the top of the column. A pH
probe in the scrubbing caustic column monitors in the pH column. As the pH falls,
caustic is injected into the scrubber. pH should be maintained at approximately 12.0.
Higher than this value will result in low concentration cyanide being produced and
inefficient caustic use. Lower than this results in a more unstable system.

The level in the scrubber sumps is maintained using a bleed off from the distribution
line. This bleed off contains recovered cyanide which goes back to the cyanide
storage tank, 46TNK14.

2.8 Tailings Disposal

Reference Drawings: 4274-00-F-004 Water and Services

4274-00-F-006 Cyanide Adsorption

After the last stage in cyanide adsorption, 48TNK28, slurry passes over the resin
safety screen, 48SCV05. The safety screen is a vibratory screen which has an
aperture to 0.6 mm and will pick up any resin passing out the adsorption circuit.
Oversize will fall into the resin bin, 48BIN05.

The undersize from the screen then enters the tails sump. Other waste streams from
the process are also combined in this sump.

Tailings are pumped to the tailings dam using variable speed 30 kW drive pumps,
48PPC19/20. The VSD is controlled to a level set point in the sump.

When the tails pumps shut down, process water is used to flush the sump.

2.9 Water Systems

Reference Drawing: 4274-00-F-004 Water and Services

There are six water systems associated with the Mirah Gold process plant.

 Raw water
 Tailings dam decant water
 Process Water
 Fire water
 Potable water
 Safety shower water

2.9.1. Raw Water Systems

Raw water is obtained from a river located nearby to the process plant. Raw water is
used for:

 Mine dust control

 Sprays for dust control at the coarse ore bin
 Sprays for the trash, tails and carbon recovery screens
 Service points for clean up around the plant
 Gold elution circuit

708608642.docx 15
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

 Cyanide recovery circuit

 Make-up to the process water pond

Two centrifugal pumps, 50TNK31/32, pump water from the river to the raw water
tank. 50TNK21. Raw water is reticulated around the plant by two centrifugal pumps,
50PPC24/25, (rated at 80 m3/h each) located at the raw water tank. The overflow
from the raw water tank reports to the process water pond, 50DAM01. An outlet is
installed on the tank for the fire water system.

2.9.2. Tailings Dam Decant Water System

Water is recovered by the decant water pump, 50PPC49. This has a capacity of
approximately 180 m3/h. The pump is mounted on a pontoon and delivers water via
polyethylene pipe to the process water dam, 50DAM0.

The decant water pump is started and stopped locally. Throughout the shift the
operator should observe that return water is discharging into the process water pond.
The pond is to be checked once each shift to determine the water level in the pond.

The tailings dam, 50DAM02, should also be inspected to ensure the pond area
around the tailings decant pontoon is free of slimes to ensure the decant water is
clear. Slimes in the decant water will accumulate in the process water pond and may
result in scaling in pipelines, blocking of spray nozzles and the problem of having to
deslime the process water dam.

Valving is provided on the decant water pump manifold to flush tailings from the
tailings distribution pipelines when tailings emplacement is changed from one side of
the dam to the other. Care is required to ensure the flushing water isolation valves
are closed when not in use to prevent tailings entering the decant water pipelines.

2.9.3. Process Water System

Raw water and tailings dam return water discharge into the process water pond,
50DAM01. This HDPE lined pond is designed to contain a utilized volume of 1400
m³. This volume is equivalent t0 12 hours milling at design tonnage.

When the plant is shutdown the decant water pumps must be turned off to prevent
the process water overflowing. This is important as the decant water contains
residual cyanide, lime and gold from continued leaching of residual gold in the
tailings dam. Two process water pumps each with suction tanks are provided for
delivery of process water to the milling circuit.

The process water pumps, 50PPC27/28, have a design maximum capacity of 200
m³/hour at a head of 50 m. This will be sufficient for milling of up to 87.5 t/h of ore
(700 Kt/a) at a leach feed density of 40% solids with excess water available for clean-
up. The process water is distributed to the mill feed chute and mill discharge hopper.
A pipeline also delivers process water to the tailings pump sump for flushing out the
tailings pipeline when the plant is shut down. The process water pumps are started
locally at the pump station. Status indication (run/stopped/faulted) is provided on the
CITECT Operator Interface.

2.9.4. Fire Water System

708608642.docx 16
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

A diesel driven pump, 50PPC26, capable of delivering 60 m³/h at a head of 40 m is

provided for fire water pumping. The fire water pump has a fuel tank with capacity for
3 hours operations and will continue pumping until the level in the raw water tank is
exhausted.

A battery charger is provided to ensure the battery on the fire water pump engine
remains charged at all times. The pump should be a test-run for 1 hour each week
and the fuel tank should be topped up.

The fire water pump discharges water into the plant raw water pipeline for fire fighting
in the process area. The fire water pump status (run/stopped/faulted) is monitored on
the CITECT operator interface computer.

2.9.5. Potable Water System

Potable water is made using raw water supply and treating it in the water treatment
plant, 50CJL01. This is a filtration and sterilization plant. The treatment plant can
process up to 12 m³/h. A supply of caustic is needed for pH adjustments. The potable
water will be stored in a 25 m³ galvanized steel tank, 50TNK18.

Potable water will be used for:

 Drinking fountains around the plant, offices and workshops
 Safety shower/eyewash stations
 Ablutions
 General uses in the laboratory, workshops and power station

Depending on the quality of the raw water supply potable water may also be used in
the gold elution circuit.

Warning: As with other safety warnings only taps clearly marked ‘Potable
Water’ should be used for drinking purposes. Water from all other
taps must be assumed unfit for human consumption and/or to be
contaminated with cyanide.

Two pumps, 50PPC29/30, are provided for distribution of potable water around the
site and to the camp.

The status of the potable water pumps (run/stopped/faulted) is monitored on the

CITECT operator interface computer.

2.9.6. Safety Shower Water System

Safety showers are provided at strategic positions around the plant:

 Hydrochloric acid storage area
 Sulphuric acid storage area
 Caustic cyanide mix tank area
 Cyanide pump area
 Cyanide mix tank area/caustic mix tank area
 Lime feeder area
 Leach tank
 Cyanide recovery
 Copper precipitation area
 Metal/Silver elution area

708608642.docx 17
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

 Cyanide elution column

 Laboratory

Water supply to the safety shower is from potable water pumps, 50PPC29/30. A 1 m³
head tank is also provided to ensure water supply to the safety showers when
electrical power is not available. All safety shower piping is insulated to prevent
scalding when a safety shower is turned on. Since water from the showers and
eyewash will come in contact with eyes and skin it is important that the showers and
eyewash is kept clean. The operation of the showers should also be tested regularly.

2.10 Air System

Warning: Compressed air can be extremely dangerous if abused, do not use

for cleaning dust from clothing. Do not direct air jets towards any
part of the body. Wear eye and ear protections and clear the area
when purging air lines.

Three air systems are provided in the process plant area:

 General plant air
 Aeration air
 Instrument air

2.10.1 General Plant Air

Compressed air at a pressure of 750 kPa is provided by two 37 kW rotary air screw
compressors, 53CMP01/02. The compressors deliver 380 m³/h each and can be
operated on a Lead/Lag basis whereby the standby compressor starts automatically
if demand exceeds the capacity of the duty compressors.

The compressors are started and stopped locally and should be swapped over on a
planned basis to ensure even wear rates. The compressors have ample capacity for
the estimated air usage and it should be possible to meet the entire plant demand
with only a single unit on line. The major uses of compressed air are:
 Leach aeration (135 m³/h)
 Resin air lift (35 Nm³/h per air lift)
 Mill lubrication systems (15 m³/h)
 Instrument air system (10 m³/h max)

Compressed air service outlets are provided at various points around the process
plant for maintenance tools. This is particularly important for mill reline maintenance.

The compressors are started and stopped locally and the status (run/stopped/faulted)
is monitored on the CITECT operator interface computer. A pressure switch is
provided on the air receiver discharge pipeline to warn of low plant air pressure. Low
pressure will initiate a trip of the carbon elution, carbon transfer, cyanide mixing and
caustic cyanide mixing sequences.

Compressed air from the compressors is piped to a 2.2 m³ capacity plant air receiver,
53RCP01. Moisture contained in the compressed air accumulates in the receiver and
is vented via an automatic blow-down valve. From the receiver all of the compressed
air flows through two coalescent air/oil separators, 53FTP07/08, to reduce the oil
content of the air. The separators will coalesce all oil droplets greater than 1 micron
size. Removal of oil from plant air is important since it is used for aeration in the

708608642.docx 18
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

leach tanks. Oil in the air would contaminate the carbon thus reducing its capacity for
loading gold. The oil can only be removed and adsorption properties of the carbon
restored by heating the carbon in the regeneration kiln.

2.10.2 Low Pressure Air

Oxygen is required for the dissolution of gold by sodium cyanide:

4Au + 8NaCN + 2H2O + O2  4NaAu(CN)2 + 4NaOH

Some ores contain minerals such as pyrrhotite, clays and organic species which
consume oxygen in the leach solution, thus limiting the leaching of gold. The oxygen
content of the slurry is also affected by the slurry temperatures and salinity. Although
test work for Mirah ores did not indicate the ore to have a high oxygen demand,
aeration is supplied to leach tank 40TNK01 and adsorption tanks 40TNK02/03 to
ensure a maximum rate of gold dissolution. The design is based on an aeration rate
of 1.5 Nm³/h/t ore. This equates to a flow rate of 48 m³/h into each of the tanks.

A rotameter is provided for monitoring and controlling the flow rate of air into each
leach vessels.

2.10.3 Instrument Air

A 23 m³/h capacity instrument air dryer, 53DRY01, and an instrument air receiver,
53RCP03, are provided for supply of super low moisture compressed air to the
sequence valves in the plant. The dryer operates by cooling the air in order to lower
the dew point, thus precipitating moisture from the air. The air supplied to the
sequence control valves needs to be free of moisture and oil to ensure reliable valve
operation and low valve maintenance costs. The instrument air dryer is started
locally. There is no indication on the CITECT operator interface computer of the air
dryer status (running/stopped/faulted). After passing through the dryer the instrument
air is stored in a 0.5 m³ air receiver. A non return valve is installed between the dryer
and receiver to prevent back flow of air from the instrument air system into the
general plant air system.

2.11 Reagent Systems

The chemicals used in the Mirah process plant are:

 Quicklime (CaO)
 Sodium cyanide (NaCN)
 Sodium hydroxide (NaOH)
 Hydrochloric acid (HCl)
 Sulphuric acid (H2SO4)
 Zinc sulphate (ZnSO4)
 Copper sulphate (first fill only)
 Fluxing agents for gold smelting including :
- Borax (Na2B4O7) anhydrous
- Boric acid (H3BO3)
- Silica flour (SiO2)
- Sodium Nitrate (NaNO3)
 Various chemicals associated with solution, solids and carbon analysis in the
laboratory and plant filtration room

708608642.docx 19
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

2.11.1 Quicklime

Quicklime Handling System

Warning: Quicklime will cause irritation and burns to skin, eyes and mucous
membranes in the nose and throat. Always wear eye protection,
rubber gloves, protective clothing and respirator when working with
quicklime. Quicklime powder should be washed from the skin as
quickly as possible with copious quantities of water. If irritation
continues seek first aid attention.

The Role of Quicklime in Gold Extraction

Quicklime is used for pH control in the leach and adsorption Section. Cyanide which
is used to dissolve the gold from the ore exists in solution as either CN - or as HCN,
dissolved hydrogen cyanide. The relative amounts of these two species in solution
depends on the pH of the system. HCN is a highly toxic gas and is easily lost from
the slurry due to the action of the tank agitators and when the tailings slurry
discharges to the carbon safety screen.

High levels of HCN in the atmosphere result in both a hazardous work environment
and increased cyanide consumption rate.

To both minimize cyanide usage and ensure a safe working environment the pH in
the leach and adsorption circuit should be maintained in the range 10.0 to 10.5.
Operation at higher pH values will result in excessively high lime usage with little
additional benefit in terms of either plant safety or reduced cyanide usage rates.

Quicklime Addition

Quicklime will be supplied to the site in 1000 kg bags and will be stored in a shed.

Based on test work lime consumption is 2 kg/t. Therefore lime usage at a design
milling rate of 87.5 tph will be 175 kg/h.

Quicklime is fed from a hopper, 46BIN04, to a belt feeder, 46FDB01.

The belt feeder has a manually operated variable speed drive.

2.11.2 Cyanide

Warning: Sodium Cyanide is highly toxic if ingested. It also forms highly toxic
hydrogen cyanide gas which can result in rapid death. Cyanide
solutions are also alkaline which can cause irritation and burns to
skin and eyes. Protective clothing must be worn when handling
cyanide. A carbon filter or external air supply respirator must be
worn when mixing cyanide. If cyanide is ingested or if exposed to
high concentrations of hydrogen cyanide gas first aid attention must
be available. All personal should be familiar with the first aid
procedures for cyanide poisoning and the required equipment
should be regularly inspected and tested by the designated first-aid
officer. Operators should endeavour to minimize working in areas

708608642.docx 20
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

where high hydrogen cyanide concentrations are likely to occur,

particularly around the cyanide recovery plant and tails pump sump.
Hydrogen cyanide can also accumulate above the surface of the
leach and adsorption tanks so care is required when working below
the level of floor grating. When working in these areas when the
plant is operating carbon filter respirators should be worn as a
safety precaution. When entering enclosed tanks the site Closed
Vessel Safety Procedures must be followed.

Roll of Cyanide in Gold Extraction

The role of cyanide in the gold extraction process is to dissolve the gold in the ore to
form a stable gold cyanide complex. The gold is then adsorbed onto carbon from
which it is subsequently stripped and recovered by electrowinning and smelting to
yield gold bullion ingots.

Cyanide Mixing

The cyanide mixing facility consists of a monorail and dual speed hoist, 46HST08, to
lift the 1 t Bulka bag of briquetted cyanide to an enclosed bag breaker 46BRR01.
From the bag breaker the briquettes fall into the mix tank, 46TNK13, which is
agitated by a 1.1 kW turbine agitator, 46AGT01.

The cyanide mix tank has a utilised volume of 17 m³. This is sufficient for mixing
three bags of cyanide to make 15 m³ solution of approximately 20% w/v NaCN.

Cyanide can be mixed using either spent electrolyte or raw water. When using raw
water caustic should be added to the mix tank to ensure a high level of protective
alkalinity before adding the cyanide (Caustic will be pumped via the caustic transfer
pump and is necessary to ensure hydrogen cyanide is not formed when the cyanide
briquettes are added to the raw water)

Level probes are installed in the mix tank to control the addition of either raw water or
spent electrolyte to the tank. The filling of the mix tank is affected via a control
sequence initiated from a local control panel.

After mixing, the cyanide solution is dumped into the cyanide storage tank, 46TNK14,
via a manual 100 mm butterfly valve.

The cyanide addition rate is anticipated to be 2.4 kg/t. At design milling rate of 87.5
t/h leach cyanide addition will be 5063 kg/d. An additional 142 kg will be consumed
for each carbon elution. Cyanide will be recovered from the cyanide recovery plant at
a net recovery of 1.18 kg/t or 2478 kg/d. Total usage will thus be approximately 2541
kg/d. A mix batch (3000 kg) will thus be sufficient for 1.2 days operation.

Cyanide Storage and Dosing

The cyanide holding tank, 46TNK14, has a utilised volume of 55 m³. At design
throughput the storage tank has a storage capacity equivalent to 4.4 days milling.
The bund around the tank has sufficient volume to contain the complete volume of
the holding tank. The cyanide feed pumps, 46PPC11/12, are mounted on elevated

708608642.docx 21
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

plinths to ensure the pumps are not submerged in the event of the bund filling with
cyanide solution.

Two centrifugal pumps transfer cyanide to the header tank, 46TNK17, one duty, one
standby. The header tank distributes cyanide to the leach tank, 40TNK01, to the
caustic cyanide tanks, 45TNK11, and to the metal eluant tank, 45TNK33. Overflow is
returned to the storage tank.

Cyanide to leach is controlled using a manual valve to limit the dosing rate into the
leach tank. The flow is a measured using a rotometer. At a leach addition of 2.25 kg/l
and 20% w/v and at design tonnages of 87.5 tph, this flow will typically be 16 l/min.

Cyanide for the caustic cyanide tank requires 142 kg/batch. This is 710 l/batch.
Cyanide to the metal eluant tank, 48TNK33, is used to make up metal eluant to 10%
w/v strength. It is critical that the strength of eluant is between 9.5% and 11%. Lower
concentrates will affect elution efficiencies. Higher concentrations will affect reagent
usage. At design flows, typical metal elution’s need to be performed 3 times a day as
5 m³ batches i.e. 50 kg of cyanide per batch. This comes to 250 l/batch.

2.11.3 Sodium Hydroxide (Caustic Soda)

Warning: Sodium Hydroxide (caustic soda) solutions are corrosive and will
cause burns to skin and eyes unless removed immediately. If
splashed with caustic solution wash it off with copious amounts of
clean fresh water, and then seek first aid attention. When flake
caustic is dissolved in water a large quantity of heat is evolved. This
could result in boiling. The mix tank agitator should be running when
adding flake caustic to the caustic mix tank. Always wear gloves and
eye protection when handling both liquid and flake caustic.

Sodium hydroxide has three uses at the Mirah gold project:

1. pH protection to minimize the generation of HCN gas during cyanide mixing.
2. To assist in the elution of gold from loaded carbon and to ensure sufficient
conductivity in the electrolyte to maximize electrowinning efficiency.
3. To absorb HCN gas that is generated in the cyanide recovery process.

Caustic Mixing

The caustic mixing facility consists of a monorail and dual speed hoist, 46HST09, to
lift the 500 kg bulka bags of flake caustic soda to an enclosed bag breaker,
46BBR02. From the bag breaker the flake falls into the agitated mixing tank,
46TNK15, which is agitated by a 1.1 kW turbine agitator, 46AGT11.

The caustic mix/storage tank has a utilized volume of 17 m³. This is sufficient for
mixing 8 x 500 kg bags of caustic flake to make a solution of approximately 23% w/v
NaOH. Raw water is used to dilute the caustic soda.

Level probes are installed in the mix tank to control the addition of raw water into the
tank. The filling of the mix tank is affected via a control sequence initiated from the
CITECT operator interface computer.

After mixing, the caustic solution is dumped into the caustic storage tank, 46TNK22,
via a manual valve.

708608642.docx 22
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

The consumption of caustic soda in each application is anticipated as follows:

50 kg per cyanide mix
142 kg per gold elution
3360 kg per day for cyanide recovery
Total usage will be approximately 3694 kg/day; therefore a mix batch (4000 kg) will
be sufficient for 1 day.

Caustic Storage and Dosing

The caustic holding tank, 46TNK22, has a utilised volume of 55 m³. At design
throughput the storage tank will have a capacity equivalent to 3.2 days milling. The
bund around the tank has sufficient volume to contain the complete volume of the
holding tank. The caustic feed pumps, 46PPC14/15, are mounted on elevated plinths
to ensure the pumps are not submerged in the event of the bund filling with cyanide
solution.

Two centrifugal pumps, 46PPC14/15, are provided for transfer of caustic to the
header tank, 46TNK19. The header tank distributes the caustic to the cyanide
scrubber, 48COL05, to electrowinning electrolyte tanks, 45TNK08/09, and to the
caustic cyanide tank, 45TNK11. Overflow is returned to the storage tank.

Caustic to the cyanide scrubber is used to provide caustic for adsorption of HCN from
the cyanide stripper, 48COL04. Caustic addition is controlled using a fully modulating
value linked to a pH meter in the scrubber (see Section 2.7.6). Typical consumption
is 11 l/min.

Caustic to the electrolyte tank is used to increase the conductivity of electrolyte to

improve current densities in the electrowinning cells, 45EWC01/06. Performance is a
problem if the current drawn by a rectifier is still low while the voltage is above 3V.

Every elution needs to make up a tank of caustic cyanide eluant. Each batch requires
680 l.

Caustic for cyanide mixing is drawn directly off a line connected to the discharge of
the caustic feed pumps.

2.11.4 Hydrochloric Acid (HCl)

Warning: Hydrochloric acid is a highly corrosive liquid. Should skin contact be

made, burns will occur unless it is removed immediately. If splashed
with hydrochloric acid wash it away with copious quantities of clean
fresh water. Always wear safety goggles and face shield, PVC
gauntlets, PVC apron and chemically resistant safety boots when
working on acid systems. Hydrochloric acid vapours can cause
irritation to the nose, throat and lungs. Ensure adequate ventilation
in all working areas. When hydrochloric acid is added to water a
large amount of heat is released. This can cause a splashing hazard.
Always add acid to water, never add water to concentrated acid.

Hydrochloric acid for the Mirah project is delivered to site as part of general freight
consignments in 220 litre plastic drums. Acid is pumped from containers by one of
two air actuated diaphragm pumps (46PPC07/08) into a 2.5 m³ acid storage vessel.
Dosing into the elution is done with a small peristaltic pump, 48PPD13, with a manual

708608642.docx 23
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

variable speed drive. For a solution acid concentration of 3% HCl and pre-soak
volume of 7.2 m³, acid consumption will be approximately 620 l/elution cycle.

2.11.5 Sulphuric Acid (H2SO4)

Warning: Sulphuric Acid is a highly corrosive liquid. Should skin contact be

made, burns will occur unless it is removed immediately. If splashed
with sulphuric acid wash it away with copious quantities of clean
fresh water. Always wear safety goggles and face shield, PCL
gauntlets, PCL apron and chemically resistant safety boots when
working on high concentration (>20% w/w) acid systems. When
working on lower concentration systems a minimum of safety
goggles, PCL gloves and chemically resistant safety boots are
required. Sulphuric acid vapours can cause severe irritation, lung
damage and other complications. Sulphuric acid is not very volatile
and therefore workplace exposures are primarily mists and aerosols
which can be avoided with adequate ventilation. When sulphuric
acid is added to water a large amount of heat is released. This can
cause a splashing hazard. Always add acid to water, never add water
to concentrated acid.

Sulphuric acid is delivered to site as 98% w/w liquid in 220 l drums. While
concentrated acid is highly corrosive to human contact, it remains passive to mild
steel while above 90% w/w. If plastics are used in concentrated acid environments,
manufacturer’s approval should be sought.

Containers will be located at the bund near the concentrated sulphuric acid tank,
48TNK29. Containers are emptied using an air operated diaphragm drum pump,
48PPS06. The pump will empty the tank contents in under 10 minutes. At design flow
4.4 tpd of acid is required. Therefore 20 x 220 l drums are used per day of milling.

The concentrated acid tank, 48TNK29, stores a total of 20 m³ (37 t) of acid at 98%
w/w. This relates to a capacity of 8.3 days milling operation at design flow rates.

Acid is consumed in:

 Cyanide elution at 1.47 kg/t of resin
 Copper precipitation at 431 kg/batch

For use in cyanide elution the acid is first diluted to 10% w/v in the sulphuric acid
dilution tank, 48TNK30. Upon a low level being reached in the dilution tank, the
sulphuric acid pump, 48PPD04, pumps acid to the tank from the storage tank. Raw
water is added on a ratio basis into the dilution tank to make up to 10% w/v. Both the
pump and raw water addition is stopped upon a high level being reached.

The dilution tank has a 6 h capacity at design flows. All diluted acid is used by the
cyanide elution column, 48COL01.

Concentrated acid is also used in the precipitation of copper in the metal elution of
resin (see Section 2.7.4). The line pumps the acid at 70 m pressure to the in-line
mixer. The pump, 48PPD05, is a double diaphragm pump and a pressure relief valve
and line has been provided for safety.

2.11.6 Other Chemicals

708608642.docx 24
MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL

Details of chemicals which are used for specialist purposes around the plant have
material and safety data sheets attached.

These are stored in dry form around the plant.

708608642.docx 25