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MINERALS
ENGINEERING
Minerals Engineering 16 (2003) 41 1-419
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Intensive cyanidation: onsite application of the InLine Leach
Reactor to gravity gold concentrates *
R.J. Longley *, A. McCallum, N. Katsikaros
Gekko Systems Pry Ltd.. 321 Learmonth Road, Ballarat, Vic 3350, Australia
Received 20 November 2002; accepted 11 February 2003
Abstract
Gekko Systems have advanced the science of intensive leaching by developing an innovative alternative to the traditional in-
tensive leach systems of agitated tank and vat leaching. As leaders in the field, Gekko present mine site results and operational data
for Australian and overseas mines. The Batch Inline Leach Reactor maintains the critical technical advantages of a rolling drum and
reliable solution clarification while simplifying the equipment to a rolling drum, two tanks and a single pump.
O 2003 Elsevier Science Ltd. All rights reserved.
Keywords: Gravity concentration; Cyanidation; Electrowinning; Leaching and reaction kinetics
1. Introduction
The last two decades has seen resurgence in the re-
covery of gold using gravity-often in conjunction with
a conventional carbon-in-pulp (CIP) or carbon-in-leach
(CIL) circuit. Generally the g ravity gold concentrates
are high-grade with gold grades of 20,000 ppm and with
relatively low mass at 0.03% of the plant feed. Bowl
centrifugal concentrators (BCC's) such as the inline
spinner, falcon and Knelson concentrators invariably
produce the gravity gold concentrates, Gray and Kats-
ikaros, 1999, although flotation may also be utilised.
The new technology exhibited by the BCC's has injected
new life into what was regarded as 'old technology'.
Treatment of these high-grade gold concentrates has
usually been through amalgamation with mercury (a
process route that has now become very minimal due to
environmental and safety concerns) or by a second stage
of gravity treatment commonly utilising tabling or a
related process. In particular the tabling of gravity
concentrates was proven to offer very low recoveries,
Longley et al., 2002-often between 30% and 60%,
*Presented at Minerals Engineering '02, Perth, Australia, September
2002.
'Corresponding author. Tel.: +61-3-5339-5859; fax: +61-3-5339-5803.
E-mail addresses: [email protected], [email protected] (R.J.
Longley).
URL: http://www.gekkos.com.
much lower than expected by the mine sites operating
these devices. An example of the tabling performance of
a Western Australian mine site is shown in Fig. 1.
The research indicated that tabling was clearly a
"below optimum" process. It was regarded as inefficient
to achieve high recoveries in a high "g" force unit like a
BCC only to lose it in the next metallurgical process.
Research also showed that the tabling of concentrates
in a number of circuits resulted directly in instanta-
neously high cyclone overflow grades when the table
tails are returned to the milling circuit and subsequent
losses from the leach circuit to tails. This behaviour is
illustrated in Fig. 2 from a Western Australian mine
site, Grigg, 2002. Due to the classification, Wills, 1979,
characteristics of a hydrocyclone, misplacement of
coarse gold particles to the overflow will occur. Particles
that may not be dissolved prior to discharge to tails
resulting in reduced recoveries.
Intensive cyanidation is proven technology that gives
high recoveries from gravity gold concentrates-this was
achieved by either a high-speed agitator in a tank or by
vat leaching. Both methods had their problems due either
to excessive wear and high energy requirement for the
agitated systems or channelling of solution and loss of
fine gold in the vat type systems giving poor recoveries.
In 1997 Gekko Systems Pty Ltd introduced the In-
Line Leach Reactor (1LR)-the first were continuous
units and treated the gravity concentrates from either
batch type concentrators or continuous concentrators
0892-6875/03/$ - see front matter O 2003 Elsevier Science Ltd. All rights reserved.
doi: 10.1016/S0892-6875(03)00054-2
412 R. J. Longley et al. I Minerals Engineering 16 (2003) 411419
Wilfley Table Recovery
100 , ,-,
0 100 200 300 400 500 600 700 800 900 1000 1100 1200
Screen Size (um)
I -A- Recovery I
Fig. 1. Gold ore-table recovery curve.
"." a
0 100 200 300
Time (minutes)
Fig. 2. Cyclone overflow grades during tabling.
such as jigs or flotation. An important breakthrough for
the InLine Leach Reactor came with the introduction of
the technology into the African market where the se-
curity issue created a compelling event. Ashanti Gold-
fields introduced the technology across all their mining
operations (six units now installed).
The Batch Inline Leach Reactor was subsequently
developed to treat smaller masses of gravity concen-
trates than are treated in the continuous system. The
batch units will treat up to 8400 kglcycle (commonly
24 h), whilst the continuous units treat from 150 kglh up
to 7000 kglh.
2. Why intensive cyanidation?
Why invest in intensive cyanidation? Each mine site
and organisation is attracted to this technology for
different reasons. However, the key factors include:
significant gravity recovery improvements
proven chemistry
security
safety benefits
major capital cost reductions for increased leach
throughput
There are over fifteen mines worldwide using InLine
Leach Reactors for intensive cyanidation of gravity gold
concentrates. These include both batch and continuous
units. While Batch Inline Leach Reactors are cost ef-
fective for small concentrate masses, higher feed rates
require a continuous reactor.
Significant gravity recovery improvements
For this process to be viable it is necessary to reliably
obtain high recoveries from the gravity concentrate-in
excess of 97%. The only proven technology giving high
gold recoveries from gravity concentrates is intensive
cyanidation coupled with either direct electrowinning or
carbon absorption.
Proven chemistry
The chemistry of cyanidation is proven and well
known with the majority of gold operations in Australia
using the process. Cyanidation as a process had been
used for the extraction of gold since 1890. The reaction
for the leaching of gold is known as Elsner's equation,
Lenahan et al., 1986:
Oxygen is an indispensable reagent in the reaction and is
provided either from atmospheric oxygen, hydrogen
peroxide or a production oxygen facility, McQuiston,
1985. The level of oxygen addition required is deter-
mined from the initial test work and/or during plant
commissioning. Fig. 3 shows leach profiles for both
oxygen and peroxide.
Intensive cyanidation, typically using cyanide levels
of 2%, requires no exotic chemicals or materials and uses
standard process operations. At these levels of cyanide
the safety procedures currently used around a CIPICIL
gold room are readily applicable with only minor
modifications.
The harsh chemical conditions exhibited by the in-
tensive cyanidation process are necessary due to the high
gold tenors within the gravity gold concentrates. Table 1
shows the relative comparison between the conditions in
a CIPICIL circuit and a Batch Inline Leach Reactor.
Security
With no requirement for manual handling of the
gravity gold concentrates and the harsh leach condi-
tions, coupled with the enclosed drum design a high level
of security is obtained. Commonly the units are fenced
off separately from the rest of the plant.
Safety benefits
Negation of the need for manual handling reduces the
occurrence of strains and sprains. Also the generation of
toxic fumes during the calcining and smelting process is
minimised. Since there is no contact with what are
commonly high sulphide materials the incidence of skin
problems is also negated.
R J. Longley et al. I Minerals Engineering 16 (2003) 411419
8 12 16
Time (hours)
Fig. 3. ILR leach kinetics utilising oxygen or peroxide.
Table 1
Comparative leach conditions
CIPICIL ILR-B Factor
Au, g/t 2.0 20,000 10,000
CN, P P ~ 500 20,000 40
0 2 , P P ~
8 15 2
Au dissolution rate, glhlt 0.1 1000 10,000
Major capital cost reductions for increased leach
throughput
The opportunity exists to recover 7040% of the total
plant gold production from the gravity circuit. Signifi-
cantly reducing the requirement for carbon handling etc.
In retro-fit installations where a plant throughput in-
crease is planned, the addition of intensive cyanidation
may reduce the requirement for any leach and CIPICIL
upgrade.
3. Batch InLie Leach Reactor design features
I
The batch models of the InLine Leach Reactor have
been developed to treat high-grade, low volume gold
bearing concentrates. The Batch Inline Leach Reactor is
available in four sizes as shown in Table 2--each model
is available in either manual or automatic modes.
3.1. Well mixed reaction zone
The ILR operates on a semi-submerged bed princi-
pal. A partially closed medium aspect ratio drum is filled
with concentrate to the overflow level and rotated. The
rolling drum technology closely resembles common
bottle roll technology but with added features. The so-
lution carrying all reagents is cycled through the drum at
Table 2
Models available
Model Maximum dry capacity
relatively high flow rate to ensure a constant supply of
cyanide and oxygen.
The action of the drum ensures a high level of solu-
tion shear at the particle surface, which removes chem-
ical passivating products that may form at the particle
surface. This also guarantees that there are no "Dead
Spots" in the solutionlsolid interface and the solid par-
ticles see fresh solution continuously.
3.2. Flexible reagent regime
Due to this relatively high shear, intense reagent en-
vironment, exceptionally rapid reaction kinetics is seen.
Oxygen utilisation is maximised and surface passivation
is minimised. The effective mixing allows a wide variety
of oxidants to be used to maximise recovery and mini-
mise operating costs.
3.3. Good electrowinning performance
Pregnant solution is well suited to recovery by elec-
trowinning. LeachAid or similar addition is not gener-
ally required so electrowinning performance is not
compromised. Where required, trace metals such as
mercury and arsenic can be precipitated in the reactor
drum and removed during clarification. Fig. 4 shows
typical site performance of electrowinning circuit on a
pregnant intensive cyanidation solution.
RJ. Longley et al. I Minerals Engineering 16 (2003) 411419
0 4 8 12 16
I
20
Time (hours)
Fig. 4. Typical electrowinning kinetics.
3.4. Coarse and fine gold leaching
Both coarse and fine gold are targeted with no
physical losses to tails of fines through short circuiting
or clarification. During drum loading all solids are re-
tained within the leaching system. Any fines that over-
flow the drum, including hydrophobic gold fines, are
retained in the solution storage cone and form part of
the leaching solution. This solution is recirculated
through the drum during leaching. In this way all solids
are contacted with leach solution and all gold is leached.
3.5. ClariJication step
A separate step is used to clarify the pregnant solu-
tion prior to transferring to electrowinning. This process
gives good control of clarification. The solids are re-
turned to the drum and flocculant addition is used as
required. This means all types of concentrates can be
treated. This includes concentrates where slimy precipi-
tates are formed as part of the leaching process.
3.6. Batch InLine Leach Reactor operation
The concentrates from the primary recovery device
report to the feed cone for de-watering, with the water
overflowing and returning to the mill circuit. Solids are
stored in the feed cone until the beginning of each leach
cycle. Figs. 5 and 6 show a Batch Inline Leach Reactor.
The Batch Inline Leach Reactor works on the prin-
cipal of the laboratory bottle roll to keep the solids in
contact with the liquor. A horizontal drum rotating at
low speed with a set of specially designed baffles and
aeration system for maximum leach performance. Res-
idence time is predicted in the laboratory and controlled
by leach cycle time. During leaching solution is contin-
ually recirculated through the solids from the solution
Fig. 5. InLine Leach Reactor.
storage tank to ensure a fresh supply of reagents, in-
cluding oxygen, is always available for leaching.
At the completion of the leach cycle the pregnant
solution is clarified then pumped to the electrowinning
circuit. Barren solids are emptied by reversing the drum
rotation and pumped to the mill circuit. Pregnant liquor
is pumped to the electrowinning circuit where it can be
recovered in a dedicated electrowinning cell or mixed
with the main elution solution. The barren solution from
electrowinning is then pumped to the CILICIP circuit
(optionally to the ILR) to reuse the residual cyanide.
Fig. 7 depicts the flow sheet for a '000 series reactor.
During the leaching step solution is recirculated from
the solution storage tank to the reactor feed and over-
flows to the sump before being returned to the solution
storage tank. The recirculation rate is controlled via a
restriction orifice in the line to the reactor drum. By re-
circulating a relatively large volume of solution through
the solids the equivalent of a low leach density i s
R.J. Longley et al. 1 Minerals Engineering 16 (2003) 411419 415
THIRD ANGLE
PLAN VlEW
C urn I
NrcG+"L mmw m
FRONT VlEW
PROJECTION @ oo w rw : WEBr axer -m
u
END VlEW
Fig. 6. Drawing of Gekko Systems Batch Inline Leach Reactor ILR1000BA.
BATCH ILR1000 FLOWSHEET
REAGENT
ADDITION
I
SOLIDS SOLUTION
STORAGE STORAGE
WATER
ADD
MOTOR
4KW
Fig. 7. Batch InLine Leach Reactor flowsheet.
SOLIDS
DISPOSAL
SOLUTION
TO EW
STORAGE
achieved. If necessary, air or oxygen can be sparged into The reactor drum rotates around a horizontal axis.
the solution storage tank during the leach cycle. The drum is rotated only fast enough to ensure that
416 R J. Longley et al. I Minerals Engineering 16 (2003) 411-419
fresh solution is mixed through the solid. The action of
the rotating drum also draws air into the slurry, which
ensures no portion of the solids can become oxygen
depleted, therefore re-precipitation of gold onto steel
particles does not occur.
At the completion of the leach cycle the drum is
stopped and the solution in the drum is drained into the
sump and pumped to the solution storage tank. Some
fine particles are carried through the drum and are re-
circulated with the solution. The solution is clarified by
allowing it to stand then periodically draining solution
from the bottom of the tanks conical base. Flocculent is
added to improve clarification performance as required.
Wash water is added to the drum and used to wash
entrained pregnant solution from the solids.
Wash water is drained from the reactor drum and
clarified. Steps 6 and 7 can be repeated as often as re-
quired.
The leached washed solids are emptied from the re-
actor drum by reversing the rotation of the drum. A
scoop inside the drum empties the solids into the sump
while water is added continuously to pump back to the
mill circuit.
The pregnant solution can be transferred to the
electrowinning section at this stage. The solution can be
transferred into a dedicated electrowinning tank and cell
for recovery or the solution can be added directly into
the elution circuit for recovery in the main plant elec-
trowinning cells. The ILR is now ready to start at step 1
with concentrate collected during the last cycle of steps.
4. Installation results
The process and design flexibility of the ILR has re-
sulted in over 20 installations world wide, with the
majority in Australia or in Africa.
The following examples illustrate the very good re-
sults the batch units have had at several mine sites.
4.1. Indonesia
Site results are shown from a gold mine in Indonesia
showing the leaching/electrowinning performance of a
Batch Inline Leach Reactor. The mine operates five
Knelson concentrators producing approximately 2500
kg's of concentrate per day. Previously the concentrate
was treated over a two stage tabling process over two
tables. The gravity concentrate was first screened over a
1 mm screen, then the minus and plus size fractions
tabled separately. First over a large table as a rougher
and the concentrate then cleaned over the second table.
The table tails were returned to the grinding circuit. The
process was very labour intensive with two or three
qualified metallurgical personnel required every second
day to process the concentrate. There were additional
personnel required as security during the tabling pro-
cess.
A sample of gravity concentrate was forwarded to
Gekko Systems Pty Ltd for laboratory scale high in-
tensity cyanide leaching and associated electrowinning
test work on the leach solutions generated. The test
work determined the leach kinetics, reagent regime and
electrowinning capacity required.
The concentrate is treated in an ILR2000 Batch-
Automatic (ILR2000BA) operating on a 24 h cycle. The
clarified solution is transferred to the gold room for
electrowinning using two Alglass electrowinning cells in
series. Since the unit is fully automated there is only
intermittent operator involvement required during the
process. Fig. 8 shows the leach and electrowinning
performance of the unit.
The ILR2000BA utilises oxygen, which is sparged
into the leach solution. DO levels of 10 ppm are main-
90 .
-- -- - - - ----.-------- --
40
-8- L~l ch Remvery
- a- Electrowlnnlng Recovery -
/
d . Mass Gold Recovered m
4 , - - - - - - -
Y
3 80.-
\
-
- 30
i?
5 \
P &
a 70
a
8
50 0 0
114 11s 116 117 118 119 120 121 in 12.3
Batch Number
Fig. 8. Leach and electrowinning results for Indonesian ILR2000BA.
R.J. Longley et al. I Minerals Engineering I6 (2003) 411419 417
Table 3
ILR2000BA performance in Indonesia
Batch no. Concentrate Leached Residue grade Leach recovery EWin recovery
mass (tonnes)
Au (gr) Ag (gr) Au (ppm) Ag (ppm) Au (%) Ag (%) Au (YO) Ag (Oh)
114
115
116
117
118
119
120
121
122
123
Average
Maximum
Minimum
tained on the drum discharge (the requirement for oxy-
gen addition was determined at the laboratory testwork
stage). The results show very good recoveries with an
average of 99.5% gold dissolution in the gravity con-
centrate. Gold electrowinning recoveries averaged 98%
on the leach solutions, Gray, 2002. From gold feed
grades of approximately 10,000 g/t, residue grades of 50
g/t are regularly obtained. Table 3 shows the detailed
performance of the unit. The silver recoveries are also
high-only 1% below the level attained for gold. Along
with associated high silver electrowinning recoveries.
4.2. Western Australia
Results from a recent trial at a mine site located in the
Yilgarn region of Western Australia using an ILRlOO
Batch-Manual to treat gold room wheel tailings from
Knelson gravity concentrates are detailed below and in
Table 4. This sulphide gravity concentrate containing
high levels of pyrrhotite was known to be extremely
oxygen consuming and difficult to leach. The addition of
either hydrogen peroxide or ProleachTM was found to
provide leaching conditions that enabled excellent re-
sults to be obtained.
With the addition of either hydrogen peroxide or
ProleachTM leaching kinetics were such that final re-
coveries were achieved after 20-22 h of leaching,
achieving 98.2% using hydrogen peroxide addition and
98.5% using ProleachTM. Overall gravity concentrate
recoveries increased from an average 63% using a gold
wheel and ranging from 28% to 85% alone to an average
98.4% ranging between 97.2% and 99.3% using the ILR
and gold wheel. Similar recoveries are expected for full
gravity concentrate leaching in the ILR, a single leach
was conducted using the full gravity concentrate with
97% recovery achieved after 19 h of leaching and 94.3%
final recovery after 49 h of leaching using hydrogen
peroxide.
This shows that the use of the ILR increased the
recovery of gold from the gravity concentrate from
a volatile average of 63.1% to a more consistent aver-
age of 98.4% overall recovery. An additional advan-
tage for the site was the possibility to increase the
number of Knelson dump cycles and therefore fur-
ther increase the overall gravity gold recovery, which
was previously limited by the time required to treat
the Knelson concentrate being produced using the
wheel.
Table 4
Western Australian minesite trial data
Feed Reagent ILR feed mass Initial Au grade Residual Au ILR Au Wheel Au Total Au
(kg) (&) grade (glt) recovery recovery recovery
Wheel tails Peroxide 680 1203 2 1 98.2% 62.5% 99.3%
Wheel tails
Wheel tails
Wheel tails
Wheel tails
Wheel tails
Full conc.
Wheel tails
Wheel tails
Wheel tails
Wheel tails
Peroxide
Peroxide
Peroxide
Peroxide
Peroxide
Peroxide
Proleach
Proleach
Proleach
Proleach
418 R J. Longley et al. I Minerals Engineering 16 (2003) 411419
+Zimbabwe pemxide
0 4 8 12 16 20 24
Time (hours)
Fig. 9. Leach results for Zimbabwe ILR1000BM.
4.3. Zimbabwe
Site results from a gold mine in Zimbabwe in Fig. 9
show the leaching performance of a Batch Inline Leach
Reactor. The mine operates Knelson concentrators
producing approximately 1000 kg's of concentrate per
day. The concentrate is treated in an ILRlOOO Batch-
Manual (ILR1000BM) operating on a 24 h cycle. The
clarified solution is transferred to the gold room for
electrowinning.
The ILRIOOOBM utilises hydrogen peroxide, which is
dosed into the leach solution. Hydrogen peroxide is used
since the site is very remote and does not have a ready
source of plant oxygen. Cyanide levels of up to 4% in
conjunction with DO levels of approximately 20 ppm
results in high leach recoveries with in 8 h, Mooney,
2002. The mineralogy on the site requires a pH of less
than 12.4 to be maintained during the leach. At pH
levels greater the 12.4 the gold dissolution rate falls al-
most to zero-believed to be due to the presence of
antimony. The gold leach recoveries attained are high-
Fig. 10. ILRIOOOBM for Zimbabwe.
over 99%. From concentrate feed grades of 4000 glt tails
residues of less than 40 g/t result.
The ILRIOOOBM was assembled and fully commis-
sioned at Gekko Systems premises in Ballarat prior to
shipment (refer Fig. 10). The unit was broken down into
standard shipping containers for shipment to Zimba-
bwe. Commissioning on site was completed within two
weeks with one experienced metallurgist from Gekko
Systems working with the plant personnel.
5. Conclusions
The Batch Inline Leach Reactor enables gold opera-
tions to significantly increase the amount of gold re-
covered from gravity. Product from InLine Spinner,
Falcon and Knelson Concentrators can now be effec-
tively and efficiently treated. It brings substantial ad-
vantages by increasing recovery, improving security,
reducing labour requirements, reducing capital costs
and improving safety.
Routine recoveries of above 98% are obtained using
proven chemistry without the requirement for exotic
chemicals-using reagents that site operations are al-
ready confident and experienced in their use.
The use of BCC's in conjunction with a Batch Inline
Leach Reactor allows for greater flexibility in the leach
and CIPICIL circuit, minimising the effects of grade
fluctuations and throughput variations.
The Batch Inline Leach Reactor is a proven, reliable
and simple addition to gravity gold circuits generating
high gold recoveries.
Advantages of the InLine Leach Reactor
Increased gravity gold recoveries.
Improved security by eliminating manual concentrate
handling.
R.J. Longley et al. 1 Minerals Engineering 16 (2003) 411419 419
0 Eliminates smelting of metal sulphide concentrates
and resultant toxic fumes.
0 High shear agitation gives thorough mixing and in-
creases reagent utilisation.
0 Treats entire concentrate without removing gold
bearing fines prior to leaching.
Flexible, up-gradable capacity (batch to continuous;
expandable drum).
Fully integrated automation system with alarm, diag-
nostic and DCS capability.
Low installed power and low power consumption.
Space efficient design.
Captures and leaches fine and coarse gold.
Engineered to prevent gold precipitation on steel
scats.
Simple system with low component count; one drum;
one pump; one sump; two tanks.
Low operating costs with no requirement for expen-
sive chemical leach agents.
Low installed power of less than 10 kW.
Dedicated clarification step reliably produces clear
electrowinning solutions.
Pregnant solution is highly suitable for recovery by
electrowinning.
References
Gray, P.D., 2002. Personal communication.
Gray, A.H., Katsikaros, N., 1999. The InLine Leach Reactor-The
new art in intensive cyanidation of high grade centrifugal gold
concentrates. In: Proceedings of the Rand01 Gold and Silver
Forum, Denver.
Grigg, N.J., 2002. Personal Communication.
Lenahan, W.C., Murray-Smith, R.; de, L., 1986. Assay and analytical
practice in the South African mining industry, SAIMM. Chamber
of Mines of South Africa, Johannesburg.
Longley, R.J., Katsikaros, N., Hillman, C., 2002. New age gold plant
flowsheet for the treatment of high grade ores. In: AusIMM-
Metallurgical Plant Design and Operating Strategies Conference,
Sydney.
McQuiston Jr., F.W., 1985. In: Weiss, N.L. (Ed.), SME Mineral
Processing Handbook, vol. 2 (Chapter 18-4).
Mooney, N.M., 2002. Personal communication.
Wills, B.A., 1979. Mineral Processing Technology-An Introduction
to the Practical Aspects of Ore Treatment and Mineral Recovery,
first ed. Pergamon Press, Oxford.