A Review of Gold Particle Size and Recovery Methods WC-97-014 PDF
A Review of Gold Particle Size and Recovery Methods WC-97-014 PDF
A Review of Gold Particle Size and Recovery Methods WC-97-014 PDF
A REVIEW OF GOLD-PARTICLE-SIZE
AND RECOVERY METHODS
ODA Classi$cation
Subsector: Geoscience
Theme: G2, Identify and ameliorate minerals-related and other geochemical toxic hazards
Project Title: Mitigation of mining-related mercury pollution hazards
Reference number: R6226
Bibliographic reference:
C J Mitchell, E J Evans & M T Styles,
A review of gold particle-size and recovery methods
BGS Technical Report WC/97/14
Keywords:
Gold, mineral processing, Malaysia, Zimbabwe, New Zealand, Papua New Guinea, Canada
Front cover illustration:
Processing of gold ore using a sluice box, Malaysia
0NERC 1997
1. INTRODUCTION
2. PARTICLE-SIZE OF GOLD
Others suggest that 75 pm or 100 pm (Stewart & Ramsay, 1993) should be the top
size of fine-grained gold. This report will use 100 pm.
The particle-size distributions quoted for gold do not reflect the particle-size
distribution of the ore. For example 50% of the gold by weight may exist in a size
fraction that only represents 10%of the ore by weight. Also the variation in the
weight distribution of gold with particle-size depends upon the nature of the ore ( and
for alluvial gold the source area). Some alluvial gold deposits may contain a
significant amount of fine grained gold whereas others will contain virtually none.
Generally the particle-size of alluvial gold falls into the range 5 mm to 100 pm.
Several examples are given in the following Tables. The information given in Tables
1 to 6 is from a BGS study of alluvial gold. The samples were sieved in the field at 2
mm and hence will not contain gold grains larger than that, although it is unlikely that
they are present. Grain size was measured by image analysis of grains hand picked
for subsequent polishing and microanalysis. The minimum size is governed by that
which could be manipulated and was considered large enough for polishing. Many
samples actually contained a small proportion of finer grains that were not measured.
Samples purchased from artisanal alluvial miners and are shown with *. They often
contained less fine gold than the samples collected by BGS staff and counterparts.
This is due to both poor technique and, in some cases, poor equipment; African
miners were seen using broken washing-up bowls and old ice cream tubs as pans.
This explains the variation in data obtained for samples collected by different people
in different ways and makes establishing the true natural variation very difficult.
As can be seem from most of the tables little information is available for gold finer
than 100 pm. In part this may be due to the inefficiency of fine gold recovery in the
studies referred to.
Lubuk Mandi
MA13* 560- 1477 939
MA14 136 - 879 442
MA 16* 136- 1599 904
MA17* 476 - 3624 1332
Mazoe
zM5 212- 1603 464
ZM89 30 - 550 249
ZM90 121 -451 222
Chegutu-Chakari" 171 - 2486 1264
Kadoma * 217 - 2067 958
Kwekwe
ZM28* 196- 1961 865
ZM29* 365 - 2237 1047
zM35 217 - 476 242
ZM73* 234 - 2428 1070
Silobela
m33* 165 - 1944 313
m34* 256- 1025 450
Zvishavane * 210- 1239 585
Table 5. Penjom area, near Kuala Lipis, Pahang, Malaysia (Henney et al, 1995)
~~~ ~~
Table 7. Mount Kare, SW of Porgera, Papua New Guinea (Bartram et al, 1991)
+5 mm 0.4
-5 mm +800 pm 29.6
-800 +250 pm 66.2
-250 +75 pm 3.6
-75 pm 0.2
Other placer deposits in Papua New Guinea have up to 50% fine gold 4 0 0 pm
(Subasinghe, 1991).
~ ~~~
+2.36 mm 10
-2.36 + 1.4 ~ll~ll 20
- 1.4 mm +600 pm 30
-600 +300 pm 30
-300 + 150 pm 10
-150 pm Not quoted
In New Zealand placer deposits contain gold up to 95% <2 mm, 50 - 70% <lmm,
mostly >200 pm (Braithwaite & Jury, 1993).
The particle-size distribution of bed-rock gold varies considerably with the type of
gold deposit and is too diverse to generalise. Much of the information gathered here
represents gold associated either with sulphide mineralisation or altered volcanic
rockdmetasediments. Gold occurs in a wide range of particle sizes from ultrafine
inclusions in pyrite (down to <1 pm, often called 'invisible gold') to native, or free,
gold particles up to 1 mm in diameter and coarser. Several examples are given :
Table lO* Average from gold-rich quartz veins. Archean Basement, Dondo Mobi,
Gabon (Leconte & Colin, 1989)
~~ ~
+500 pm 14
-500 +250 pm 5
-250 +125 pm 11
-125 +63 pm 6
-63 pm 64
2.2.1. Explosion breccia, Wau Valley, Papua New Guinea (Eltham, 1984). The gold
occurs generally <100 pm, occasionally recrystallised as coarse grains (>100 pm).
2.2.2. Altered metasediments, Wafi River, Papua New Guinea (Erceg et al, 1991).
The gold occurs as grains <3 pm in diameter associated with pyrite.
2.2.3. Mineralised turbidites, Peak Gold Mine, New South Wales, Australia (Davies,
1992). The gold ranges in size from 2 to 300 pm.
2.2.4. Mineralised volcanic rocks, Ladolam gold deposit, Lihir Island, Papua New
Guinea (Moyle et al, 1991). The gold occurs as inclusions <5 pm within pyrite, as
free gold up to 100 pm in oxidised ore and up to 500 pm in quartz veins.
2.2.5. Granulite, Renco Reefs gold mine, Zimbabwe (Leroy, 1995). The gold is fine
grained (65% e15 pm) and 28% occurs as free gold associated with native bismuth.
2.2.6. Gold in glacial till overlying Archean greenstone, Ontario, Canada (Shelp &
Nichol, 1987) is up to 90% 4 0 0 pm, mostly e125 pm.
2.2.7. Gold in streams draining gneiss & plateau basalts, Harris Creek, British
Columbia, Canada (Day & Fletcher, 1989) is mainly cl00 pm.
The following table gives a summary of the overall range and average of the available
particle-size data for alluvial and bedrock gold (the figures in brackets represent the
particle-size which most of the data falls into).
This section will briefly outline the various mineral processing methods commonly
used to recover gold, giving an indication of the size-range of material processed and
typical gold recovery figures. Panning is not considered as no 'hard data' was found.
The methods considered mainly involve the physical separation of gold from 'gangue'
(which ranges from vein material in bed-rock deposits to sand and silt grade material
in alluvial deposits) using gravity-based processing methods. Gold has a high specific
gravity (19.3 g/cm3) in relation to most common gangue minerals (ranging from 2.65
to 3 g/cm3) and is therefore eminently suitable for gravity processing. Considering the
minute quantity of gold normally present in even the most auriferous ores (down to
Table 12. Particle-size range and typical ef'ficiencies of gravity and chemical
gold recovery methods
Spirals 3000 to 75 pm 65 to 80 %
N.B. Recovery data are specific to particle-size, ore nature and processing operation.
Certain gold grain characteristics influence the efficiency of gold recovery methods,
particularly gravity separation. The influence of density upon the behaviour of a gold
grain will lessen as the surface area to mass ratio increases. Gold is usually non-
spherical, and it is typically flakier with decreasing grain size. This is mainly due to
the malleability of gold, distorting rather than fracturing in response to loading and
impact (during crushing and grinding of the ore, and alluvial transport). This irregular
shape leads to porosity; cavities and pores are often infilled with lower density
material lowering the density of the composite particle. The flaky shape, porosity and
hydrophobic surface properties often cause gold to float. This is especially a problem
for fine grained gold. Gold grain surfaces are often coated with an hydrophobic
organic layer or iron oxide coatings and some are leached free of impurities (such as
silver) leaving a rim of pure gold, all of these render the surface hydrophobic (Wang
& Poling, 1983).
The mineralogical character of the gold is often not considered when planning a
processing plant, especially if the gold responds well to standard gravity and
cyanidation processes. However, if the gold recovery is poor (430%) the ore is
termed refractory and a detailed mineralogical investigation becomes necessary.
This will involve the determination of the mode of occurrence of minute gold grains
and the proportion of invisible gold. Gold usually occurs as native gold. A solid
solution exists with many heavy metals including electrum (Au, Ag), argentian gold
(Au, Ag), cuprian gold (Au, Cu), palladian gold (Au, Pd), mercurian gold (amalgam)
(Au, Hg) and Au-Ag-Hg alloy. Other gold-bearing minerals occur only in very small
amounts including gold tellurides, gold selenides, gold sulphides and intermetallic
compounds such as amalgam (Au, Hg), aurostilbite (Au, Sb) and maldonite (Au, Si)
(Petruk, 1989).
The sluice box is by far and away the most commonly used means of concentrating
gold from alluvial gravels. They are generally cheap to make, easy to operate and
require minimal technical knowledge to maintain (Hancock, 1991). Essentially a
sluice box consists of a sloping open rectangular flume with regularly spaced
transverse bars, or riffles,through which a dilute slurry of water and alluvial gravel
flows. Heavy minerals, including gold are usually captured in the upstream side of the
riffles (or the downstream side depending upon the design of sluice box). These are
regularly removed by raking or cleaning-out the sluice box riffles.
Sluice boxes are effective for the recovery of gold with particle-size from 25 mm to
100 pm. The efficiency of gold recovery varies from 80 to 100% in well operated
sluices run by modern commercial companies to less than 50% in makeshift sluices
run by small-scale miners. A typical small-scale operation would involve 2 to 3
people, with 1 digging and feeding the sluice, the second picking out stones and the
third monitoring the wash water (Hancock, 1991). In New Zealand gold recoveries
are up to 80%, the remainder is mainly finer than 250 pm and is physically
recoverable by gravity separation (Fricker, 1986). In Yukon recoveries up to 98% are
i) The design of the sluice box, including the slope, width and length, and
the type of riffles incorporated.
In Papua New Guinea sluice boxes consist of a wooden launder tilted 5 to 15" with
transverse wooden slats (Subasinghe, 1991). In Yukon expanded metal riffles are
incorporated into sluices operating at a relatively shallow slopes (7- 12") with feed
rates of 20 m3/hr and water flows of 40 l/s/m are used for recovering gold finer than 1
mm. Angle iron riffles used in sluices with steeper slopes (12-14"), faster feed rates,
40 m3/hr and faster water flows, 80 l/s/m are used for recovering gold coarser than 1
mm. Flat bar riffles ('nugget trap') may be suitable for recovering gold coarser than 6
mm (Clarkson, 1994).
A porous matting is often used to line the floor between riffles, particularly in the
lower part of the sluice box, in order to enhance the recovery of gold during
operation. Oscillation of the sluice box during operation may improve gold recovery
from alluvial gravel with a high proportion of heavy minerals or clay. However
oscillation leads to reduced gold recovery from other alluvial gravels (Clarkson,
1994).
The recovery of gold increases with sluice length and particle-size as indicated here
(Fricker, 1986):
Table 13. Gold recovery with increasing sluice length and particle-size
0.5 m 4 34 50
1.0 m 5 50 68
1.5 m 6 58 78
2.0 m 7 59 80
ii) The particle-size range of the gold and the accompanying sediments.
The recovery of gold present in sand grade as compared to gravel grade material has
been determined as follows (Fricker, 1986):
Fine gold (e100 pm) is a problem for sluices and up to 60% of the total gold content
reports to the tailings (i.e. is not recovered). Gold recovery efficiencies of up to 50%
are achievable for material finer than 200 pm (Wang & Poling, 1983) and up to 40 to
50% for material finer than 100 pm (Subasinghe, 1991; Stewart & Ramsay, 1993).
The 'slimes' content (this can mean material less than 10 pm in size to less than 75
pm in size) of the feed can adversely affect gold recovery. Scrubbing and screening
prior to sluicing can improve gold recovery (by up to 20%) by freeing gold trapped in
clay-bound and weakly cemented material (Clarkson, 1994). If no coarse-grained
gold is present the sluice can be operated using conditions appropriate for the
recovery of fine-grained gold. However if coarse-grained gold does exist the ore can
be split into coarse and fine grained material. Gold can then be recovered from the
coarse-grained material by using a second sluice operated using conditions
appropriate for coarse-grained gold recovery. The treatment of coarse and fine
material separately will increase overall gold recovery.
Sluices are often operated in an attempt to recover coarse- (nugget) and fine-grained
gold in a single pass (Subasinghe, 1991). However these require distinctly different
hydrodynamic conditions. Coarse gold is best separated using high feed rates, with
steep sluice tilt and high riffles - the coarse gold drops out and finer gold remains
entrained in the flow of material down the sluice. Fine gold recovery requires lower
feed rates, shallower tilts and smaller riffles. Attempting to recover both coarse- and
fine-grained gold at the same time will result in poor overall recoveries. A slower rate
will improve recovery of fine gold but decrease the removal of gangue and reduce
overall throughput. The effect of varying sluice feed and wash water is similar to that
of varying sluice tilt. In many cases sluices are operated with water diverted from
local streams and it is more practical to vary sluice tilt than the wash water rate. The
steeper the tilt the faster the wash rate.
A pinched sluice is similar to a riffled sluice box, minus the riffles, that tapers to the
downstream end (Figure 1). During operation the minerals present in the feed slurry
segregate with heavy minerals adjacent the floor of the sluice and progressively
lighter minerals occurring at the top of the flow. The heavy mineral concentrate is
separated by the use of an inclined plate over which the slurry flows from the end of
the sluice.
Pinched sluices and Reichert cones are effective in the processing of material in the
size range 3 mm to 30 pm. Typically used as a primary rougher (preconcentration of
gold prior to gold recovery) or scavenger (reprocessing of waste to improve overall
gold recovery) where high capacity, low operating cost is required. For example gold
recoveries of 50 to 60% are achieved with Reichert cones at New Celebration gold
Mine in Western Australia (Martins et al, 1993). Used (to remove coarse gold) ahead
of expensive stages such as froth flotation or chemical leaching, which work better on
fine gold, they can save costs. The recovery of coarse gold requires ore to be ground
to a size suitable for flotation or leach times to be extended. Up to 60% gold can be
recovered by Reichert cones this way (Feree, 1993).
3.2. Jigs
Jigs are effective in the processing of material in the size range 25 mm to 75 pm.
Material is best pre-screened and processed as separate coarse and fine fractions.
Typically for gold below 100 pm recovery falls to less than 50%. In a combined
sluicing-jigging operation gold recovery may be as high as 89 to 95% (Wang &
Poling, 1983). In an Alaskan operation conversion of a sluice plant to a jig plant
increased gold recovery by 37% (Fricker, 1986) and in a New Zealand operation a
similar conversion increased gold recovery by 14% (Braithewaite & Jury, 1993). A
Kelsey centrifugal jig has been used to concentrate fine gold-bearing sulphides from a
process tailings stream with recoveries of >70% (Brewis, 1995). The following table
compares gold recovery between a jig and a sluice at different grain sizes (Fricker,
1986):
The commonest form of shaking table used is the wet table (the 'dry' form is known
as an air table, which uses air as the fluid separating medium). It consists of a flat
table (or 'deck') with parallel riffles to trap the heavy minerals (Figure 3). The 'deck' is
vibrated longitudinally and inclined laterally during operation. A perforated pipe
feeds wash water from the upslope side. The slurried feed is introduced at the top
upslope corner. The minerals in the feed segregate. The heavy minerals sink to the
deck, migrate along the riffles and are discharged over the end of the deck. The light
minerals, entrained in the water, pass straight over the riffles and down to the bottom
and so to the tailings.
Shaking tables are effective in the processing of xAerial in the size range 3 mm to 15
pm. Shaking tables have been used to recover 88% of the gold present in a
concentrate produced on a spiral (Eltham, 1984). Wang & Poling (1983) record that
up to 90% of gold coarser than 40 pm can be recovered, whereas typically only 20%
of 20 - 40 pm gold can be recovered. The efficiency drops greatly below 40 pm. The
following table gives the size distribution of gold present in a shaking table middling
product from a commercial mine in Malaysia i.e. material that had passed over the
table and was stockpiled for possible later reprocessing. Estimated assay of around 10
ghonne is higher than the mined ore. There is considerable scope for increased yield
with more effective processing.
+250 pm 35.3
-250 +120 pm 42.11
-120 +63 pm 21.81
-63 pm 0.75
3.4. Spirals
The spiral concentrator is described as a 'low feed rate, low feed density' flowing film
gravity separator. It consists of a helical conduit of modified semi-circular cross-
section, usually with between 3 and 5 complete 'turns' (Wills, 1992) (Figure 4).
Material is fed onto the top of the spiral as a slurry with typically 25 to 30% solids by
weight. As the material flows spirally downwards the particles stratify due to factors
such as centrifugal force, differential settling, hindered settling and reverse
classification. There is usually a density gradation across the profile of the spiral with
heavy minerals concentrating next to the axis and minerals of lower density being
swept to the outer edge. Concentrate, middling and tailing products are collected with
the use of adjustable splitter plates.
Rotating cones find application in arid and semi-arid countries where water is at a
premium. These concentrators use the least amount of water of any wet gravity
separator and produce a high-grade concentrate in a single pass. They consist of a
squat cone (included angles of 105" to 115") which is tilted and rotated. A high-
density pulp is introduced at the top edge of the cone and wash water at the bottom
leading edge. As the cone rotates the heavy minerals migrate to the centre of the cone
and are drawn off. The light minerals ovefflow the lower edge of the cone as a
tailings.
Rotating cones are effective in the processing of material in the size range 3 mm to 30
pm. The concentrate grade is determined by : the slope of the cone; the grade of the
ore; and, the residence time of the material in the cone during operation.
Commonly used makes are the Knudsen and the Knelson bowl concentrators. A bowl
concentrator consists of a rotating cylinder that segregates heavy minerals from light
minerals by a combination of centrifugal force and wash water action. The Knelson
bowl concentrator is claimed to recover "gold particles ranging from 6 mm to less
than one micron in a single pass" (sales brochure). Recovery is effective down to
approximately 30 pm.
The Mozley Multi-gravity separator (MGS) consists of a tilted drum that tapers
slightly to the downslope end (Figure 5). The drum simultaneously rotates and is
shaken longitudinally. Sample slurry is added to the upslope end and as it migrates
down the drum it segregates into heavy and light minerals. The heavy minerals report
to the inside wall of the drum, where they are pushed to the upslope end by scrapers.
The light minerals remain entrained in the wash water and report to the downslope
end. The MGS has been likened to a shaking table wrapped round itself into a drum.
The MGS can be used to process material in the size range 1 mm down to 1 pm. An
MGS has been used to recover 76% of the gold present in a zinc flotation concentrate
(Mozley sales literature).
Froth flotation has the potential to be used for the recovery of fine gold. Desliming is
usually required to remove material finer than 10 to 20 pm. Recoveries between 78%
and 93% have been achieved (Wang & Poling, 1983). Flotation trials using amy1
xanthate on different size fractions have reported gold recoveries of up to 90% (160
pm), 85 % (250 pm) and 70% (360 pm) (Lins & Adamian, 1993). Froth flotation
trials have been carried out on material from old tailings ponds in Canada. The
following collector combinaticx were tested: I) Aerofloat 208 (Sodium diethyl and
sodium di-secondary butyl dithiophosphate), and ii) Aero 30 1 Xanthate (Sodium
secondary butyl xanthate). A recovery of approximately 92% was achieved with
material sized to 60 - 70% e75 pm. Sieve analysis indicated that 95% of the gold in
the concentrate was e75 pm in particle-size (Cristovici, 1986). Froth flotation is
effective in the processing of material in the size range 850 pm to 100 pm.
are recovered. A recovery of up to 98% is quoted for one operation in Papua New
Guinea (Eltham, 1984).
i) The Merill-Crowe process, is used to remove the gold from the cyanide by
cementation with powdered zinc.
- Carbon-in-pulp (CIP) from leach pulps typically slimes, ground ores and calcines.
An alternative to CIP is RIP (Resin-in-pulp) which is easier to use and less sensitive
to the influence of naturally occurring carbon.,
Typical gold recovery efficiencies for cyanidation range from 95 to 99% (Marsden &
Fuerstenau, 1993). Gold recovery is reported to be 80% from refractory gold ore
residues from France (ground to 80% finer than 31 pm) ( Lucion & Cuyper, 1993).
Gold recovery is reported to be approximately 82.5% from the processing of uranium
mill tailings at Cluff Lake, Saskatchewan. It was found that gold loss to tailings was
associated with natural carbon present in the uranium tailings (Melis & Rowson,
1989). Cyanidation trials were carried out on material from old tailing ponds. A
recovery of 90.5% was achieved using material 60% <75 pm (Cristovici, 1986).
Cyanidation is more effective for finer grained gold as it relies on dissolution and is
particularly effective for the recovery of gold finer than 200 pm. Free coarse gold is
often recovered prior to cyanidation to avoid the cost of grinding and the extra
reagents required.
Table 16 gives relative ranking to gold recovery methods in terms of their financial
cost (capital and operating) and also their impact on the environment.
Table 16. Relative cost & environmental impact of gold recovery methods
Sluice box 1 1
Jig 3 1
Shaking table 2 1
Spiral 3 1
Rotating cone 2 1
Bowl 4 1
Drum 4 1
Magnetic separation 4 1
Electrostatic separation 4 1
Hydrocycloning 2 1
Froth flotation 3-4 4
Amalgamation (mercury) 2 4
Cyanidation 3-4 4
~~
The review of separation techniques shows that several methods are effective for the
recovery of gold coarser than approximately 100 pm but for gold finer than
approximately 50 pm only chemical methods are very efficient. The efficient
recovery of gold coarser than 50 pm should be possible using simple gravity methods
and some recommendations for possible implementation are given below. If there is
evidence that there is significant gold finer than 50 pm a cyanide treatment of the fine
tailings is necessary for recovery.
Optimise clean-out
The time interval between clean-out of sluice box riffles is dependent upon the
nature of the material processed and the operating conditions applied. It is
recommended that the time interval should be short enough to enhance the
recovery of fine gold (that would otherwise be lost due to solids packed
around the riffles). However this should be tempered by the requirement to
maintain a relatively high throughput, which if reduced by too much cleaning
will ultimately reduce gold production.
Appropriate configuration
It is recommended that the tilt of the sluice box should increase with
increasing particle-size. Typically (in the Yukon, Canada) for material finer
than 1 mm 7 to 12" is used and coarser than 1 mm 12 to 14".
5. CONCLUSIONS
5.1. Alluvial gold has a particle-size range typically between 5 mm and 100 pm
(however there is little information about the amount of gold finer than 100 pm).
Hard rock gold has a wide range of particle-size depending upon the nature of the ore,
and in some cases down to less than 5 pm.
5.3. The efficiency of gold recovery depends upon the processing method and the
proficiency of operation. A well operated modern sluice box can potentially recover
up to 98% of gold coarser than 100 pm. However gold finer than 100 pm will be lost
unless a fine processing method (e.g. shaking table or bowl concentrator) is used to
reprocess the fine tailings.
5.4. If small-scale operators can be made to work at efficiencies close to that achieved
by large companies, and in the laboratory, this will be as good as, and often superior,
to mercury amalgamation.
5.5. Recommendations for the recovery of fine gold include improving current
operating practice, modifying the process used, and introducing more efficient
alternatives.
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Institute of Mining and Metallurgy, p.264-270.
Walsh, DE & Rao, PD (1988) Study of the compound water cyclone's concentrating
efficiency of free gold from placer material. CIM Bulletin, 81, No. 919, p. 53-
61.
Wang, W and Poling, GW (1983) Methods for recovering fine placer gold. CIM
Bulletin, 76, No. 860, p.47-56.
Plon
Toi linqs
over f tow -- -
00000
Hutch
/
1I Concentrate
1 discharge spigot
-rtl-
I -
\
I
I
Figure 5. Schematic outline diagram of an MGS (Multi-gravity
separator)
i Trammel screening
at 500 p m
SI uice box
to recover coarse
gold (>500
-c\.
n
Coarse tailings
(>500 pm)
\
to recover fine gold (e500 pm)
(c500 pm)
I 1
Screen
4 0 0 pm tailings
on 200 pm
Fine concentrate
(containing gold 4
-
200 - 40 pm)
Shaking table
to recover fine gold from
fine-grained sluice tailings
Fine tailings
(4200 pm; gold <40 pm
if present)