SP327: BISHA GOLD PLANT

PLANT OPERATING MANUAL

DRAFT REV 1 – 01/04/2010

Document Type: Plant Operating Manual

Project no: SP327 BISHA
Client: BISHA MINING SHARE COMPANY
Revision Date Comment Reviser Client
1 01/04/2010 Draft issued for client comments K.Mutyavaviri

Bisha Plant Operating Manual i

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Table of Contents
1. SAFETY .................................................................................................................................... 1-1
1.1 GENERAL SAFETY INSTRUCTIONS .............................................................................................................. 1-1
1.2 UNDERSTANDING SAFETY INSTRUCTIONS................................................................................................. 1-2
1.2.1 Housekeeping:................................................................................................................................... 1-2
1.2.2 Personal Protective Equipment: ........................................................................................................ 1-2
1.3 CONDITION OF HAND TOOLS: ................................................................................................................... 1-4
1.4 SCAFFOLDING: ........................................................................................................................................... 1-6
1.5 WELDING OR FLAME CUTTING .................................................................................................................. 1-6
1.6 LIFTING EQUIPMENT.................................................................................................................................. 1-6
1.7 HAZARDOUS SUBSTANCES: ....................................................................................................................... 1-7
1.8 ERGONOMICS ............................................................................................................................................ 1-7
1.9 FIRE PREVENTION AND PROTECTION ........................................................................................................ 1-7
1.10 SYMBOLIC SAFETY SIGNS ........................................................................................................................... 1-7
1.11 TRAFFIC OFFENCES .................................................................................................................................. 1-10
1.12 ENVIRONMENTAL MANAGEMENT .......................................................................................................... 1-10
1.13 SAFETY CHECKLIST ................................................................................................................................... 1-10
1.14 MAINTENANCE SAFETY PRECAUTIONS .................................................................................................... 1-10
1.15 MATERIAL SAFETY DATA SHEETS (MSDS) ................................................................................................ 1-11
2. SCADA SYSTEM ..................................................................................................................... 2-12
2.1 SCADA SCREENS ....................................................................................................................................... 2-12
2.2 LOGON SCREEN........................................................................................................................................ 2-12
2.3 ACCESS LEVELS SCREEN ........................................................................................................................... 2-12
2.3.1 Systems Screen ................................................................................................................................ 2-13
2.3.2 Task Bar Screen ............................................................................................................................... 2-13
2.3.3 Overview Screen .............................................................................................................................. 2-13
2.3.4 Historical Trend Screen ................................................................................................................... 2-13
2.3.5 Real time Trend Screen ................................................................................................................... 2-13
2.3.6 Report Screen .................................................................................................................................. 2-13
2.3.7 Alarm Screen ................................................................................................................................... 2-13
2.3.8 Start-up and Shut-down Sequences: ............................................................................................... 2-14
2.3.9 Status of drives on the SCADA:........................................................................................................ 2-14
2.3.10 Status of valves on the SCADA: ....................................................................................................... 2-14
2.4 TAG NAME DEFINITIONS ON THE SCADA: ............................................................................................... 2-14
2.4.1 Motor Tag Names ........................................................................................................................... 2-14
2.4.2 Valve Tag names ............................................................................................................................. 2-15
2.4.3 Instrument and Alarm Tag names .................................................................................................. 2-15
2.5 MOTOR CONTROLLER FACEPLATES: ........................................................................................................ 2-16
2.5.1 Field Control .................................................................................................................................... 2-17
2.5.2 SCADA Control ................................................................................................................................. 2-17
2.5.3 Sequence Control ............................................................................................................................ 2-17
2.5.4 Duty / Standby Control.................................................................................................................... 2-17
2.6 VALVE CONTROL FACEPLATES: ................................................................................................................ 2-18

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 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3. DESIGN CRITERIA................................................................................................................... 3-21

3.1 INTRODUCTION ....................................................................................................................................... 3-21
3.1.1 Site Data.......................................................................................................................................... 3-22
3.1.2 Ore Characteristics .......................................................................................................................... 3-22
3.1.3 Operating Schedule ......................................................................................................................... 3-23
3.1.4 Grinding .......................................................................................................................................... 3-23
3.1.5 Production ....................................................................................................................................... 3-24
3.1.6 Crushing & Stockpile Plant .............................................................................................................. 3-24
3.1.7 Grinding .......................................................................................................................................... 3-26
3.1.8 Classification ................................................................................................................................... 3-28
3.1.9 Preleach Thickening ........................................................................................................................ 3-29
3.1.10 Leach & CIL ...................................................................................................................................... 3-30
3.1.11 Detoxification .................................................................................................................................. 3-33
3.1.12 Acid Wash ....................................................................................................................................... 3-35
3.1.13 Elution ............................................................................................................................................. 3-36
3.1.14 Electrowinning ................................................................................................................................ 3-40
3.1.15 Regeneration................................................................................................................................... 3-43
3.1.16 Goldroom ........................................................................................................................................ 3-44
3.1.17 Lime Silo & Slaking System.............................................................................................................. 3-44
3.1.18 Cyanide ........................................................................................................................................... 3-46
3.1.19 Caustic Soda .................................................................................................................................... 3-47
3.1.20 Hydrochloric Acid ............................................................................................................................ 3-48
3.1.21 Activated Carbon ............................................................................................................................ 3-48
3.1.22 Flocculant Plant .............................................................................................................................. 3-48
3.1.23 Detoxification Reagents .................................................................................................................. 3-49
3.1.24 Plant Diesel Storage ........................................................................................................................ 3-50
3.1.25 Plant Air Requirements ................................................................................................................... 3-51
3.1.26 Water Balance ................................................................................................................................ 3-52
3.1.27 Water Ponds ................................................................................................................................... 3-55
4. CRUSHING OPERATING MANUAL ........................................................................................... 4-56
4.1 INTRODUCTION ....................................................................................................................................... 4-56
4.1.1 Safety .............................................................................................................................................. 4-56
4.2 PLANT DESIGN CRITERIA .......................................................................................................................... 4-57
4.3 PROCESS DESCRIPTION ............................................................................................................................ 4-58
4.3.1 Control Loops .................................................................................................................................. 4-59
4.3.1.1 Alarms......................................................................................................................................... 4-61
4.3.2 Interlocks:........................................................................................................................................ 4-61
4.3.2.1 Lanyard (Pull) Switches ............................................................................................................... 4-62
4.3.2.2 Underspeed Switches ................................................................................................................. 4-62
4.3.2.3 Drive Faults ................................................................................................................................. 4-62
4.3.2.4 Level Transmitter/Switch ............................................................................................................ 4-62
4.3.3 Interlocks Summary ........................................................................................................................ 4-63
4.4 OPERATING GUIDELINES.......................................................................................................................... 4-64
4.4.1 Pre-start Checks .............................................................................................................................. 4-64
4.4.2 Normal Start-up Procedure ............................................................................................................. 4-65
4.4.2.1 Primary Crushing ........................................................................................................................ 4-65
4.4.3 Normal Shutdown Procedure .......................................................................................................... 4-65
4.4.4 Emergency Shutdown Procedure and Power Failure ...................................................................... 4-66
4.4.5 General Operation .......................................................................................................................... 4-66

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 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

4.4.5.1 ROM Bin Level ............................................................................................................................ 4-66

4.4.5.2 Process Interruption ................................................................................................................... 4-66
4.4.5.3 Adjusting Crusher Gaps .............................................................................................................. 4-66
4.4.5.4 Tramp Metal Removal ................................................................................................................. 4-67
4.4.5.5 Jaw Crusher Blockages ................................................................................................................ 4-67
4.4.5.6 Operator Routine Inspections .................................................................................................... 4-67
4.4.6 Trouble shooting: ............................................................................................................................ 4-68
5. MILLING PLANT ..................................................................................................................... 5-69
5.1 MILLING SAFETY PROCEDURES: ............................................................................................................... 5-69
5.2 GENERAL PPE (PERSONAL PROTECTIVE EQUIPMENT) ............................................................................. 5-69
5.3 THE MAIN ISSUES OF CONCERN ARE HIGHLIGHTED BELOW: .................................................................. 5-69
5.3.1 Cyanide ........................................................................................................................................... 5-69
5.3.2 SAG and Ball Mill ............................................................................................................................. 5-69
5.3.3 Conveyor belts ................................................................................................................................. 5-70
5.3.4 Transfer Points and Discharge Chutes ............................................................................................ 5-72
5.3.5 Pebble Crusher / Scats Storage Bin ................................................................................................. 5-72
5.3.6 Forklifts and Bobcats....................................................................................................................... 5-73
5.3.7 Centrifugal Slurry Pumps ................................................................................................................ 5-73
5.3.8 Sumps and Pumps ........................................................................................................................... 5-74
5.3.9 Automated valves ........................................................................................................................... 5-75
5.3.10 Mill Start Up .................................................................................................................................... 5-75
5.3.11 Normal/ Emergency Shutdown ....................................................................................................... 5-76
5.4 THE COMMINUTION THEORY .................................................................................................................. 5-76
5.4.1 SAG/ Ball Milling: ............................................................................................................................ 5-77
5.5 CLASSIFICATION THEORY ......................................................................................................................... 5-80
5.6 MILLING PROCESS DESCRIPTION ............................................................................................................. 5-81
5.6.1 Introduction .................................................................................................................................... 5-81
5.6.2 Milling Major Equipment ................................................................................................................ 5-81
5.6.3 Process Description ......................................................................................................................... 5-82
5.6.4 Addition of Grinding Media............................................................................................................. 5-84
5.7 MILLING CONTROL PHILOSOPHY ............................................................................................................. 5-84
5.7.1 Control ............................................................................................................................................ 5-84
5.7.2 Control Loops .................................................................................................................................. 5-86
5.7.3 Milling SCADA Display ..................................................................................................................... 5-87
5.7.3.1 General Milling Page ................................................................................................................... 5-87
5.7.3.2 Mill Lubrication Page (Sag and Ball Mills) ................................................................................... 5-88
5.7.3.3 The Mill Motor Page ................................................................................................................... 5-88
5.7.3.4 Alarms......................................................................................................................................... 5-89
5.7.4 Interlocks......................................................................................................................................... 5-89
5.7.4.1 Interlock Summary ..................................................................................................................... 5-89
5.8 OPERATING PROCEDURES IN MILLING .................................................................................................... 5-93
5.8.1 Start-up procedures ........................................................................................................................ 5-93
5.8.1.1 SAG Mill ...................................................................................................................................... 5-94
5.8.2 Field operator duties ....................................................................................................................... 5-95
5.8.3 Planned shutdown procedures........................................................................................................ 5-95
5.8.4 Emergency Shutdown ..................................................................................................................... 5-96
5.9 Operation of Barring Gear ....................................................................................................................... 5-97
5.9.1 Preconditions for starting barring drive .......................................................................................... 5-97

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PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

5.10 Trouble shooting: ..................................................................................................................................... 5-98

6. PRE-LEACH THICKENING ........................................................................................................ 6-99
6.1 INTRODUCTION ....................................................................................................................................... 6-99
6.1.1 General Area Safety Policies and Procedures.................................................................................. 6-99
6.1.1.1 General PPE (Personal Protective Equipment) ........................................................................... 6-99
6.2 PROCESS DESCRIPTION .......................................................................................................................... 6-101
6.2.1 Controls ......................................................................................................................................... 6-107
6.2.1.1 Linear screen ............................................................................................................................ 6-107
6.2.1.2 Thickener .................................................................................................................................. 6-107
6.3 PRELEACH THICKENER SCADA DISPLAY ................................................................................................. 6-109
6.3.1 Alarms ........................................................................................................................................... 6-109
6.3.2 Interlocks....................................................................................................................................... 6-109
6.4 PLANT OPERATING PROCEDURES .......................................................................................................... 6-111
6.4.1 Start up procedures: After extended period. ................................................................................. 6-111
6.4.2 Planned shutdown procedures. ..................................................................................................... 6-112
6.4.3 Emergency procedures. ................................................................................................................. 6-112
6.4.4 Trouble shooting: .......................................................................................................................... 6-113
6.4.4.1 Linear screen ............................................................................................................................ 6-113
6.4.4.2 Thickener: ................................................................................................................................. 6-114
7. CARBON IN LEACH PLANT (CIL) ............................................................................................ 7-116
7.1 SAFETY ................................................................................................................................................... 7-116
7.1.1 General PPE (Personal Protective Equipment) .............................................................................. 7-116
7.2 LEACHING & CIL PRINCIPLES .................................................................................................................. 7-116
7.3 CIL PROCESS DESCRIPTION .................................................................................................................... 7-119
7.4 LEACH CONTROL PHILOSOPHY .............................................................................................................. 7-120
7.4.1 CIL Scada Page .............................................................................................................................. 7-121
7.4.2 CIL Alarms ..................................................................................................................................... 7-122
7.4.3 CIL Interlocks ................................................................................................................................. 7-122
7.4.4 CIL Equipment ............................................................................................................................... 7-122
7.4.4.1 Linear Trash Screen (32-LISC-01) .............................................................................................. 7-122
7.4.4.2 Kemix inter-stage screens (32-INSC-01 TO 32-INSC-08) ........................................................... 7-122
7.5 DETAILED PROCEDURES ......................................................................................................................... 7-123
7.5.1 Feed slurry pH control: .................................................................................................................. 7-123
7.5.2 CIL Feed Slurry Sampling ............................................................................................................... 7-124
7.5.3 Cyanide Concentration .................................................................................................................. 7-124
7.5.3.1 Calculation: ............................................................................................................................... 7-125
7.5.4 CIL tanks carbon concentration: ................................................................................................... 7-125
7.5.5 Slurry Density ................................................................................................................................ 7-125
7.5.6 Oxygen addition & monitoring...................................................................................................... 7-126
7.6 CARBON MANAGEMENT ....................................................................................................................... 7-126
7.6.1 Counter current transfer of the 6.0 t batch: .................................................................................. 7-127
7.6.2 Loaded carbon transfer to Acid Wash Column ............................................................................. 7-127
7.6.3 Inter-stage carbon transfer procedures: ....................................................................................... 7-128
7.6.4 Cleaning Inter-stage screens ......................................................................................................... 7-128
7.6.5 Detection of carbon losses through inter-stage screens ............................................................... 7-130
7.6.6 Carbon fouling............................................................................................................................... 7-130
7.6.7 Trouble shooting: .......................................................................................................................... 7-130

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 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

8. TAILINGS DETOXIFICATION .................................................................................................. 8-132

8.1 SAFETY: .................................................................................................................................................. 8-132
8.2 CYANIDE DETOXIFICATION PRINCIPLES: ................................................................................................ 8-132
8.2.1 Destruction of cyanide using Sodium Metabisulphite ................................................................... 8-133
8.2.1.1 General ..................................................................................................................................... 8-133
8.2.1.2 Chemistry.................................................................................................................................. 8-133
8.3 PROCESS AND PLANT DESCRIPTION: ..................................................................................................... 8-135
8.4 DETOX CONTROL PHILOSOPHY .............................................................................................................. 8-137
8.4.1 Detox SCADA Display .................................................................................................................... 8-138
8.4.2 Alarms ........................................................................................................................................... 8-138
8.4.3 Interlocks....................................................................................................................................... 8-138
8.4.4 Detox Equipment ........................................................................................................................... 8-140
8.4.4.1 Carbon Safety Screen (34-LISC-01) ........................................................................................... 8-140
8.4.4.2 Detox Reactors .......................................................................................................................... 8-140
8.4.4.3 Detox Feed Pumps .................................................................................................................... 8-140
8.4.4.4 Detox Measuring and Control Devices ..................................................................................... 8-140
8.4.5 Detox Start-up procedures ............................................................................................................ 8-141
8.4.6 Normal operating procedures: ...................................................................................................... 8-141
8.4.7 Planned shutdown procedures ...................................................................................................... 8-142
8.4.8 Trouble shooting: .......................................................................................................................... 8-142
8.4.8.1 Carbon safety screen: ............................................................................................................... 8-142
8.5 APPENDICES ........................................................................................................................................... 8-143
9. TAILINGS HANDLING DEWATERING...................................................................................... 9-144
9.1 SAFETY ................................................................................................................................................... 9-144
9.2 THICKENER ............................................................................................................................................. 9-144
9.2.1 Sumps and Pumps ......................................................................................................................... 9-144
9.2.2 Automated valves ......................................................................................................................... 9-145
9.2.3 Standard PPE................................................................................................................................. 9-145
9.3 PROCESS AND PLANT DESCRIPTION: ..................................................................................................... 9-146
9.3.1 Thickening Process ........................................................................................................................ 9-147
9.3.1.1 Principle of Operation .............................................................................................................. 9-147
9.3.2 Specific Issues for Thickeners ........................................................................................................ 9-150
9.3.3 Controls ......................................................................................................................................... 9-151
9.3.3.1 Thickener .................................................................................................................................. 9-151
9.3.3.2 Gland service ............................................................................................................................ 9-153
9.3.3.3 Spillage handling ....................................................................................................................... 9-153
9.4 TAILINGS THICKENER SCADA DISPLAY ................................................................................................... 9-153
9.4.1 Alarms ........................................................................................................................................... 9-153
9.4.2 Interlocks....................................................................................................................................... 9-154
9.5 TAILINGS DAM ....................................................................................................................................... 9-155
9.5.1 Plant operating procedures: ......................................................................................................... 9-155
9.5.1.1 Start up procedures: After extended period. ........................................................................... 9-155
9.5.1.2 Planned shutdown procedures ................................................................................................. 9-157
9.5.1.3 Emergency procedures. ............................................................................................................ 9-157
9.5.2 Trouble shooting: Thickener .......................................................................................................... 9-157
9.6 APPENDICES ........................................................................................................................................... 9-158
10. REGENERATION .............................................................................................................. 10-159

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 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

10.1 PROCESS AND PLANT DESCRIPTION: ................................................................................................... 10-159

10.1.1 Process description ..................................................................................................................... 10-159
10.1.2 Safety .......................................................................................................................................... 10-160
10.1.3 Sodium Cyanide (NaCN): ............................................................................................................. 10-161
10.2 PPE FOR CIL SECTION ........................................................................................................................... 10-163
10.2.1 Standard PPE............................................................................................................................... 10-163
10.2.2 The following PPE must be used in addition to the normal CIL PPE: ........................................... 10-163
10.3 PLANT DESCRIPTION ............................................................................................................................ 10-164
10.3.1 Retort Tube ................................................................................................................................. 10-165
10.3.2 Discharge Hopper........................................................................................................................ 10-166
10.3.3 Kiln Normal Drive ........................................................................................................................ 10-166
10.3.4 Kiln DC Drive ................................................................................................................................ 10-166
10.3.5 Quench pan (44-PAN-01) ............................................................................................................ 10-167
10.3.6 Carbon Sizing Screen (44-SCRN-01)............................................................................................. 10-167
10.4 CONTROLS ........................................................................................................................................... 10-167
10.4.1 Vendor package .......................................................................................................................... 10-168
10.4.2 Interlocks..................................................................................................................................... 10-169
10.4.3 Alarms: ........................................................................................................................................ 10-170
10.5 PLANT OPERATING PROCEDURES: ....................................................................................................... 10-170
10.5.1 Key operating parameters .......................................................................................................... 10-170
10.5.2 Normal operating procedures ..................................................................................................... 10-170
10.5.2.1 Eluted carbon transfer ............................................................................................................ 10-170
10.5.3 Kiln start-up procedures .............................................................................................................. 10-170
10.5.3.1 Pre-checks............................................................................................................................... 10-170
10.5.3.2 Kiln start-up ............................................................................................................................ 10-171
10.5.3.3 Kiln operation ......................................................................................................................... 10-171
10.5.3.4 Kiln planned shutdown procedures (When the eluted carbon hopper is empty) .................. 10-172
10.5.4 Trouble shooting ......................................................................................................................... 10-172
10.6 APPENDICES ......................................................................................................................................... 10-172
11. CARBON FINES DEWATERING ......................................................................................... 11-174
11.1 PROCESS DESCRIPTION ........................................................................................................................ 11-174
11.1.1 Interlocks..................................................................................................................................... 11-174
12. ACID WASH .................................................................................................................... 12-175
12.1 SUMMARY DESCRIPTION ..................................................................................................................... 12-175
12.1.1 Safety procedures ....................................................................................................................... 12-176
12.1.2 Principal hazards ......................................................................................................................... 12-176
12.1.3 Emergency Procedures ................................................................................................................ 12-176
12.2 ACID WASH OPERATING PHILOSOPHY................................................................................................. 12-178
12.3 DETAILED PROCESS AND PLANT DESCRIPTION .................................................................................... 12-178
12.3.1 Water Wash ................................................................................................................................ 12-179
12.3.2 Acid wash .................................................................................................................................... 12-179
12.3.3 Neutralisation and rinsing .......................................................................................................... 12-179
12.3.4 Carbon transfer to elution ........................................................................................................... 12-180
12.3.5 Preparation of fresh acid solution ............................................................................................... 12-180
12.4 ACID WASH PLANT MAJOR EQUIPMENT: ............................................................................................ 12-180
12.5 ACID WASH CONTROL PHILOSOPHY .................................................................................................... 12-181
12.5.1 Acid Wash VDU Page Features ................................................................................................... 12-182

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12.5.2 Alarms ......................................................................................................................................... 12-182

12.5.3 Interlocks..................................................................................................................................... 12-182
12.6 DESCRIPTION OF ACID WASH PROCEDURE ......................................................................................... 12-183
12.6.1 Water Wash (before Acid wash) ................................................................................................. 12-183
12.6.2 Acid Wash Procedure .................................................................................................................. 12-184
12.6.3 Rinse stage .................................................................................................................................. 12-184
12.6.4 Transfer to Elution Column Procedure ........................................................................................ 12-185
12.6.5 Acid Neutralisation ..................................................................................................................... 12-186
12.7 APPENDICES ......................................................................................................................................... 12-186
13. ELUTION ........................................................................................................................ 13-187
13.1 SAFETY ................................................................................................................................................. 13-187
13.2 THE MAIN HAZARDS ARE DISCUSSED BELOW ..................................................................................... 13-187
13.2.1 Sodium Cyanide (NaCN) .............................................................................................................. 13-187
13.2.1.1 Principal hazards..................................................................................................................... 13-187
13.2.1.2 Emergency Procedures ........................................................................................................... 13-188
13.2.2 Caustic Soda (NaOH) ................................................................................................................... 13-188
13.2.2.1 Principal hazards..................................................................................................................... 13-188
13.2.2.2 Emergency Procedures ........................................................................................................... 13-188
13.3 SUMMARY OF ELUTION PRINCIPLES .................................................................................................... 13-190
13.3.1 Elution Process Fundamentals .................................................................................................... 13-191
13.3.2 Elution Plant Major Equipment. .................................................................................................. 13-193
13.4 ELUTION PROCESS DESCRIPTION ......................................................................................................... 13-193
13.4.1 Selective Copper Stripping .......................................................................................................... 13-193
13.4.2 Gold Elution................................................................................................................................. 13-194
13.5 Elution Control Philosophy .................................................................................................................. 13-195
13.5.1 Eluant Tank ................................................................................................................................. 13-195
13.5.2 Elution Column ............................................................................................................................ 13-195
13.5.3 Elution Step ................................................................................................................................. 13-195
13.5.4 Elution Heaters............................................................................................................................ 13-195
13.5.4.1 Elution and Elution Heating VDU Pages .................................................................................. 13-196
13.6 SCADA DISPLAY .................................................................................................................................... 13-196
13.6.1 Description of Elution PROCEDURE ............................................................................................. 13-196
13.6.1.1 Copper Stripping ..................................................................................................................... 13-196
13.6.1.2 Gold Elution ............................................................................................................................ 13-197
13.6.1.3 Alarms..................................................................................................................................... 13-198
13.6.1.4 Elution Interlocks .................................................................................................................... 13-198
13.6.2 Program – Elution ....................................................................................................................... 13-199
13.6.2.1 Copper Stripping ..................................................................................................................... 13-199
13.6.2.2 Gold Elution ............................................................................................................................ 13-201
13.6.3 Eluted Carbon Transfer to Regeneration Kiln Procedure ............................................................ 13-203
13.7 ELUTION Equipment ............................................................................................................................ 13-204
13.7.1 Elution Column (42-COLM-01): ................................................................................................... 13-204
13.7.2 Elution Pumps (42-PUMP-01/02) ............................................................................................... 13-204
13.7.3 Thermic Oil Heaters (42-HETR-01/2) ........................................................................................... 13-205
13.7.3.1 De-scaling Heat Exchangers .................................................................................................... 13-205
13.7.4 Elution Troubleshooting .............................................................................................................. 13-206
13.8 ELUTION TEMPERATURE MEASUREMENT LISTING ............................................................................. 13-206
13.9 ELUTION PRESSURE MEASUREMENT LISTING ..................................................................................... 13-207

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PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

13.10 APPENDICES .................................................................................................................................... 13-207

14. ELECTROWINNING AND CATHODE WASH ........................................................................ 14-208
14.1 SUMMARY ........................................................................................................................................... 14-208
14.2 SAFETY ................................................................................................................................................. 14-208
14.3 ELECTRO-WINNING SAFETY PROCEDURES .......................................................................................... 14-208
14.3.1 Sodium Cyanide (NaCN) .............................................................................................................. 14-209
14.3.1.1 Principal hazards..................................................................................................................... 14-209
14.3.1.2 Emergency Procedures ........................................................................................................... 14-209
14.3.1.3 In the event of HCN gas emissions ......................................................................................... 14-209
14.3.2 Caustic Soda (NaOH): .................................................................................................................. 14-209
14.3.2.1 Principal hazards..................................................................................................................... 14-209
14.3.2.2 Emergency Procedures: .......................................................................................................... 14-210
14.4 ELECTRO WINNING PROCESS PRINCIPLES OF OPERATION .................................................................. 14-212
14.4.1 Theoretical background .............................................................................................................. 14-212
14.4.1.1 Rectifier .................................................................................................................................. 14-212
14.4.1.2 Anode ..................................................................................................................................... 14-212
14.4.1.3 Cathode .................................................................................................................................. 14-212
14.4.1.4 Electrolyte............................................................................................................................... 14-213
14.4.2 Electrowinning Equipment .......................................................................................................... 14-213
14.4.3 Electrowinning Cell...................................................................................................................... 14-214
14.5 ELECTRO-WINNING PROCESS DESCRIPTION ........................................................................................ 14-214
14.5.1 Electrowinning Controls .............................................................................................................. 14-215
14.5.2 Alarms ......................................................................................................................................... 14-216
14.5.3 Interlocks..................................................................................................................................... 14-216
14.6 OPERATING PROCEDURES ................................................................................................................... 14-217
14.6.1 Electrowinning ............................................................................................................................ 14-217
14.6.2 Filter Press Operating Procedures ............................................................................................... 14-218
14.6.3 Care of Filter Cloths ..................................................................................................................... 14-220
14.6.4 Cloth Washing ............................................................................................................................. 14-220
14.6.5 Electrowinning Troubleshooting ................................................................................................. 14-221
14.6.6 SCADA Display ............................................................................................................................. 14-222
14.7 APPENDICES ......................................................................................................................................... 14-222
15. GOLDROOM ................................................................................................................... 15-223
15.1 SUMMARY DESCRIPTION ..................................................................................................................... 15-223
15.2 SAFETY AND SECURITY PROCEDURES .................................................................................................. 15-224
15.2.1 Cathode Wash and Pressure Filtration Operations ..................................................................... 15-224
15.2.1.1 PPE Required .......................................................................................................................... 15-224
15.2.2 Calcine Oven Operation .............................................................................................................. 15-225
15.2.2.1 PPE Required .......................................................................................................................... 15-225
15.2.3 Smelting Furnace Operation ....................................................................................................... 15-226
15.2.4 The additional PPE is listed below ............................................................................................... 15-226
15.2.4.1 PPE Required .......................................................................................................................... 15-226
15.2.5 Handling of gold bars .................................................................................................................. 15-227
15.3 TREATMENT OF THE GOLD SLUDGE PRODUCED FROM THE ELECTRO-WINNING CELLS ..................... 15-228
15.3.1 Theoretical Background .............................................................................................................. 15-228
15.3.1.1 Filter cake handling ................................................................................................................. 15-228
15.3.1.2 Drying and calcination ............................................................................................................ 15-228

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15.3.1.3 Smelting .................................................................................................................................. 15-228

15.3.2 Fluxes are usually made up of a mixture of the following ingredients: ...................................... 15-229
15.3.2.1 Silica (Sand)............................................................................................................................. 15-229
15.3.2.2 Soda Ash ................................................................................................................................. 15-229
15.3.2.3 Borax ....................................................................................................................................... 15-229
15.3.2.4 Oxidizing Agent ....................................................................................................................... 15-229
15.3.2.5 Bullion ..................................................................................................................................... 15-230
15.3.2.6 Slag ......................................................................................................................................... 15-230
15.3.3 Main Equipment Used................................................................................................................. 15-231
15.3.4 Operations .................................................................................................................................. 15-232
15.3.5 Calcination furnace operating procedures .................................................................................. 15-232
15.3.5.1 Calcine Furnace Operating Procedures. ................................................................................. 15-233
15.3.5.2 Operator Check List ................................................................................................................ 15-234
15.3.6 Smelting furnace operating procedures ...................................................................................... 15-234
15.3.7 Smelting Furnace Operating Procedures .................................................................................... 15-234
15.3.8 Operator Check List ..................................................................................................................... 15-236
15.3.9 Handling of gold bars .................................................................................................................. 15-236
15.3.10 Handling of slag .......................................................................................................................... 15-237
15.4 INSTRUMENTATION AND AUTOMATIC CONTROLS ............................................................................. 15-237
15.4.1 Automatic operations: ................................................................................................................ 15-237
15.4.1.1 Alarms..................................................................................................................................... 15-237
15.4.1.2 Interlocks ................................................................................................................................ 15-237
15.4.1.3 Scada display .......................................................................................................................... 15-237
15.5 APPENDICES ......................................................................................................................................... 15-237
16. SERVICES ........................................................................................................................ 16-238
16.1 INTRODUCTION ................................................................................................................................... 16-238
16.2 DIESEL .................................................................................................................................................. 16-238
16.2.1 Safety .......................................................................................................................................... 16-238
16.2.1.1 PPE Required .......................................................................................................................... 16-238
16.2.2 Introduction ................................................................................................................................ 16-238
16.2.3 Instructions ................................................................................................................................. 16-238
16.2.4 Health Hazards............................................................................................................................ 16-239
16.2.4.1 First aid ................................................................................................................................... 16-239
16.2.4.2 Safe handling and use ............................................................................................................. 16-239
16.3 PLANT DESCRIPTION ............................................................................................................................ 16-240
16.3.1 Diesel........................................................................................................................................... 16-240
16.3.1.1 Controls .................................................................................................................................. 16-240
16.3.1.2 Interlocks ................................................................................................................................ 16-240
16.3.1.3 SCADA Display ........................................................................................................................ 16-241
16.4 COMPRESSED AIR ................................................................................................................................ 16-241
16.4.1 Compressed air services .............................................................................................................. 16-241
16.4.2 Compressed Air Safety ................................................................................................................ 16-241
16.4.3 Plant Air process description ....................................................................................................... 16-242
16.4.3.1 Controls: ................................................................................................................................. 16-242
16.4.4 Plant Air Start Up ........................................................................................................................ 16-243
16.5 APPENDICES ......................................................................................................................................... 16-244
17. WATER CIRCUITS ............................................................................................................ 17-245
17.1 INTRODUCTION ................................................................................................................................... 17-245

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17.2 PLANT DESCRIPTION ............................................................................................................................ 17-246

17.2.1 Raw Water Circuit ....................................................................................................................... 17-246
17.2.1.1 Controls .................................................................................................................................. 17-247
17.2.1.2 Interlocks ................................................................................................................................ 17-248
17.2.2 SCADA Display ............................................................................................................................. 17-249
17.2.3 Process Water Circuit .................................................................................................................. 17-249
17.2.3.1 Controls .................................................................................................................................. 17-249
17.2.3.2 Interlocks ................................................................................................................................ 17-249
17.2.4 Potable Water Circuit .................................................................................................................. 17-250
17.2.4.1 Controls .................................................................................................................................. 17-250
17.2.5 SCADA Display ............................................................................................................................. 17-250
17.2.5.1 Interlocks ................................................................................................................................ 17-250
17.2.6 Gland Water................................................................................................................................ 17-251
17.2.6.1 Controls .................................................................................................................................. 17-251
17.2.6.2 Interlocks ................................................................................................................................ 17-251
17.2.7 Fire Water ................................................................................................................................... 17-251
17.2.7.1 Interlocks ................................................................................................................................ 17-252
17.3 EQUIPMENT LIST .................................................................................................................................. 17-252
17.4 APPENDICES ......................................................................................................................................... 17-252
18. REAGENTS ...................................................................................................................... 18-253
18.1 INTRODUCTION ................................................................................................................................... 18-253
18.2 SUMMARY DESCRIPTION ..................................................................................................................... 18-253
18.3 REAGENTS HANDLING OPERATING PROCEDURES ............................................................................... 18-254
18.3.1 Hydrochloric Acid (HCl). .............................................................................................................. 18-254
18.3.1.1 Function and use of Hydrochloric Acid in the gold recovery process ..................................... 18-254
18.3.1.2 Safety ...................................................................................................................................... 18-254
18.3.1.3 Safe handling procedures ....................................................................................................... 18-256
18.3.1.4 Make-up Procedures for dilute acid batch ............................................................................. 18-257
18.3.1.5 Interlocks ................................................................................................................................ 18-258
18.3.1.6 SCADA screen ......................................................................................................................... 18-258
18.3.1.7 VDU displays ........................................................................................................................... 18-259
18.3.1.8 VDU controls ........................................................................................................................... 18-259
18.3.1.9 Caustic acid solution step-by-step make-up instructions ....................................................... 18-259
18.3.1.10 Appendices ......................................................................................................................... 18-261
18.3.2 Lime............................................................................................................................................. 18-261
18.3.2.1 Function and use of lime in the gold recovery process .......................................................... 18-261
18.3.2.2 Safety ...................................................................................................................................... 18-262
18.3.2.3 Safe handling procedures ....................................................................................................... 18-263
18.3.3 Lime Slaking process description ................................................................................................ 18-264
18.3.3.1 Controls and Interlocks ........................................................................................................... 18-266
18.3.3.2 The main interlocks will be as follows .................................................................................... 18-266
18.3.3.3 Appendices ............................................................................................................................. 18-267
18.3.4 Caustic Soda (Sodium Hydroxide-NaOH)..................................................................................... 18-267
18.3.4.1 Function and use of caustic soda in the gold recovery process.............................................. 18-267
18.3.4.2 Safety ...................................................................................................................................... 18-267
18.3.4.3 Safe handling procedures ....................................................................................................... 18-269
18.3.4.4 Caustic Soda Make-up and Dosing System Operating Procedures ......................................... 18-270
18.3.4.5 Instrumentation and controls ................................................................................................. 18-271
18.3.4.6 Interlocks ................................................................................................................................ 18-272
18.3.4.7 SCADA screen ......................................................................................................................... 18-272

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18.3.4.8 VDU displays ........................................................................................................................... 18-272

18.3.4.9 VDU controls ........................................................................................................................... 18-273
18.3.4.10 Caustic Soda make-up instructions: ................................................................................... 18-273
18.3.4.11 Appendices ......................................................................................................................... 18-275
18.3.5 Cyanide (Sodium Cyanide-NaCN) ................................................................................................ 18-275
18.3.5.1 Function and use of Sodium Cyanide in the gold recovery process ....................................... 18-275
18.3.5.2 Safety ...................................................................................................................................... 18-276
18.3.5.3 Safe handling procedures: ...................................................................................................... 18-279
18.3.5.4 Cyanide Make-up and Dosing System Operating Procedures:................................................ 18-280
18.3.6 Appendices .................................................................................................................................. 18-286
18.3.7 Flocculants .................................................................................................................................. 18-286
18.3.7.1 Function and use of flocculants .............................................................................................. 18-286
18.3.7.2 Safety ...................................................................................................................................... 18-286
18.3.7.3 Safe handling and use ............................................................................................................. 18-287
18.3.7.4 Flocculant solution Make-up Procedures ............................................................................... 18-288
18.3.7.5 Flocculant Solution Make-up Plant Equipment Schedule. ...................................................... 18-289
18.3.8 Appendices: ................................................................................................................................. 18-290
18.3.9 Copper Sulphate (CuSo4) ............................................................................................................. 18-290
18.3.9.1 Function and use of copper sulphate ..................................................................................... 18-290
18.3.9.2 Safety ...................................................................................................................................... 18-290
18.3.9.3 Hazards, Symptoms of Exposure, Prevention Measures and First AID measures................... 18-291
18.3.9.4 Safe handling procedures ....................................................................................................... 18-291
18.3.9.5 Copper Sulphate solution Make-up Procedures: .................................................................... 18-293
18.3.10 Appendices .................................................................................................................................. 18-297
18.3.11 Sodium Metabisulphite (Na2S2O5) ............................................................................................... 18-297
18.3.11.1 Function and use of sodium metabisulphite ...................................................................... 18-297
18.3.11.2 Safety.................................................................................................................................. 18-297
18.3.11.3 Sodium metabisulphite solution Make-up Procedures: ..................................................... 18-299
18.3.12 Appendices .................................................................................................................................. 18-303

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List of Figures
Figure 5-1: Ball mill Power Draft as a Function of the Charge ............................................................ 5-79
Figure 5-2: Typical Hydro cyclone Cluster Arrangement .................................................................... 5-80
Figure 5-3: Typical Overflow Ball Mill Cutoff. ..................................................................................... 5-83
Figure 6-1: GKD Delkor Linear Screen Typical Installation. .............................................................. 6-101
Figure 6-2: Linear Screen Operating Principles. ............................................................................... 6-102
Figure 6-3: Flocculation Mechanism................................................................................................. 6-103
Figure 6-4: GKD Delkor Thickener..................................................................................................... 6-103
Figure 6-5: Settling Zones in “High Rate” Thickening. ...................................................................... 6-104
Figure 7-1: Gold dissolution rate versus time................................................................................... 7-117
Figure 9-1: Flocculation Mechanism................................................................................................. 9-147
Figure 9-2: GKD Delkor Thickener..................................................................................................... 9-148
Figure 9-3: Settling Zones in “High Rate” Thickening ....................................................................... 9-148
Figure 10-1: Safety Shower Features. ............................................................................................... 10-163
Figure 12-1: Fouling of Carbon Particle’s Surface and Inner Structure ............................................ 12-175
Figure 12-2: Danger Signs For Dilute Hydrochloric Acid ................................................................... 12-176
Figure 12-3: Safety Shower Features ................................................................................................ 12-177
Figure 12-4: Acid Wash Section Safety Signs .................................................................................... 12-177
Figure 13-1: Danger Signs for Sodium Cyanide Solutions ................................................................. 13-187
Figure 13-2: Danger Signs for Caustic Soda ...................................................................................... 13-188
Figure 13-3: Safety Shower Features ................................................................................................ 13-189
Figure 13-4: Elution Section Safety Signs.......................................................................................... 13-190
Figure 13-5: Elution Pumps arrangement and construction ............................................................ 13-204
Figure 14-1: Danger Signs for Sodium Cyanide Solutions ................................................................. 14-209
Figure 14-2: Danger Signs for Caustic Soda ...................................................................................... 14-210
Figure 14-3: Safety Shower Features ................................................................................................ 14-210
Figure 14-4: Elution Section Safety Signs.......................................................................................... 14-211
Figure 14-5: Gold Electro-winning Process Mechanism ................................................................... 14-213
Figure 15-1: Cathode Wash PPE signs .............................................................................................. 15-224
Figure 15-2: Calcine Oven PPE signs ................................................................................................. 15-225
Figure 15-3: Furnace Operator Protective Clothing ......................................................................... 15-226
Figure 15-4: Smelting Furnace PPE ................................................................................................... 15-227
Figure 15-5: Gold Bullion Pouring Operation ................................................................................... 15-230
Figure 16-1: Diesel Reticulation and Controls .................................................................................. 16-240
Figure 16-2: Compressed air Reticulation and Controls ................................................................... 16-243
Figure 17-1: Raw Water Circuit Controls .......................................................................................... 17-248
Figure 17-2: Typical Raw Water SCADA Display ............................................................................... 17-249
Figure 17-3: Typical Process Water SCADA Display. ......................................................................... 17-249
Figure 17-4: Portable Water Circuit Controls. .................................................................................. 17-250

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Figure 17-5: Typical Potable Water SCADA Display. ......................................................................... 17-250

Figure 17-6: Typical Gland Water SCADA Display............................................................................. 17-251
Figure 18-1: Danger Signs for Concentrated Acid............................................................................. 18-254
Figure 18-2: Safety Shower Features ................................................................................................ 18-256
Figure 18-3: Acid Wash Plant Arrangement. .................................................................................... 18-258
Figure 18-4: Acid Make-up System. .................................................................................................. 18-258
Figure 18-5: Typical Acid Wash SCADA Screen. ................................................................................ 18-259
Figure 18-6: Sites of the Reagents Stores and Make-up plant. ........................................................ 18-270
Figure 18-7: Reagents Make-up plant Arrangement. ....................................................................... 18-271
Figure 18-8: Caustic Soda Make-up System P&ID. ........................................................................... 18-272
Figure 18-9: Typical SCADA Screen for Caustic and Cyanide solutions make-up. ............................ 18-273
Figure 18-10: Danger Signs for Cyanide.......................................................................................... 18-276
Figure 18-11: Danger Signs for Caustic Soda .................................................................................. 18-278
Figure 18-12: Safety Shower Features ............................................................................................ 18-279
Figure 18-13: Sites of the Reagents Stores and Make-up plant. .................................................... 18-281
Figure 18-14: Reagents Make-up plant Arrangement. ................................................................... 18-281
Figure 18-15: Cyanide Make-up Plant Controls. ............................................................................. 18-283
Figure 18-16: Typical SCADA Screen for Caustic and Cyanide solutions make-up. ........................ 18-284
Figure 18-17: Flocculant Plant Vendor Design Parameters ............................................................ 18-288
Figure 18-18: Flocculant Plant Simplified P&ID. ............................................................................. 18-289
Figure 18-19: Typical Flocculant Plant SCADA Screen. ................................................................... 18-290
Figure 18-20: Safety Shower Features ............................................................................................ 18-292
Figure 18-21: Copper Sulphate Make-up Plant Controls. ............................................................... 18-295
Figure 18-22: Typical SCADA Screen for Copper Sulphate solutions make-up............................... 18-296
Figure 18-23: Safety Shower Features ............................................................................................ 18-298
Figure 18-24: Sodium metabisulphite Make-up Plant Controls. .................................................... 18-301
Figure 18-25: Typical SCADA Screen for Sodium metabisulphite solutions make-up. ................... 18-302

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1. SAFETY
The goal of Bisha Mining Share Company. is to maximize production with no safety incidents and/or
accidents. This is accomplished through personal awareness complemented by suitable procedures
(which will be issued by plant management), use of the correct personal protective equipment, warnings
and guards. The safety instructions detailed below are efforts to make plant operating personnel
understand some of the safety basics. Please note: Where the Procedures or Instructions given in this
Manual differ from the Site or Statutory Regulations and Requirements, the Site / Statutory
Regulations must take precedence.

While this operating manual is mainly intended for plant operating personnel, some safety instructions
pertaining to maintenance personnel have been included to make the plant operators aware of what the
maintenance personnel have to observe and take corrective action in the event where such instructions
are not observed.

1.1 GENERAL SAFETY INSTRUCTIONS

At a time close to completion of plant installation, all personnel and supervisors should be given
complete instruction in the use of the system and all of its equipment. Field inspection and classroom
techniques are two valuable types of training.

A formal safety training programme for operating, maintenance and supervisory personnel will go a long
way towards establishing and maintaining the highest standards of safety in the workplace.

Concurrent with the completion of the installation and the trial runs of the plant, a “Safety Check-up” is
recommended. The check-up should also include all mechanical and electrical operating equipment, plus
the structures, walkways, ladders, stairs, headroom, and access ways. It is at this time that a detailed
physical inspection of the facility and the installed equipment will often reveal the need for additional
guards, safety devices and warning signs.

At no time should the plant equipment be used to handle material other than that originally specified.
Capacity and belt speed ratings should not be exceeded.

Only trained personnel should be allowed to operate the plant. They should have complete knowledge
of conveyor operation, electrical controls, safety and warning devices, and the capacity and performance
limitations of the plant.

The location and operation of all emergency control and safety devices should be made known to all
personnel. Surrounding areas should be kept free of obstructions or materials that could impede ready
access and a clear view of such safety devices at all times.

A programme should be established to provide frequent inspections of all equipment. Guards, safety
devices and warning signs should be maintained in their proper positions and in good working order.
Only competent and properly trained and authorised persons should adjust or work on safety devices.

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A “Walking Inspection” of a plant is a good means by which well-trained maintenance personnel can
often detect potential problems from any unusual sounds made by such components as gearboxes,
bearings, motors etc.

Hands and feet should never come in contact with any component or the equipment. Poking at or
prodding material should be strictly prohibited. Contact with, or work on the plant must occur only
while the equipment is stopped, with the electrical control locked off.

No person should be allowed to ride on, step on, or cross over a moving conveyor, nor to walk or climb
on conveyor structures, without using the walkways, stairs, ladders and crossovers provided.

Good housekeeping is a prerequisite for safe conditions. All areas around the plant, and particularly
those surrounding drives, walkways, safety devices and control stations should be kept free of debris and
obstacles, including inactive or unused equipment, components, wiring and obsolete / non-applicable
warning signs or posted instructions.

Any machine or conveyor found to be in an unsafe condition for operation, or one that does not have all
guards and safety devices in excellent condition, should not be used unless adequate supplementary
safety devices are installed.

All persons should be barred by appropriate means from entering an area where falling material may
present a hazard. Warning signs and barricades can be used.

First class maintenance is a prerequisite for the safety operation of all equipment. Maintenance,
including lubrication should be performed with the equipment stopped and locked out. Special
lubricating equipment; lube extensions, pipes, and the like can be installed so as to permit lubrication of
an operating conveyor or machine without any foreseeable hazards.

Good lighting contributes to a safe working environment.

1.2 UNDERSTANDING SAFETY INSTRUCTIONS

1.2.1 Housekeeping:
Good housekeeping is second nature to good skill

 When machinery is being stripped, parts must be stored tidily and securely in a demarcated
area.
 Redundant and superfluous items must be removed from the work area.
 Spilled liquids such as oils and other slippery substances must be cleaned up immediately.
 Have a place for every necessary item and keep everything in its place.
 Waste and rubble must be disposed of in the waste bins provided.

1.2.2 Personal Protective Equipment:

Head protection – Hard hats must be used in:

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 All identified areas and where symbolic signs are displayed.

 Any workplace where there is a possibility of falling objects.
 All areas where there are overhead cranes in operation.
 Areas where overhead work is being carried out.

Eye protection – safety glasses must be worn when:

 All identified areas and where symbolic signs are displayed.

 Working within the plant security fence
 Working with hammer and chisel.
 Welding, flame cutting, soldering and similar operations.
 Grinding and cutting operations.
 Air pressure work.
 Drilling or similar work.
 Hilti-gun operations.
 Work in dusty areas.
 Where appropriate symbolic signs are displayed.
 Eye protection must also be used by helpers or bystanders.

Breathing apparatus and respirators must be used:

 All identified areas and where symbolic signs are displayed.

 Where air contains toxic or harmful elements.
 Any work area where dust, gases, vapours or smoke exists.
 When working with or handling any hazardous substance.
 Any area where symbolic signs are displayed.
 In any confined space.

Ear protection must be worn where:

 All identified areas and where symbolic signs are displayed.

 The equivalent noise level to which Employees are exposed in any work place is equal to or
exceeds 85dB (A).
 Demarcated noise zone areas.
 When working with angle grinders.
 When working with pneumatic tools.
 When working with a Hilti-gun.

Hand protection – gloves must be worn when:

 All identified areas and where symbolic signs are displayed.

 Materials are handled.
 Welding and cutting operations are being performed.

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 Grinding work is being performed.

 Hazardous / chemical substances are handled.
 In areas indicated by appropriate signs.

Safety belts / harnesses shall be used to:

 All identified areas and where symbolic signs are displayed.

 Arrest falling persons effectively in case of a fall incident.
 Prevent a person falling as a result of an unintentional slip or loss of balance.
 Prevent a person being engulfed by particulate material.

Overalls:

 No person working in close proximity to moving machinery shall wear, or be permitted to wear
any loose outer clothing, jewellery or ornament, watch or key-chain, long loose hanging hair, or
anything which may be caught up in the moving parts of such machinery.
 The use of nylon overalls is not recommended as they cause serious harm when exposed to heat
or fire.
 No Operator, maintenance worker or visitor shall wear rings while within the Plant Security
Fence.

Special Safety Rules

Special Safety rules are in place for work in the following areas:

 Gold Room
 Cyanide Make Up
 Caustic make up
 Hydrochloric Make up

Reference to the relevant document is made.

1.3 CONDITION OF HAND TOOLS:

Hammers:

 Must have a good balanced handle.

 The handle must be fitted with a proper wedge.
 Cracked, burred or worn hammer heads must not be used.
 Homemade or welded hammers must not be used.
 Soft metal must be used on hardened pins.
 Do not use wrenches or other tools as a hammer.

Set Spanners:

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 Use only the correct size spanner for the job.

 Do not overstrain spanners, rather obtain special tools.
 Do not use spanners with worn jaws.
 Screwdrivers:
 Never use screwdrivers as chisels.
 Handles must be kept in good condition.
 A screwdriver with a dull or twisted tip must not be used.
 Never carry a screwdriver in your pocket.

Files:

 Do not use a file as a chisel, hamper or pry.

 Never use a file without a proper crack-free handle.
 A file must never be cleaned by being struck against a vice or any metal object.

Knives and Chisels:

 Always cut away from your body when using a knife.

 Do not use a blunt knife or chisel.
 Always keep sharp tools in a pouch or pocket.
 Use a face shield or goggles when performing chipping work.
 Always remove all burrs from the head.
 Use a hammer heavy enough to do the job.
 Homemade chisels must never be used.

Electrical Equipment:

 Only competent persons are allowed to repair electrical equipment.

 Only use portable electrical equipment that is in a good condition and that has been checked for
earth continuity.
 Never tamper with electrical installations.
 Report all electrical deficiencies to your supervisor.
 Never try to rectify any electrical fault.

Ladders:

 Always secure a ladder properly before attempting to climb on it.

 All ladders must be fitted with non-skid devices.
 No ladders with damaged stiles; or damaged or missing runs may be used.
 A ladder which is required to be leaned against an object for support shall be no longer than 5
metres.

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 No work will be performed on a ladder unless all necessary precautionary measures have been
taken to prevent articles from falling off and suitable sheaths or receptacles in which hand tools
shall be kept are used.

1.4 SCAFFOLDING:
Framework – no scaffold is to be used unless it:

 Is secured at suitable vertical and horizontal distances to the structure.

 Is inspected once a week by a competent person and all findings are recorded in a register or
report book.
 All scaffolds must be erected, altered or dismantled by or under the supervision of a competent
person.
 Before using scaffold platforms, ensure that:
 Every plank is made of solid wood and is at least 275mm wide and 38mm thick.
 Planks are without cracks and splinters and are properly strapped.
 Every plank is firmly secured to prevent its displacement.
 Every platform is so constructed as to prevent materials and tools from falling through.
 Scaffold platforms are provided with guardrails of at least 900mm and not exceeding 1000mm in
height.
 Toe-boards are provided which are at least 150mm high and no open space exists between toe-
boards and platform.
 Platforms are free of waste, projecting nails or any other obstructions, and are kept in a non-slip
state.
 Planks extend not less than 70mm and not more than 200mm beyond the frame.
 Convenient and safe access is provided to the scaffold platforms.

1.5 WELDING OR FLAME CUTTING

No Welding or Flame Cutting shall be undertaken unless:

 The person has been fully instructed in the safe use of the equipment and in the hazards, which
may arise.
 Leads and electrode holders are effectively insulated.
 The workplace is effectively partitioned off and signs erected.
 Eyes, face, hands, feet, body and respiratory system are effectively protected by wearing the
correct personal protective equipment.
 Effective ventilation is provided and maintained.
 The insulation of the electrical leads is in a sound condition.

1.6 LIFTING EQUIPMENT

No lifting machine or lifting tackle shall be used unless:

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 It is in a good condition and safe to use.

 It is conspicuously and clearly marked with the safe workload, which it is designed to carry with
safety.
 Chains and ropes are in a good condition.
 Hooks are fitted with safety clips.
 Nobody shall permit or require persons to be raised or lowered by means of a lifting machine.
 Nobody shall use a jib crane with a hoisting capacity of 5 tons or more unless it is fitted with a
device that will automatically indicate to the operator that the load being lifted in any position is
within the capacity of the crane.

1.7 HAZARDOUS SUBSTANCES:

 Never use chemicals without wearing the correct personal protective equipment.
 Always store chemicals in the correct storage places.
 Always dispose of chemicals in purpose-made bins or containers.

1.8 ERGONOMICS
Manual materials handling is involved in some 30% of all injuries.

 To ensure the least injuries:

 Keep all repetitive lifts between knuckles and shoulder height.
 Keep carrying to a minimum.
 Avoid high lifting rates.

1.9 FIRE PREVENTION AND PROTECTION

 No Smoking is allowed within the Plant security fence.
 Fires can cause major damage, injuries and loss of life. In order to prevent fires, ensure that:
 Cigarette butts, matches, etc. are not discarded carelessly.
 Only the quantity of flammable liquid required for one day is kept at the workplace.
 Oil/Grease-soaked waste must be disposed of in containers with a lid provided for such material.
 All containers holding flammable liquids must be kept tightly closed when not in actual use.
 Fire fighting equipment is kept free from obstruction.
 Naked flames are kept away from inflammable substances.
 Never smoke in non-smoking areas.

1.10 SYMBOLIC SAFETY SIGNS

 Every worker must understand and obey symbolic safety signs.
 The colour board in the work environment must be checked before any taps or valves are used.
 Some the common safety signs are shown below

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Warning Signs

Prohibitive Signs

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General Signs

Mandatory Signs

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Fire Signs

1.11 TRAFFIC OFFENCES

 All traffic signs must be obeyed at all times.
 Any person ignoring or violating traffic rules on site can be prevented from driving or entering
the premises.

1.12 ENVIRONMENTAL MANAGEMENT

In order to have a safe and clean environment the following measures must be adhered to:

 When working in a dusty area, always keep dust wet.

 Ensure that no hazardous substance or waste enters drains.
 Disposal of hazardous waste must be performed according to the prescribed manner.
 Empty containers, which have contained hazardous substances, must not be disposed of in
waste bins, but punctured or flattened and then disposed of in the prescribed manner.

1.13 SAFETY CHECKLIST

Safety and housekeeping inspections should be undertaken on a monthly basis. These should be
performed by each responsible department’s appointed Safety Representative.

1.14 MAINTENANCE SAFETY PRECAUTIONS

Before carrying out any repair or maintenance tasks on the equipment, the equipment and other
associated plant items, the following safety precautions shall be strictly observed:

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 The machine shall be switched off and the corresponding electrical power supply isolated
(locked-out) in the respective substation. Note: The Lock-out System must be fool proof.
 Warning notices shall be placed on the corresponding switchgear (starter or isolator) and the
control room personnel shall be informed beforehand.
 Any machine or conveyor immediately “Up-stream” of the machine being serviced must be
locked-out or an arrangement shall be made to prevent the material being accidentally fed to
the machine or conveyor being serviced.
 Proper safety equipment such as safety belts, hard hats, goggles, gloves and shoes shall be worn
and used when carrying out the required maintenance tasks.
 Any safety guards or hand railing removed for the access shall be replaced before the machine or
conveyor is put back into service.
 Any repairs or complicated maintenance tasks shall be supervised by the experienced
maintenance foreman or his delegated senior member of maintenance staff.

1.15 MATERIAL SAFETY DATA SHEETS (MSDS)

The MSDS of each reagent fully outlines the personal protective equipment, safe handling, what to do in
the event of a spill and/or exposure of personnel. Typical MSDS for the reagents that will be used at
Bisha are given in Appendix. However, specific MSDS should be supplied by the vendor from which Bisha
Mining Share Company will procure the specific reagents from.

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2. SCADA SYSTEM
The operator will use a PC based Supervisory Control and Data Acquisition (hereafter called the
“SCADA”) system to observe and operate the plant. A computer display is used as the visual interface.
The plant areas are presented in graphic form on individual screens. Each screen display’s all drives and
instruments in that area, with the status of drives and current value of instruments given. Alarms are
generated and displayed in a dedicated portion of the screen.

More detail on each individual SCADA screen is provided in the description of each plant area. The
SCADA screen description contains a “Screen Features” section, which details all the values, drive status,
alarms or indicators displayed on the screen, and a “Controls” section describing all the values or settings
which are available to the operator for control actions.

2.1 SCADA SCREENS

There are various standard screens used in the applications that are listed below:

 Logon
 Access level
 Systems
 Task bar
 Overview
 Historical trend
 Real-time trend
 Report
 Alarm

2.2 LOGON SCREEN

This screen allows the operator to logon to the system using his user name and secret password. Once
logged onto the system he can access certain sections of the plant and the functions he can perform will
depend on his access level. To logon, the operator “clicks” the mouse over the drop down list under
username and finds his name in the list and “clicks” on it so that his name appears in the username
block, then moves the cursor to the password block and “clicks” the mouse in the block, he is then able
to type in his password. Once logged on he can now enter the plant via the OVERVIEW screen.

2.3 ACCESS LEVELS SCREEN

This screen allows the operator to change the value of the access level of predefined items like starting
and stopping of drives, PID configuration, Set point adjusting etc. The access to this screen requires a
very high access level, as it is the backbone to the security of the system. To exit this page the operator
presses the close button, which will take him back to the OVERVIEW Screen. It is therefore restricted to
selected management members.

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2.3.1 Systems Screen

This screen shows PLC networking, which includes the network connections and Programmable Logic
Controllers (PLC) communications connections and lets the operator know the status of his
communication to the PLC’s. It is clearly indicated by a GREEN line if communication is active and RED
lines if communication not active.

2.3.2 Task Bar Screen

The TASKBAR is a small screen running along the top of the page. It allows the operator to easily access
different areas in the plant via predefined buttons. Examples are the Report Page, Historical Trend pages
and so on. The TASKBAR also shows the two most recent alarms in the system and their status. If more
detail is required the operator can go into the ALARM screen via the TASKBAR and investigate further.

2.3.3 Overview Screen

This screen gives the operator a simple graphical representation of the whole plant and more detailed
representations of sections of the plant so he can scroll down from here to different areas as and when
required. It also doubles as an area alarm window, letting the operator know in which area there is an
alarm by flashing a box around the affected area. The operator can zoom into that area and identify the
alarm in more detail. The OVERVIEW screen also includes important motor currents, feed conveyor
tonnages and other details giving the operator overall indication of how the plant is running.

2.3.4 Historical Trend Screen

The historical trend screen shows very important historical plant status information, which allows the
operator to integrate the operation of his plant over various periods up to the previous 30 days. An
eight-pen graph allows to trend selected data on historical data window. It is also used to pre-define pen
configurations by area so with a ’click’ of the mouse the operator can load the trend window with a
default pen configuration. It allows the operator to select the length of his chart by HOUR, DAY, 7 DAYS
or MONTH dependent on which button pressed. The operator is also able to scroll back or forward by
selecting the scroll by period and moving back or forward. There is also the facility to zoom into a
specific area of interest.

2.3.5 Real time Trend Screen

This trend screen is similar to the Historical trend page but only allows the operator to look at a pre-
defined period and selectable tags. The value of these tags are shown as a 0 – 100% of full scale of the
tag and not actual value.

2.3.6 Report Screen

Not Part Of This Scope but can be added at a later date

2.3.7 Alarm Screen

The alarm screen will show, in red text, all current, unacknowledged alarms in chronological order. The
time of the alarm and a descriptive field detailing the alarm will be listed. Clicking on the alarm will

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acknowledge it and the alarm line will change to blue. When the alarm causing condition is rectified, the
alarm line will change to black.

Certain alarms may be acknowledged in the plant overview or area overview screens by clicking on the
item that is flashing in alarm mode, such as a tripped motor.

2.3.8 Start-up and Shut-down Sequences:

Generally, the operator will initiate start/stop sequences via a single keystroke or mouse “click”, using
the SCADA. The drives will then be started and stopped by the PLC. In several areas, notably CIL, Water,
Reagents, Regeneration and Gold Room, the operator will either start drives individually from the
SCADA, or the drives will be started in the field.

2.3.9 Status of drives on the SCADA:

The status of drives (icons) displayed on the SCADA is as follows:

Green display - Running

Red display - Stopped, ready to start

Purple - Stopped – Interlocks Un-Healthy

Flashing red & yellow - Stopped; tripped out, not ready to start

Yellow display - Alarm acknowledged

2.3.10 Status of valves on the SCADA:

The status of valves displayed on the SCADA is as follows:

Green display - Open

Red display - Closed

Flashing blue & yellow - Transient State

Flashing red & yellow display - Valve Fault - did not close or open on command

2.4 TAG NAME DEFINITIONS ON THE SCADA:

These Tag names are generic through the whole system

2.4.1 Motor Tag Names

The tag name starts with the area, then the abbreviated description of the type unit driven by the motor
and then the sequential number of the unit in that area.

Example 11-CRUS-01 is the Primary Crusher in area 01.

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The abbreviated description of the unit is a four-letter code usually shortened from the full name. For
example, a pump is PUMP and a crusher is CRUS etc.

2.4.2 Valve Tag names

Valves are identified by tag names. The tag name starts with the alphanumeric area code derived from
the P&ID number complete with a subordinate sequential letter e.g. A or B, etc. The letter “V” is then
used to denote a valve and a sequential three digit unique number for the valve in each area is assigned.
Key (control) valves sequential three digit numbers are indicated on the P&ID near the valve.

Example: PID1110-V-01.

2.4.3 Instrument and Alarm Tag names

Instruments are identified by tag names in order to accommodate a system for identifying alarms.
Instrumentation that reports to or via the SCADA with a tag name that starts with the alphanumeric area
code derived from the Process Flow Diagram (PFD) area. This is followed by multi letter code to describe
what variable is measured and/or controlled by the instrument. Finally, the equipment tag or line
number related to the instrumentation is used as identification.

INSTRUMENT LETTERING AREA DECRIPTION

SYMBOL FIRST SECOND THIRD FOURTH 11 Crushing/stockpiling
A Alarm - - - 21 Grinding
C - Control Control/closed - 23 Gravity
D Density Device - - 31 Preleach thickening
DP Differential - - - 32 CIL
Pressure
E Voltage Element - - 34 Detoxification
F Flow - - - 35 Tailings dewatering
H Hand - High High 36 TSF
I Current Indicator Indicator - 41 Acid wash
J Power - - - 42 Elution
K Time - - - 43 Electrowinning
L Level - Low Low 44 Regeneration
N Torque - - - 45 Goldroom
O - - Open - 51 Cyanide & caustic
P Pressure Pressure - - 52 Flocculant
Q Quantity - Totalising - 53 Lime
R - Recorder - Record 54 Detox reagents
S Speed Switch Switch - 55 Diesel
T Temperature Transducer Transmitter - 56 Air
U Siren - - - 61 Process water
V Vibration - Valve Valve 62 Raw & Portable water
W Weight - - - 63 Raw water supply
X Multivariable - - - 71 Camp water
Y Relay/comput - - -

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e
Z Position - - -

2.5 MOTOR CONTROLLER FACEPLATES:

There are two different types of Motor Control Faceplates. The first (type 1) is for motors on units that
do not have an automatic start-up. These are mostly pumps that are critical to continuous operation of
the plant. Units that do have an automatic start-up are designated type (2) shown below:

Type 1

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Type 2

There are four different methods for starting the motors as listed below: -

2.5.1 Field Control

This control is primarily for maintenance and allows an operator to start the motor from the Start / Stop
station in the field. In this mode, the Control Room Operator can disable interlocks using the SCADA
allowing an operator to run a drive, out of a sequence.

2.5.2 SCADA Control

This control allows the Control Room Operator to start and stop the motor with the “click” of a mouse.
All disabled interlock functions are automatically reset to ensure all interlocks are in place and associated
drives running before the motor starts.

2.5.3 Sequence Control

This control is for the Control Room Operator to start and stop the motor as part of a sequence of events
with the “click” of a mouse once the sequence he wants to start is selected. All disabled interlock
functions are automatically reset to ensure all interlocks are in place and the motors and units in that
sequence are ready to run.

2.5.4 Duty / Standby Control

This type of control is for the operator to select which pump he wants to run as his duty pump if there
are duty and standby pumps. This mode is not applicable in Field Control mode, i.e. if pump A is running

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as the duty pump and the operator wants to start pump B (for example to test it during maintenance
without stopping the duty pump), the operator can put pump B in Field control mode and start pump B
in the field.

2.6 VALVE CONTROL FACEPLATES:

There are two different types of valve control faceplates for ON / OFF type valves. These are shown
below.

Manual Operation from SCADA with Feedback

This type of valve control is from the SCADA and allows the operator to open and close the valve by the
“click” of a mouse. It is a manual operation performed by the control operator from the SCADA.
Proximity switches confirm if it is open or closed. There is a valve open fault and valve closed fault
indication to warn if the valve does not reach it intended position within a certain time.

Any interlocks associated with the valve are also shown on this faceplate.

Field Operation:

With all Solenoid type, pneumatic valves the operator is able to bypass the operation in the field by
removing the power from the solenoid and operating it via a mechanical bypass lever.

Valve symbols:

Control valves are represented by symbols are shown on the SCADA screen complete with their full valve
identification number.

The valves are animated with colour coding as follows:

Green - Open

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Red - Closed

Flashing blue and yellow - in transition - either opening or closing

Flashing red and yellow - faulty in transition - no closed or open signal

received before timeout expiry when being
opened or closed

PID Controllers:

Generic PID Controller Faceplate

A generic faceplate display pops-up whenever the user clicks on any defined valve symbol or a controller
symbol, which are located on the process detail displays. The initial location of this pop-up is the top-left
corner of the screen, and the user is able to relocate it if necessary, by using its top-bar.

The faceplate includes the following:

Indications

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 Controller tag as per the SCADA database.

 Bar graph and numeric values is displayed for the Controller's Measurement, Set point & Output
 Indications of output/valve directions: i.e. Close, Open
 Controller mode: AUTO or MANUAL
 Set point mode: LOCAL or REMOTE
 Alarm settings for the Measurement value: High-High, High, Low, and Low-Low
 Scale, which conforms to the SCADA database Engineering Units
 Engineering Units of the measurement.

Buttons

 AUTO/MANUAL: toggle to allow change of the controller mode. The 'bumpless transfer' logic is
done in the PLC.
 SETPOINT: set via either, a direct value typed in or UP/DN buttons (only in Auto mode). The
UP/DN buttons will raise or lower the set point respectively, by 1% of the span, each time they
are clicked upon. The minimum set point value is clipped to the process variable’s (PV)
Minimum engineering unit. The maximum set point value is clipped to the PV's maximum
engineering unit
 MANUAL OUTPUT: set via UP/DN buttons. (Only in Manual mode). The up/down buttons will
raise or lower the output respectively, by 1% each time they are clicked upon.
 ALARMS: Clicking on this button will call a pop-up display, which shows graphically and
numerically the HH, H, L, LL measurement tag alarms. Using a password the user is able to set
the alarm levels.

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3. DESIGN CRITERIA
3.1 INTRODUCTION
The Bisha Gold Process Plant was designed utilising proven Carbon In Leach (CIL) process technology to
produce saleable gold and silver bullion from the treatment of oxides ores. This will be followed by a
copper concentrator at the end of two years and then followed by a copper/zinc concentrator. The gold
plant was thus designed so that it will be easy to add on the additional equipment required for the two
concentrators.

The design criteria consist of the following sections:

 Crushing and ore stockpiling

 Grinding
 Pre-leach Thickening
 Carbon in Leach
 Cyanide Destruction
 Tailings disposal
 Acid Washing
 Elution
 Electrowinning & Smelting
 Carbon Regeneration
 Reagents mixing, storage and distribution
 Water and air services

The design criteria take into account the possibility of increased throughput either by ensuring that a
piece of equipment is adequately sized (crushing & stockpile) or sufficient room is allowed for to ensure
future expansion.

Data used in the design criteria has been derived from various references listed below.

References

Design Basis Document (Developed by both BMSC & SENET)

BMSC (Owner)

Feasibility Study Report

Metallurgical Test work (SGS Lakefield)

Vendor Data or Recommendation

SENET (design / judgement)

Industry Standard or Practice

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Handbook (Engineering Handbook)

Assumption based on experience

3.1.1 Site Data

Location Eritrea Owner

Elevation mASL 560 Owner

0
Temperature: min summer C 15 Owner
0
Max summer C 50 Owner
0
Min winter C 10 Owner
0
Max winter C 40 Owner

Evaporation: Annual Average mm Owner

Wind velocity: mean km/h Owner

Maximum km/h Owner

3.1.2 Ore Characteristics

Mining method Open Pit Owner

Max. Lump Size mm 800 Owner

Ore Head Grade Average:- g/t Au 8.0 Owner

g/t Ag 32.9 Owner

% Cu 0.10% Owner

% Zn 0.08% Owner

Moisture Content % 5% Owner

Ore specific SG 3.17 Testwork

3
Crushed ore bulk RD t/m 1.90 Assumption

MacPherson AG/SAG WI kWh/t 8.4 Testwork

Bond Rod Work Index kWh/t 12.7 Testwork

Bond Ball Work Index kWh/t 17.4 Testwork

Bond Abrasion Index 0.40 Testwork

JK Tech Parameters:- A 67.4 Testwork

b 1.62 Testwork

ta 1.14 Testwork

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3.1.3 Operating Schedule

Crushing

Annual throughput tpa 2,000,000 Owner

Days per year days 363 Owner

Days per week days 7 Owner

Hours per day hrs 24 Industry Practice

Maintenance hrs/week 8 Industry Practice

Utilisation % 67% Industry Practice

Utilised hours hrs/week 107.2 Calculated

Utilised hours hrs/Annum 5,574 Calculated

Calc crusher throughput tph 368 Calculated

Selected Crusher throughput tph 370

3.1.4 Grinding
Annual throughput tpa 2,000,000 Owner

Days per year days 365 Owner

Possible hours per annum hrs 8,760 Calculated

Maintenance hrs/week 6 Industry Practice

No. of relines per annum # 2 Industry Practice

Mill reline duration hrs/reline 36 Industry Practice

Available hours per annum hrs 8,376 Calculated

Mill utilisation % 96% Industry Practice

Mill operating hrs per annum hrs 8,041 Calculated

Overall utilisation/availability % 92% Calculated

Calc mill throughput tph 248.7 Calculated

Selected mill throughput tph 250 SENET

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3.1.5 Production
Gold Production

Annual throughput tpa 2,000,000 Owner

Feed Grade g/t Au 8.00 Owner

CIL Solution Tails ppm 0.015 Industry Practice

CIL % Solids % w/w 50 Owner

Leach Dissolution % 87.2 Testwork

Overall CIL Recovery % Au 87 Calculated

Gold Production kg/pa 13,922 Calculated

Silver Production

Feed Grade g/t Ag 32.9 Owner

CIL Solution Tails ppm 0.015 Industry Practice

CIL % Solids % w/w 50 Owner

Leach Dissolution % Ag 36 Testwork

Overall CIL Recovery % Ag 36 Calculated

Silver Production kg/pa 23,658 Calculated

3.1.6 Crushing & Stockpile Plant

ROM Bin

Maximum Lump Size mm 800 Owner

Construction SENET
3
Capacity m 100 SENET

Ore haulage truck capacity t 100 Owner

Method of dumping Truck & FEL Owner

ROM Grizzly Type Static Owner

ROM Grizzly spacing mm 800 x 800 Owner

Method of Handling Oversize Rockbreaker Owner

Apron Feeder

Type D7 Plate Feeder SENET

Width m 2.15 SENET

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Length m 8.062 SENET

Inclined/Horizontal Inclined SENET

Nominal Capacity tph 670 Calculated

Pitch mm Vendor

Drive Type Hydraulic Industry Practice

Motor Size kW 95.5 Vendor

Vibrating Grizzly Feeder (VGF)

Purpose Scalp off fines

VGF openings mm 125 SENET

VGF undersize % 32.5% Handbook

VGF undersize tph 218 Calculated

VGF oversize tph 452 Calculated

Primary Crusher

Type Jaw Industry Practice

Max Diagonal Lump Size Feed mm 1,131 Calculated

Feed tonnage tph 452 Calculated

Crusher P80 mm 150 Testwork

Crusher CSS mm 125 Vendor

Crusher Discharge & Stockpile Feed Conveyors

Design Dry Tonnage tph 670 Owner

Maximum Lump Size mm 250 Handbook

Moisture Content % 5 Owner

Design Wet tonnage tph 704 Calculated

Bulk Density t/m3 1.90 Calculated

SAG Mill Feed Conveyor

Design Dry Tonnage tph 450 Owner

Maximum Lump Size mm 250 Handbook

Moisture Content % 5 Owner

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Design Wet tonnage tph 473 Calculated

Bulk Density t/m3 1.90 Calculated

Stockpile

Type Open Industry Practice

Design Live ore storage days 1.5 Owner

Design Live ore storage t 9,000 Owner

Reclaim Method Pan Feeders Owner

No. of reclaim feeders # 4 Industry Practice

No. of feeders operating # 2 Industry Practice

Design Feeder capacity tph 450 Calculated

3.1.7 Grinding
Process Data

SAG BALL

Discharge type Grate Overflow

Grate openings mm 60 - Vendor

Dry Tonnage tph 250 250 SENET

Feed Size (F80) mm 125 2 Testwork

Product Size (P80) um 2,000 75 Testwork

Solids Discharge density % w/w 72 72 Senet

Closed/Open Circuit Open Closed Industry

Mill Size

Diameter (inside shell) mm 6,100 5,500 Vendor

Effective grinding length mm 3,000 8,300 Vendor

3
Effective volume inside worn liners m 84 176 Vendor

Effective feed opening mm 1,500 1,340 Vendor

Effective discharge opening mm 1,800 2,120 Vendor

Mill Speed

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Critical speed (worn liners) rpm 17.3 17.24 Vendor

Operating speed rpm 13.15 13.85 Vendor

Percent of critical speed % 76 75 Handbook

Main Drive

Installed Power kW 2,000 4,500 Vendor

Drive Type VSD Fixed Owner

Motor Speed rpm 992 992 Vendor

Charge

Max ball charge % v/v 8-10 30 Industry

Max total charge % v/v 15 38 Industry

Ball consumption kg/t 0.317 0.905 Calculated

Top Ball Size mm 125 40 Calculated

Mill Liners

Type Polymet Rubber Vendor

Liner consumption kg/t 0.063 0.116 Calculated

Trommel Screens

Pebbles as % of Fresh Feed % 25 - Industry

Solids screen undersize tph 250 625 Calculated

Mill discharge solids density % 72 72 Senet

3
Trommel spray water m /hr 15 15 Senet
3
Total slurry in trommel undersize m /hr 228 455 Calculated

Type of trommel panels PU PU Vendor

Screen apertures mm 12 x 50 10 x 50 Vendor

Screen open area % 40 40 Vendor

3 2
Screen drainage rate m /m /hr 400 400 Vendor
2
Required area m 0.63 1.26 Calculated

Selected trommel diameter m 1.799 2.44 Vendor

Selected trommel length m 1.817 2.49 Vendor

Height of advancing spiral m 0.15 0.20 Vendor

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2
Selected trommel area m 1.93 3.53 Vendor

Pebble Re-cycle Conveyor

Dry Tonnage tph 65 Estimate

Maximum Lump Size mm 60 Handbook

Moisture Content % 10 Estimate

Wet tonnage tph 71.5 Calculated

3
Bulk Density t/m 1.90 Calculated

3.1.8 Classification
Cyclone Feed & Products

Solids in cyclone overflow tph 250 Calculated

Solids in cyclone overflow % w/w 35 Industry Practice

Circulating Load % 250 Industry Practice

Solids in underflow tph 625 Calculated

Solids in underflow % w/w 72 Industry Practice

Solids feed to cyclone tph 875 Calculated

Solids in cyclone feed % 55.3 Calculated

3
Slurry feed to cyclones m /hr 983 Calculated

Design cyclone overflow P80 um 75

Mill Discharge Sump

3
Slurry feed to cyclones m /hr 983 Calculated

Sump residence time mins 2.4 Estimate

3
Calculated live volume m 39.3 Calculated
3
Selected sump volume m 40 SENET

Cyclones

Type Cluster

No. of operating cyclones # 4 Vendor

No. of standby cyclones # 2 Vendor

No. of blank cyclones # 2 Vendor

Operating pressure kPa 75 Vendor

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PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3.1.9 Preleach Thickening

Trash Screen Splitter Box
3
Cyclone overflow slurry m /hr 543 Calculated

Splitter residence time sec 12 Estimate

3
Calculated live volume m 1.81 Calculated
3
Selected sump volume m 2

Trash Screen

Type of screen Linear Owner/SENET

Cyclone overflow solids tph 250 Calculated

Cyclone overflow solids % w/w 35 Industry Practice

3
Cyclone overflow slurry m /hr 543 Calculated

Cyclone overflow solids % v/v 14.5 Calculated

Screen cloth aperture mm 600 x 650 Industry Practice

3 2
Screen flux m /m /hr 95 Handbook
2
Calculated screen area m 5.72 Calculated
2
Selected Screen m 6 Vendor

Screen kW kW 3 Vendor
3
Spray water m /hr 14 Handbook

Preleach Thickener Feed Sump

3
Trash screen underflow slurry m /hr 550.2 Calculated

Sump residence time mins 2.5 Estimate

3
Calculated live volume m 22.9 Calculated
3
Selected sump volume m 23 SENET

External Dilution Tank (Part of Thickener)

3
Trash screen underflow slurry m /hr 550.2 Calculated
3
Calculated live volume m 40 Calculated

Thickening

Type High rate

Solids throughput tph 250 Calculated

Bisha Plant Operating Manual 3-29

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Solids feed to thickener % w/w 35 Testwork

2
Specific settling area t/m /hr 0.3 Testwork
2
Calculated thickener area m 833 Calculated

Calculated thickener diameter m 32.6 Calculated

Selected thickener diameter m 35 Supplier

Percentage Solids in underflow % w/w 50 Testwork

3
Water in thickener underflow m /hr 250 Calculated
3
Water in thickener overflow m /hr 214 Calculated

Thickener overflow tank residence time minutes 9 Selected

3
Thickener overflow tank m 37.5 Calculated
3
Thickener overflow tank m 40.0 Selected

3.1.10 Leach & CIL

Feed Characteristics

Solids Flow to Leach/CIL tph 250 Calculated

Solids % by weight % w/w 50 Testwork

Solids SG 3.17 Testwork

3
Slurry flow rate m /hr 328.9 Calculated
3
Slurry SG t/m 1.52 Calculated

Feed Grade g/t Au 8.00 Owner

Feed Grade g/t Ag 32.9 Owner

Total leach residence time hrs 24 Testwork

Required leach efficiency % Au 87.2 Testwork

Leach Splitter Box

3
Leach feed slurry m /hr 328.9 Calculated

Splitter residence time sec 45 Estimate

3
Calculated live volume m 4.1 Calculated
3
Selected sump volume m 5.0 SENET

Leach Tank Sizing

Residence time hrs 4 Testwork

Bisha Plant Operating Manual 3-30

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Air hold up allowance % 8 Industry Practice

3
Calculated leach volume m 1,430 Calculated

Number of leach tanks # 1 Industry Practice

3
Selected leach tank volume m 1,430 SENET

CIL Tank Sizing

Residence time hrs 20 Calculated

Air hold up allowance % 8 Industry Practice

3
Calculated volume required m 7,149 Calculated

Number of tanks # 8 Vendor

3
Volume per tank m 894 Calculated
3
Selected tank volume m 900 SENET

CIL/Carbon Design

Au Ag Combined

Leach Feed Grade g/t 8.00 32.90 40.90

Leach/CIL Dissolution % 87.2 36 46

Tails Grade- Solids g/t 1.024 21.056 22.080

Tails Grade-Solution g/t 0.015 0.015 0.030

Metal in solution ppm 6.961 11.829 18.790

Upgrade ratio 576 576 576

Design incremental C loading g/t 4,010 6,814 10,823

Eluted C value g/t 50 50 100

Loaded C value g/t 4,060 6,864 10,923

Metal pulled out of circuit g/day 41,766 70,974 112,830

Equivalent amount of carbon t C/day 9.57 9.57 9.57

Selected C advance rate t C/day 12 12 12

Loaded Carbon Transfer

Transfer Method Recessed Impeller Vertical Spindle Pump

Transfer time hrs 1.5 SENET

Quantity of carbon per batch t 6 Calculated

Bisha Plant Operating Manual 3-31

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Number of batches per day # 2 SENET

Carbon transfer rate tph 4 Calculated

Design carbon concentration g/L 20 SENET

3
Slurry flow during loaded C transfer m /hr 200 Calculated

Loaded Carbon Screen Sizing

Type of screen Linear Owner/SENET

Solids flow % w/w 50 Calculated

3
Slurry flow m /hr 200 Calculated

Solids % v/v 24 Calculated

Screen cloth aperture mm 600 x650 Industry Practice

3 2
Screen flux m /m /hr 40 Handbook
2
Calculated screen area m 5 Calculated
2
Selected Screen m 6 Vendor

Screen kW kW 3 Vendor
3
Spray water m /hr 14 Handbook

Intertank Carbon Transfer

Transfer Method Recessed Impeller Vertical Spindle Pump

Transfer time hrs 1.5 Vendor

Quantity of carbon per batch t 6 Vendor

Carbon transfer rate tph 4 Calculated

Number of batches per day # 2 SENET

Design carbon concentration g/L 20 Vendor

3
Slurry flow during C transfer m /hr 200 Calculated

Inter-stage Screen Sizing

3
Leach/CIL Flow rate m /hr 328.9 Calculated
3
Intertank carbon transfer m /hr 200 Calculated
3
Eluted carbon transfer m /hr 48.6 Calculated
3
CIL Spillage m /hr 64.7 Assumed
3
Elution Spillage m /hr 40 Assumed

Bisha Plant Operating Manual 3-32

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Barren Electrolyte m /hr 14.53 Calculated
3
Total Flow m /hr 697 Calculated

Selected screen aperture µm 800 Industry Practice

% Open area % 22.2 Vendor

3 2
Screen flux m /m /hr 100 Vendor
2
Screen area required m 6.91 Calculated
2
Selected screen m 7 Vendor

3.1.11 Detoxification
Tails (Carbon Safety) Screen

Type of screen Linear Owner/SENET

CIL solids flowrate tph 250 Calculated

CIL solids % w/w 50 Testwork

3
Water in CIL tails m /hr 250 Calculated

Feed solids to tails screen % v/v 20 Assumption

3
Required dilution water m /hr 58 Calculated
3
Slurry feed rate to screen m /hr 652 Calculated

Screen cloth aperture mm 800 x 800 Industry Practice

3 2
Screen flux m /m /hr 110 Handbook
2
Calculated screen area m 3.58 Calculated
2
Selected Screen m 6 Vendor

Screen kW kW 3 Vendor
3
Spray water m /hr 14 Handbook

Detox Feed Sump

Solids from tails screen tph 250 Calculated

Solids from tails screen % w/w 43.1 Calculated

Detox feed density % w/w 40 Industry Practice

3
Detox Sump dilution water m /hr 45.5 Calculated
3
Slurry flow to detox m /hr 453.9 Calculated

Sump residence time mins 2 Assumption

Bisha Plant Operating Manual 3-33

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Minimum live volume m 15.13 Calculated
3
Selected sump volume m 16 SENET

Detox Splitter Box

3
Detox feed slurry m /hr 453.9 Calculated

Splitter residence time sec 45 Estimate

3
Calculated live volume m 0.6 Calculated
3
Selected sump volume m 1 SENET

Detox Tank Sizing

Residence time hrs 3 Testwork

Air hold up allowance % 15 Industry Practice

3
Calculated pre-leach volume m 1,601 Calculated

Number of tanks # 2 Vendor

3
Volume per tank m 801 Calculated
3
Selected tank volume m 810 SENET

WAD cyanide in detoxified tails mg/L 10 Industry Practice

Tails Thickener Feed Sump

3
Slurry from detox m /hr 453.9 Calculated

Sump residence time mins 2 Estimate

3
Calculated live volume m 15.1 Calculated
3
Selected sump volume m 16 SENET

Tails Thickening

Type High rate

Solids throughput tph 250 Calculated

Solids feed to thickener % w/w 40 Testwork

2
Specific settling area t/m /hr 0.2 Testwork
2
Calculated thickener area m 1250 Calculated

Calculated thickener diameter m 39.9 Calculated

Selected thickener diameter m 45 Vendor

Percentage Solids in underflow % w/w 50-55 Testwork

Bisha Plant Operating Manual 3-34

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Water in thickener underflow m /hr 250 Calculated
3
Water in thickener overflow m /hr 125 Calculated

3.1.12 Acid Wash

Acid Wash Column

Carbon batch size to be washed t 6 Vendor

Acid type HCl Industry Practice

Acid strength % 3 Industry Practice

3
Carbon bulk density t/m 0.45 Industry Practice

Column Material of construction FRP Owner/SENET

Column working pressure kPa 150 Industry Practice

Column design pressure kPa 250 Industry Practice

1 BV m3 13.3 Calculated

Flow direction Upflow Industry Practice

Superficial velocity m/hr 17.7 Calculated

Type of carbon mesh 8 x 16 Vendor

Bed expansion % 1 Handbook

3
Bed expansion volume m 0.1 Calculated
3
Minimum column volume m 13.5 Calculated

Column diameter m 1.385 Calculated

Height of dished end m 0.46 Calculated

3
Volume of dished end m 0.39 Calculated
3
Volume of straight portion of column m 13.1 Calculated

Length of straight portion m 8.74 Calculated

3
Total volume of column m 13.9 Calculated
3
Selected column volume m 14 SENET

Total height of column m 9.7 Calculated

Column L/D ratio 7.0 Calculated

Acid Wash & Rinsing

Acid wash flowrate BV/hr 2 Industry Practice

Bisha Plant Operating Manual 3-35

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Acid wash flowrate m /hr 26.7 Calculated

Acid wash time hrs 1 Industry Practice

Rinsing fluid raw water Industry Practice

Rinsing fluid flowrate BV/hr 2 Industry Practice

3
Rinsing fluid flowrate m /hr 26.7 Calculated

Rinsing time hrs 1.5 Industry Practice

Time to load column hrs 1.5 Owner/SENET

Total acid wash cycle hrs 3.0 hrs Calculated

Acid Wash Tank

Minimum tank volume BV 1 Industry Practice

3
Minimum tank volume m 13.3 Calculated
3
Selected tank volume m 14 SENET

Material of construction FRP Owner/SENET

Acid Wash Column Unloading

Unloading method Hydraulic SENET

Unloading time hrs 1 Owner/SENET

Carbon flowrate tph 6 Calculated

% C in slurry % 20 Industry Practice

Slurry flowrate tph 51.4 Calculated

Transfer water flowrate m3/hr 41.1 Calculated

Pressurizing water as % of transfer water % 20 Industry Practice

3
Pressurizing water m /hr 8.2 Calculated
3
Transport water m /hr 32.9 Calculated

3.1.13 Elution
Copper Stripping
0
Operating Temperature C Ambient Industry Practice

Operating pressure kPa Atmospheric Industry Practice

Cyanide concentration % 2 Industry Practice

Strip solution volume BV 1 Industry Practice

Bisha Plant Operating Manual 3-36

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Strip time hrs 0.5 Owner/SENET

Strip efficiency (copper removal) % 90 Industry Practice

Elution Cycle

Elution Method AARL Owner/SENET

0
Operating Temperature C 120 Industry Practice

Operating pressure kPa 350 Industry Practice

Flow through column-nominal BV/hr 2 Industry Practice

Flow through column-maximum BV/hr 3 Industry Practice

Carbon transfer method Hydraulic SENET

Time to load column hrs 1 Industry Practice

Heat up contents to temp hrs 2 Industry Practice

Caustic cyanide soak hrs 0.50 Industry Practice

Cyanide concentration % 2 Industry Practice

Caustic concentration % 3 Industry Practice

No. of BV for Water wash BV 9 Industry Practice

Water wash period hrs 4.5 Calculated

Cooling of column contents BV 1 Industry Practice

Cooling of column contents hrs 0.5 Calculated

Column unloading hrs 1 Industry Practice

Total elution cycle hrs 9.5 Calculated

Strip Batch Sizing

Au Ag Combined

Design carbon loading g/t 4,060 6,864 10,923

Design Eluted Carbon value g/t 50 50 100

Metal per elution kg 24.1 40.9 64.9

Metal production per month kg 1,160 1,972 3,132

No. of Elution per day # 2 2 2

No. of elution per month # 60 60 60

Minimum strip batch size t 5.7 5.7 5.7

Bisha Plant Operating Manual 3-37

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Selected strip size t 6 6 6

Elution Column

Carbon batch size to be washed t 6 Vendor

Column Material of construction 304 SS Owner/SENET

Column working pressure kPa 350 Industry Practice

Column design pressure kPa 450 Industry Practice

1 BV m3 13.3 Calculated

Flow direction Upflow Industry Practice

Superficial velocity m/hr 17.7 Calculated

Type of carbon 8 x 16 Owner/SENET

Bed expansion % 1 Handbook

3
Bed expansion volume m 0.1 Calculated
3
Minimum column volume m 13.5 Calculated

Column diameter m 1.385 Calculated

Height of dished end m 0.46 Calculated

3
Volume of dished end m 0.39 Calculated
3
Volume of straight portion of column m 13.1 Calculated

Length of straight portion m 8.74 Calculated

3
Total volume of column m 13.9 Calculated
3
Selected column volume m 14 SENET

Total height of column m 9.7 Calculated

Column L/D ratio 7.0 Calculated

Eluant Tank

Minimum tank volume BV 1 Industry Practice

3
Minimum tank volume m 13.3 Calculated
3
Selected tank volume m 14 SENET

Material of construction Carbon Steel Industry Practice

Elution Column Unloading

Unloading method Hydraulic SENET

Bisha Plant Operating Manual 3-38

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Unloading time hrs 1 Owner/SENET

Carbon flowrate tph 6 Calculated

% C in slurry % 20 Industry Practice

Slurry flowrate tph 51.4 Calculated

3
Transfer water flowrate m /hr 41.1 Calculated

Pressurizing water as % of transfer water % 20 Industry Practice

3
Pressurizing water m /hr 8.2 Calculated
3
Transport water m /hr 32.9 Calculated

Thermic Oil Heater Sizing

Specific heat capacities:

0
Carbon kcal/kg/ C 0.24 Handbook
0
Water kcal/kg/ C 1.00 Handbook
0
304 SS kcal/kg/ C 0.1201 Handbook
0
Carbon Steel kcal/kg/ C 0.12 Handbook

First Stage Heating

0
Eluant initial temp C 25 SENET
0
Eluant final temperature C 90 Vendor

Mass of eluant heated up kg 14,000 Calculated

Eluant tank steel mass kg 1,259 Calculated

0
Initial column & contents temp C 25 SENET
0
Final column & contents temp C 120 Industry Practice

Mass of carbon kg 6,000 Vendor

Mass of column kg 1,985 Calculated

Second Stage Heating

0
Wash water initial temp C 25 SENET
0
Eluate exiting column C 110 Vendor
0
Eluate temp exiting reclaim heat exch. C 85 Vendor
0
Wash water exiting reclaim heat exchanger C 50 Vendor
0
Wash water exiting primary heat exch. C 115 Vendor

Bisha Plant Operating Manual 3-39

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Mass of water kg 106, 000 Calculated

Heat Calculations

First stage kW kW 628 Vendor/Calculated

Second stage kW kW 1,798 Vendor/Calculated

Selected No. of heaters # 2 Vendor

Fuel Type Diesel Owner/SENET

3.1.14 Electrowinning
Pregnant Tank Sizing

Total bed volumes per elution BV 10 Calculated

3
Volume per BV m 13.3 Calculated
3
Minimum preg tank volume m 133 Calculated

Allowance 20% 20 Assumption

3
Selected preg tank volume m 160 Calculated

No. of elutions per day # 2 Vendor

No. of preg tanks required # 2

Barren Tank Sizing

Total bed volumes per elution BV 10 Calculated

3
Volume per BV m 13.3 Calculated
3
Minimum barren tank volume m 133 Calculated

Allowance 20% 20 Assumption

3
Selected tank volume m 160 Calculated

No. of elutions per day # 2 Vendor

Time to empty barren tank hrs 11 Assumption

3
Barren flowrate m /hr 14.53 Calculated

Electrowinning Time Calculations

Au Ag Combined

Elution batch size tC 6 6 6

Carbon Loading g/t 4,060 6,854 10,923

Eluted Carbon Loading g/t 50 50 100

Bisha Plant Operating Manual 3-40

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Metal production g 24,057 40,881 64,938

Running time per day hrs 22 22 22

No. of elutions per day # 2 2 2

Electrowinning time per batch hrs 11 11 11

3
Volume of preg solution per batch m 133 133 133

Preg solution grade at start ppm 180 307 487

Barren solution ppm 5 5 5

Overall efficiency % 97 98 98

Single pass efficiency % 70 70 70

3
Total preg feed to cells m /hr 70 70 70

Calculated electrowinning time hrs 9.76 11.20 10.57

Determination of No. of Cells

3
Actual Pregnant solution flow m /min 1.17 Calculated

Recommended flow m³/(min.m²) 0.40 Industry Practice

Selected cathode dimensions mm 700 x 700 Vendor

Cathode Area m² 0.49 Calculated

Required preg flowrate m³/min 0.196 Calculated

No. of Double Cells # 5.65 Calculated

Selected No. of Double Cells # 6 Vendor

Cell Current Calculations

Au Ag

Atomic weight g/mol 197 108

1 Faraday is equivalent to Coulombs 96,487 96,487

Oxidation state of cyanide complex 1 1

Coulombs/Mole Coulombs/mole 96,487 96,487

Coulombs per gram Coulombs/g 490 894

Metal per Coulomb g/Coulomb 0.00204 0.00112

Couloms/Amp-hour 3,600 3,600

Metal/Amp-hour g/Amp-hour 7.350 4.025

Bisha Plant Operating Manual 3-41

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Current Efficiency % 13 13

Coulombs/gram including current efficiency 3,768 6,881

Metal production g 24,057 40,881

Total Coulombs needed C 9.06E+07 2.81E+08

Electrowinning time hrs 11 11

Total Cell Amps A 2,248 6,976

Header Tank Sizing

3
Flow to cells m /hr 180 Calculated

Number of Header Tanks # 2 SENET

Residence time mins 0.5 SENET

3
Minimum tank volume m 0.75 Calculated
3
Selected tank volume m 1.0 SENET

Gold Sludge Filter Sizing

Maximum Number of Elutions # 4 Calculated

Gold Produced per Elution kg 64.9 Calculated

Gold Produced per Filtration kg 259.8 Calculated

% Of Gold in Sludge % 65% Industry Practice

Dry Weight of Sludge kg 399.6 Calculated

% Moisture in Filter Product % 20% Industry Practice

Wet weight (Filter Product) kg 499.5 Calculated

% Solids Feed to Filter % 15 SENET

Solution kg 2,265 Calculated

Solution SG t/m³ 1.00 Industry Practice

Solution Volume Litres 2,265 Calculated

Solids Bulk SG t/m³ 9.8 Industry Practice

Solids Volume Litres 40.78 Calculated

Total Volume of Sludge Litres 2,305 Calculated

Slurry SG t/m³ 1.16 Calculated

Particle Size µm <100 Industry Practice

Bisha Plant Operating Manual 3-42

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3.1.15 Regeneration
Kiln type Horizontal Vendor

Heating method Diesel Fired Owner/SENET

Temperature Control Automatic Vendor

0
Regeneration temperature C 700-750 Industry Practice

Eluted carbon batch size tC 6 Calculated

No. of elutions per day # 2 Vendor

Regeneration batch size tC 12 Calculated

Regeneration time hrs 20 Industry Practice

Regeneration rate kg/hr 600 Calculated

Kiln Feed Hopper Sizing

Eluted carbon batch size tC 6 Vendor

No. of elutions per day # 2 Vendor

Hopper batch size tC 12 Calculated

3
Minimum volume of hopper m 27 Calculated

Regenerated Carbon Screen

Solids Feed tph C 0.60 Calculated

% Solids % 50% SENET

Slurry flow m3/hr 1.78 Calculated

Type of deck W/Wire SS

Profile M28 Handbook

Size mm 1.0 Vendor

Open area % 22.2 Handbook

Drainage rate m3/hr/m2 80 Handbook

Minimum screen area m2 0.022 Calculated

Regenerated Carbon Transfer Vessel

Regenerated carbon batch size tC 3 Calculated

3
Minimum volume of hopper m 7 Calculated/SENET

Carbon Transfer Tank

Bisha Plant Operating Manual 3-43

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Water flow during carbon transfer m /hr 41.1 Calculated

Residence time hrs 1 SENET

Allowance % 25 SENET
3
Tank volume m 51.4 Calculated

Carbon attritioning tank

Carbon batch size tC 1 Owner/SENET

Minimum tank live volume m3 2.2 Calculated

Carbon Fines Handling

Type of equipment Disc filter Vendor

Filtered fine carbon product Briquettes Testwork

Filtered fine carbon % moisture % 50% Testwork

Batch size kg C 150 Calculated

Batches per day # 2 Calculated

3.1.16 Goldroom
Calcining/Drying

Type of furnace 6 tray Industry Practice

Heating method Electric Owner/SENET

0
Operating Temperature C 700-750 Industry Practice
0
Maximum Temperature C 1,000 Vendor

Smelting Furnace

Type of furnace Induction Owner/SENET

Type of crucible TPX 400 Vendor

Crucible Capacity Litres 24 Vendor

Bullion Mold Capacity kg 30-32 Vendor

3.1.17 Lime Silo & Slaking System

General Information on type of lime

Delivery Bulk Bags Vendor

Type of lime Quick lime Vendor

Physical form Fine (Powder) Vendor

Bisha Plant Operating Manual 3-44

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Available CaO 90-92% CaO Vendor

3
Apparent packed SG 0.99 t/m Vendor

Non slakeables 10% Industry Practice

Nominal size 100 µm Vendor

Maximum particle 3 mm Vendor

Silo Sizing

Oxides Supergene Primary

Ore treatment rate tph 250 250 250 Calculated

CaO consumption kg/t 3.0 5.1 4.0 Testwork

CaO consumption tpd 18.0 30.6 24 Calculated

Bulk lime consump tpd 19.6 33.3 26.1 Calculated

Storage capacity days 3 3 3 Owner/SENET

Storage capacity t 58.70 99.78 78.26 Calculated

3
Storage Capacity m 59.3 100.8 79.1 Calculated
3
Selected silo size m 100 SENET

Lime Silo Loading System Sizing

3
Lime silo capacity m 100 SENET

Lime silo capacity t 101 Calculated

Loading time per day hrs 10 Owner/SENET

Loading rate tph 10.1 Calculated

Milk of Lime Storage & Dosing Tank Sizing

Oxides Supergene Primary

CaO consumption kg/t 3.0 5.1 4.0 Testwork

Bulk Lime consump t/hr 0.815 1.386 1.087 Calculated

Lime in slurry % 12 12 12 SENET

3
Slurry SG t/m 1.09 1.09 1.09 Calculated
3
Slurry flowrate m /hr 5.73 10.60 8.31 Calculated

Holding capacity days 1 1 1 Owner/SENET

3
Calculated tank size m 126 233 183 Calculated

Bisha Plant Operating Manual 3-45

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Selected tank size m 240 SENET

Lime Slaker Sizing

Slaking time hrs 6.0 Owner/SENET

3
Slaked lime volume m 240 Calculated
3
Slaked Lime slurry density t/m 1.09 Calculated

Lime solids % 12 SENET

Lime in slurry (solids) t 31.39 Calculated

% of unslakeables in feed % 10 Industry Practice

Lime feed to slaker tph 5.81 Calculated

3
Slaking water flowrate m /hr 43 Calculated

3.1.18 Cyanide
General information

Delivery 1t Bulk Bags in Boxes Vendor

Physical form Briquettes Vendor

Available NaCN % 98.5 Vendor

3
Bulk density t/m 0.85 Vendor

Cyanide Make Up Tank

Leach/CIL cyanide consumption kg/t 0.50 Testwork

Leach/CIL cyanide consumption kg/day 3,000 Calculated

No. of elutions day # 2 Vendor

Cyanide strength in eluant % 2 Industry Practice

3
Eluant tank volume m 14 Calculated

Elution Cyanide consumption/ day kg 560 Calculated

Combined Cyanide Cons kg/day 3,560 Calculated

Mixing strength % 25 SENET

3
Cyanide solution density t/m 1.128 Industry Practice

Mixing tank capacity days 2 Owner/SENET

Calculated no. of cyanide bags per make up 6.8 Calculated

Selected no. of bags per mix # 7 SENET

Bisha Plant Operating Manual 3-46

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

3
Minimum make up volume m 24.8 Calculated
3
Selected make up volume m 25 SENET

Cyanide Storage & Dosing Tank

Required storage volume days 2 Owner/SENET

3
Daily cyanide solution usage m 11.96 Calculated
3
Minimum volume of storage tank m 24.82 Calculated
3
Selected storage tank volume m 25 SENET

3.1.19 Caustic Soda

General information

Delivery 25kg Bags Vendor

Physical form Pearls Vendor

Available NaOH % 98.5 Vendor

Caustic Tank

No. of elutions day # 2 Vendor

Caustic strength in eluant % 3 Industry Practice

3
Eluant tank volume m 14 Calculated

Elution Caustic consumption per day kg 840 Calculated

Caustic strength during electrowinning % 0.5 Industry Practice

3
Electrowinning volume m 133 Calculated

Electrowinning caustic cons. per day kg 247 Calculated

HCl strength % 3 Industry Practice

3
Volume of HCl to be neutralised m 14 Calculated

Neutralize every # of acid washes # 4 Industry Practice

Equivalent daily caustic usage (neutralize) kg 460 Calculated

Combined Caustic Cons kg/day 1,794 Calculated

Mixing strength % 20 Industry Practice

3
Cyanide solution density t/m 1.24 Industry Practice

Caustic tank capacity days 2 Owner/SENET

Calculated no. of caustic bags per make up 143.5 Calculated

Bisha Plant Operating Manual 3-47

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

Selected no. of bags per mix # 144 SENET

3
Minimum make up volume m 14.52 Calculated
3
Selected make up volume m 15 SENET

3.1.20 Hydrochloric Acid

Delivery form Drums Vendor

Amount in drum L 200 Vendor

Delivered HCl strength % 33 Vendor

3
Delivered HCl SG t/m 1.15 Industry Practice

HCl strength in acid wash tank % 3 Industry Practice

3
Volume of acid wash tank m 14 Calculated
3
33% HCL required per make up m 1.107 Calculated

Method of transfer from drum Drum pump SENET

Transfer time mins 30 SENET

3
Drum pump flowrate m /hr 2.21 Calculated

3.1.21 Activated Carbon

Delivery form Bulk Bags Vendor

Quantity per bag t 0.50 Vendor

Type of carbon 8 x 16 Owner/Vendor

Size mm 0.991 x 2.36 Calculated

Carbon consumption g/t 50 Industry Practice

Consumption kg/day 275 Calculated

3.1.22 Flocculant Plant

Delivery 25kg Bags Vendor

Total Consumption kg/t 72 Testwork

Consumption kg/day 432 Calculated

Make up strength % w/w 0.25 Industry Practice

No. of make ups per day # 6 Owner/SENET

Diluted concentration % w/w 0.025 Industry Practice

Bisha Plant Operating Manual 3-48

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3.1.23 Detoxification Reagents

General Information

Residual cyanide in tailings g/L 0.150 Owner/Vendor

Cyanide in detoxified tails g/L 0.002 Owner/Vendor

Cyanide destruction g/L 0.148 Calculated

Solids in tailings tph 250 Calculated

Solids in tailings % w/w 40 Industry Practice

Solution in tailings m3/hr 375 Calculated

Solution in tailings m3/day 8,261 Calculated

Sodium Metabisulphite Make Up Tank

Delivery 1t Bulk Bags Vendor

Consumption g/L NaCN 3.4 Testwork

Cons kg/day 4,157 Owner/Vendor

Mixing strength % 25 Owner/Vendor

3
Cyanide solution density t/m 1.08 Industry Practice

Mixing tank capacity days 1 Owner/SENET

Calculated no. of cyanide bags per make up 4.5 Calculated

Selected no. of bags per mix # 5 SENET

3
Minimum make up volume m 18.52 Calculated
3
Selected make up volume m 20 SENET

Sodium Metabisulphite Storage Tank

Required storage volume days 1 Owner/SENET

3
Daily solution usage m 16.8 Calculated
3
Minimum volume of storage tank m 16.8 Calculated
3
Selected storage tank volume m 20 SENET

Copper Sulphate Make Up Tank

Delivery 1t Bulk Bags Vendor

Consumption g/L NaCN 0.68 Owner/Vendor

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Cons kg/day 826 Calculated

Mixing strength % 15 Owner/Vendor

3
Cyanide solution density t/m 1.17 Industry Practice

Mixing tank capacity days 1 Owner/SENET

Calculated no. of cyanide bags per make up 0.8 Calculated

Selected no. of bags per mix # 1 SENET

3
Minimum make up volume m 5.72 Calculated
3
Selected make up volume m 30 SENET

Copper Sulphate Storage Tank

Required storage volume days 2 Owner/SENET

3
Daily solution usage m 5.16 Calculated
3
Minimum volume of storage tank m 10.3 Calculated
3
Selected storage tank volume m 30 SENET

3.1.24 Plant Diesel Storage

Main Plant Storage Tank

Diesel SG 0.85 Industry Practice

Thermic oil heaters time on high fire hrs 2 Vendor

Thermic oil heaters on low fire hrs 5 Vendor

3
Diesel consumption on high fire-thermic m /hr 0.05 Vendor
3
Diesel consumption on low fire-thermic m /hr 0.03 Vendor
3
Diesel consumption per elution- thermic m 0.217 Calculated

Regen kiln heaters time on high fire hrs 2 Vendor

Regen kiln heaters on low fire hrs 18 Vendor

3
Diesel consumption on high fire-regen m /hr 0.09 Vendor
3
Diesel consumption on low fire-regen m /hr 0.043 Vendor
3
Diesel consumption per elution- regen m 0.954 Calculated

No. of elutions per day # 2 Owner/Vendor

3
Total diesel consumption per day m /day 1.561 Calculated

Storage capacity days 10 Owner/SENET

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3
Storage Tank m 16 Calculated

Diesel Header Tank

3
Total diesel consumption m /day 1.561 Calculated
3
Total diesel consumption m /hr 0.071 Calculated

Required residence time hrs 12 Industry Practice

3
Minimum volume m 0.85 Calculated
3
Selected tank volume m 1.0 SENET

3.1.25 Plant Air Requirements

Plant Compressor Sizing
3 3
Leach/CIL air demand Nm /hr/1000m 72 Industry Practice

No. of CIL Tanks # 5 Calculated

3
Tank Volume m 1,430 Calculated
3
Total Leach/CIL Air requirements Nm /hr 515 Calculated
3 3
Detox air demand Nm /hr/1000m 1,000 Industry Practice

No. of Detox Tanks # 2 Owner/SENET

3
Tank Volume m 810 Calculated
3
Total Detox Air requirements Nm /hr 1,620 Calculated
3
Plant General Nm /hr 100 Industry Practice
3
Lime area Nm /hr 40 Vendor
3
Milling area Nm /hr 50 Vendor
3
Plant Workshops Nm /hr 40 Industry Practice
3
Total compressed air Nm /hr 2,364 Calculated
3
Selected compressor size Nm /hr 3,000 SENET

Compressor Discharge Pressure kPa 750 Industry Practice

Instruments air

Instruments air demand Nm3/hr 200 Calculated

Compressor Discharge Pressure kPa 750 Industry Practice

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3.1.26 Water Balance

During
During Dry Season During Wet Season Commissioning

Average Average Average

Monthly Hourly Monthly Hourly Monthly Hourly Monthly
Usage Demand Usage Demand Usage Demand Usage

hrs m3/h m3 m3/h m3 m3/h m3

Process Water: Before Preleach Thickening

Mill Flush/Seal Water 670 10.0 6,701 10.0 6,701 10.0 6,701

SAG Mill Feed Dilution Water 670 113.8 76,273 113.8 76,273 113.8 76,273

Water in Lime Slurry 670 5.5 3,685 5.5 3,685 5.5 3,685

SAG Mill Trommel Screen Spray Water 670 15.0 10,051 15.0 10,051 15.0 10,051

Ball Mill Feed Dilution Water 670 0.0 0 0.0 0 0.0 0

Ball Mill Trommel Spray Water 670 15.0 10,051 15.0 10,051 15.0 10,051

Mill Sump Dilution Water 670 307 205,917 307.3 205,917 307.3 205,917

Trash Screen Spray Water 670 14.0 9,381 14.0 9,381 14.0 9,381

Mill Hosing Water 60 6.0 360 6.0 360 6.0 360

Total Process Water Before Preleach 322,419 322,419 322,419

Raw Water Before Preleach Thickener

Gland Water (Mill Discharge, Preleach feed &

Preleach thick UF Pumps) 670 3.00 2,010 3.0 2,010 3.0 2,010

Gravity Fluidising Water 670 0.00 0 0.0 0 0.0 0

ILR Reagents Make Up 0 0 0

ILR Rinse Water 0 0 0

ILR Tails Transport Water 30 0.00 0 0.0 0 0.0 0

Floc Make-up Water 91 60.00 5,475 60.0 5,475 60.0 5,475

Floc Dilution Water 670 36.0 24,123 36.0 24,123 36.0 24,123

Total Raw Water Before Preleach Thickener 31,608 31,608 31,608

Preleach Thickener

Total water to Preleach Thickener 354,027 354,027 354,027

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Total solids to Preleach thickener 166,667 166,667 166,667

% Solids in Thickener U/F 50% 50% 50%

Water in thickener U/F 166,667 166,667 166,667

Water in Preleach Thickener O/F 187,361 187,361 187,361

PROCESS WATER-REST OF PLANT

Loaded C Scr Spray Water 120 14.0 1,680 14.0 1,680 14.0 1,680

Interstage Screen Wash Water 120 1.0 120 1.0 120 1.0 120

Regen Screen Spray Water 600 4.8 2,880 4.8 2,880 4.8 2,880

Acid Washed Carbon Transfer Water 40 32.9 1,315 32.9 1,315 32.9 1,315

Regen Carbon Transfer Water 10.0 32.9 329 32.9 329 32.9 329

Tails Scr Spray Water 670 14.0 9,381 14.0 9,381 14.0 9,381

Tails Safety Screen Dilution Water 670 51.5 34,481 51.5 34,481 51.5 34,481

Tails Dilution (Before Detox) 670 59.5 39,898 59.5 39,898 59.5 39,898

CIL Hosing Water 60 6.0 360 6.0 360 6.0 360

Tailings Hosing Water 60 6.0 360 6.0 360 6.0 360

Acid Wash Hosing Water 60 6.0 360 6.0 360 6.0 360

Goldroom Hosing Water 60 6.0 360 6.0 360 6.0 360

Reagents Hosing Water 60 6.0 360 6.0 360 6.0 360

Total Process water-Other Areas 91,884 91,884 91,884

Raw Water-Other Areas

Acid Wash Make-up Water 7.0 25.79 181 25.8 181 25.8 181

Acid Wash Rinse Water 60 26.67 1,600 26.7 1,600 26.7 1,600

Elution Make-up Water 180.0 26.67 4,800 26.7 4,800 26.7 4,800

Cathode High Pressure Water 220 1.00 220 1.0 220 1.0 220

Cyanide Make-up Water 8 50.00 375 50.0 375 50.0 375

Caustic Make-up Water 8 30.00 225 30.0 225 30.0 225

Detox Tails Gland Service Water 670 1 670 1.0 670 1.0 670

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Tails Thickener Floc Dilution Water 670 36.0 24,123 36.0 24,123 36.0 24,123

Total Raw Water-Other Areas 32,193 32,193 32,193

Tailings Thickener

Total water to Tails Thickener 290,744 290,744 290,744

Total solids to Tails Thickener 166,667 166,667 166,667

% Solids in Thickener U/F 50% 50% 50%

Water in thickener U/F 166,667 166,667 166,667

Water in Tailings Thickener O/F 124,077 124,077 124,077

COMBINED PROCESS WATER RECOVERED 311,438 311,438 311,438

TOTAL PROCESS WATER REQUIREMENTS 414,303 414,303 414,303

Raw Water Top Up to Process 102,865 102,865 102,865

Raw Water Top Up to Process-m3/hr 154 154 154

Non Recoverable Raw Water

Hard Rock Crushing Dust Suppression 465 7 3,252 7.0 3,252 7.0 3,252

Stockpile Tunnel Dust Suppression 670 3 2,010 3.0 2,010 3.0 2,010

Lime Safety Shower 6 6 6

CIL Safety Showers 6 6 6

Tailings Safety Showers 6 6 6

Acid Wash Safety Showers 6 6 6

Elution Safety Showers 6 6 6

Goldroom Safety Showers 6 6 6

Reagents Safety Shower 6 6 6

Ablution Buildings 720 6.25 4,500 6.25 4,500 6.3 4,500

Total Non-Recoverable Raw Water 9,804 9,804 9,804

Total Raw For Raw Water Needs 670 73,606 73,606 73,606

Ave. Raw Water Flow Rate 110 110 110

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Total Plant Raw Water 176,471 176,471 176,471

Total Plant Raw Water-m3/hr 263 263 263

Water Consumption m3/t 1.0588 1.0588 1.0588

3.1.27 Water Ponds

Field 1 Field 2 Field 3 Raw Process Gland Potable
3
Flow m /hr 263 263 263 263 620 20 5

Time hrs 13.5 13.5 1.5 15 3 0.5 48

3
Calc Vol m 3,555 3,555 395 3,950 1,818 10 240
3
Selected Vol m 3,600 3,600 500 4,000 2,000 10 240

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4. CRUSHING OPERATING MANUAL

4.1 INTRODUCTION
Ore bodies close to the surface or outcrops have undergone significant weathering over a long period of
time. These contain little or no sulphide minerals as those originally present have been oxidised in the
weathering process. Oxidised ores are generally soft as they are products of decomposition of the
original massive rocks. They are therefore characterised by variable amounts of clayey materials
interspersed with hard rocks and boulders. As mining proceeds deeper the ores mined may contain a
transition layer with properties between those of the weathered and the original ore bodies. This means
that sulphide concentrations are likely to increase in some manner with depth in the weathered ore
bodies.

The Bisha crushing plant has been designed as a single stage crushing circuit . The gold production phase
requires a crushing rate of 370 tph, however the crushing plant has been designed to crush ore at a
maximum of 670 tonnes per hour to a product size of 80% minus 125mm suitable for SAG milling. This
design throughput will ensure that both supergene and primary ore sulphide can be treated at increased
throughputs with no modifications required in the crushing circuit.

The Bisha Crushing section Operating Manual covers the following:

 Crushing operations
 Conveying system
 Stockpiling and Reclaim

4.1.1 Safety
Operators must beware of moving machinery (e.g. Conveyors, crushers etc…) as well as of falling rocks.
Dust emissions can be severe in dry windy conditions or when the dust suppression unit does not
function satisfactorily. The prescribed PPE are described
below:

 Hardhat, Safety Glasses, Steel-toed boots and High- WEAR HEAT WEAR HIGH
WEAR HARD WEAR EYE RESISTANT VISIBILITY
PROTECTION

visibility Clothing must be worn at all times.

HAT SAFETY BOOTS CLOTHES

 Long pants and long sleeved shirts must be worn at

WEAR

all times.
PROTECTIVE
CLOTHING

 Dust respirator or dust mask must be worn when

required. WEAR DUST
MASK
WEAR
RESPIRATOR

WEAR EAR
PROTECTION

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 Hearing protection must be worn in high noise areas, as signposted.

 Use other safety devices as required.

Read in conjunction with Primary Crusher, Stockpile & Reclaim PFD (PFD 1100) and P&ID (PID1110)
drawings

4.2 PLANT DESIGN CRITERIA

Plant design criteria relevant to the operation of these sections are excerpted from the design criteria
section of the document. The design criteria are based on the following sources, the reference numbers
for which are shown against each of the criteria:

1 - Design Basis Document (Developed by both BMSC & SENET)

2 - BMSC (Owner)

3 - Feasibility Study Report

4 - Metallurgical Test work (SGS Lakefield)

5 - Vendor Data or Recommendation

6 - SENET (design / judgement)

7 - Industry Standard or Practice

8 - Handbook (Engineering Handbook)

9 - Assumption based on experience

Planned operating days per annum 363 2

Planned operating hours per day 24 7
Maintenance hours allowed per week 8 7
Planned operating hours per annum 5 574 6
Availability 96 % 6

Annual capacity (design) 2 Mt/a 2

Throughput rate (design) 370t/h 6

Major equipment in the Primary crusher, stockpiling and reclaim section includes:

Equipment No. Equipment ID KW Description Supplier

11-BIN-01 ROM Bin 100m3 Senet
11-APRF-01 Apron feeder D7 Plate feeder, MMD
2150x8062mm,Hydraulic

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VSD, min 360tph

11-VGRZ-01 Vibrating grizzly feeder 15 Model GF-4500-1500, Vibramech
1.5mx4.7m
11-CRUS-01 Primary jaw crusher 200 Nordberg C140, Feed Metso
830mm, discharge 150mm
11-HYST-01 Crushing area hoist
11-CONV-01 Primary Crusher discharge 15 1.050mW x 23m L, 1.2m/s, SENET
conveyor Min 360TPH
11-CONV-02 Stockpile feed conveyor 110 1.050mW x 140m L, 1.2m/s, SENET
11-STPL-01 Crushed ore stockpile 10 000 Ton Live SENET
11-CONV-03 SAG mill feed conveyor 37 1.050mW x 140m L, 1.2m/s,
11-FEDR-01/2/3 Stockpile reclaim feeders 1,2 3 3.2 Model PF-20-12, 1.2m x 2m Vibramech
x 0.2m pan
11-RBKR-01 Rock breaker
11-WEIG-01 Crushed ore weightometer
11-HYST-02 Apron feeder hoist
11-HYST-03 Grizzly hoist
11-DUSP-01 ROM tip Dust suppression unit 25.5
11-DUSP-02 Crushing dust suppression 5.5
11-FAN-01 Stockpile fan
11-WEIG-02 SAG mill feed weightometer
11-MAGT-01 Magnet 7.5
11-HYST-04 Stockpile pan feeder hoist
11-CRUS-02 Pebble crusher (Future)

4.3 PROCESS DESCRIPTION

ROM ores are transported from the pit(s) to the gold extraction plant using 36 ton dump trucks. The
ROM bin was however sized to take up to CAT 777 dump trucks to allow for any increased production in
the future with no modifications required. The ROM ore is dumped either directly to the static grizzly on
top of the 100 ton capacity tipping bin (11-BIN-01) or stockpiled in a designated area of the ROM pad to
create feed stocks of various ore types and ore grades. These surge stockpiles ensure ROM ore
availability in the event of flooding in the quarry and afford better control over the cash flow as high
grade ores can be treated when additional revenue is required. Ores from the ROM pad stockpiles are
fed to the tipping bins using FEL. The 800 x 800 mm fixed grizzly (11-GRIZ-01) mounted above the ROM
bin will scalp off the oversize material which can be broken down to the right size using the mine’s rock
breaker (11-RBKR-01). The rock breaker should however be used rarely, probably less than 1% of crusher
operating time. Excess use indicates that mining is producing off specification feed in terms of size.

During the gold production phase, the crushing plant will operate at a crushing rate of 360 tons per hour
tons per hour, treating feed ore from a maximum lump size of 800mm to a product size of 80% passing
150mm suitable for SAG milling.

Ore is reclaimed from the ROM bin using a 2.15m wide, 8.062 m long variable speed pan apron feeder
(11-APRF-01) and discharged onto a vibrating scalping grizzly (11-VGRZ-01) with 125mm spacings. Surges
in the crusher feed are smoothened by the action of heavy chains hung above the apron feeder

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discharge from the bin structure. The apron feeder spillage together with the vibrating grizzly undersize
report to the crusher discharge conveyor (11-CONV-01). Vibrating grizzly oversize reports to the primary
jaw crusher (11-CRUS-01) where it is reduced to 80% passing 150mm before being discharged on to the
crusher discharge conveyor. The crushed material is then transferred to the stockpile feed conveyor (11-
CONV-02) which then conveys the material to the 9 000 ton live capacity crushed ore stockpile (11-STPL-
01). The crushed ore is reclaimed from the stockpile using variable speed pan feeders (11-FEDR-01, 11-
FEDR-02 and 11-FEDR-03) onto the mill feed conveyor (11-CONV-02).

Three overhead hoists (11-HYST-01/02/03) are installed for use on the primary crusher, apron feeder
and grizzly sections and are used to facilitate maintenance and dislodging chokes in the event of
oversized slabby rocks reporting to the primary crusher

In any mining operation, it is inevitable that tramp iron will find its way into the system. This tramp iron
poses a danger to downstream equipment and needs to be removed. For this purpose, a magnet (11-
MAGT-01) is installed on the stockpile feed conveyor (11-CONV-02) to remove tramp metal from the ore
stream. The electromagnet is supported from a manual chain block hoist, which enables for its removal
and cleaning to a waste bin. A metal detector (11-METD-01) is installed downstream of the magnet to
stop the conveyor in the event that metal is not removed by the magnet.

Pebbles recycled by a system of conveyors from the SAG mill trommel screen join the mill feed stream
on the mill feed conveyor (11-CONV-03) and are refed into the mill. A provision has been put in place for
future installation of a pebble crusher (11-CRUS-02) to allow size reduction of the pebbles before being
refed into the mill. A bunker is also available for temporary storage of mill pebbles during the short
periods when the SAG mill run while the mill feed conveyor is down. The pebbles can then be reclaimed
by FEL and blended with ROM ore as feed to the primary crusher.

Containment of dust is effected by the use of skirting, dust enclosures, and a dust suppression system
(11-DUSP-01/2) which use fine water sprays on main dust generating points of ROM bin tipping point,
ROM bin discharge crusher discharge and the stockpile reclaim feeders. A dust extraction fan (11-FAN-
01) installed on the stockpile tunnel end also removes dust generated from the reclaim feeders.

4.3.1 Control Loops

The objective of process control and instrumentation in the crushing plant is to maintain operating
conditions that result in an optimum throughput-product size relationship; obtaining maximum
throughput at a constant and required product size.

Process control and instrumentation are included in the crushing section for the following reasons:

 Allows the plant to operate at a chosen feed rate to achieve a total of 900000 TPA target of Mill
Feed.
 Minimises the effect of disturbances in ROM supply and grade from the mine.
 Provides for safe and efficient start-up, operation and shutdown of the process.

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o The ROM tipping bin (11-BIN-01) is equipped with an ultrasonic level transmitter (1110-
LT-01). A minimum operating level (15%) in the bin is maintained at all times in order to
reduce damage to equipment (bin liners and apron feeder (11-APRF-01) from excessive
impact during tipping of ore into the bin. The level transmitter operates a traffic light
giving permission to tip into the bin or not to tip into the bin. The traffic light will flash
green when tipping is permitted and red when the bin is full. To avoid tipping into the bin
while maintenance is taking place, the traffic light has an option to be manually
controlled by the SCADA operator. The SCADA operator will put the traffic light to show
RED, denying permission to tip into the bin when maintenance is taking place in the bin,
and/or on ancillary equipment,
o Crusher (11-CRUS-01) feed rate is controlled by varying the apron feeder (11-APRF-01)
speed using the double idler weightometer (11-WEIG-01) readings in a simple feedback
control loop with target feed rate set from the SCADA control system. The feedback loop
will speed up the apron feeder if the tonnage recorded on the weightometer is less than
the set tonnage, and vice versa. The weightometer will measure the instantaneous
tonnage (tph) and the cumulative tonnes passed over the conveyor. The weightometer
will therefore be used for both plant control and metallurgical accounting purposes.
Local and remote display of instantaneous and totalised tonnages will be available.
o The double idler weightometer, mill feed belt weigher (11-WEIG-02) is used to control
the feed rate to the SAG Mill by varying the speed of the stockpile pan feeders (11-FEDR-
01/2/3). Selection of the combination of pan vibrating feeders to run will done manually
by the control room operator and will be done in such a way that different parts of the
stockpile are reclaimed at the same rate. The weightometer will measure the
instantaneous tonnage (tph) and the cumulative tonnes feed to the SAG Mill. The
weightometer will therefore be used for both plant control and metallurgical accounting
purposes. Local and SCADA display of instantaneous and totallised tonnages will be
available.
o The belt magnet (11-MAGT-01) is installed on the stockpile feed conveyor (11-CONV-02)
to remove any tramp metal.
o All conveyor belts (11-CONV-01/2/3) are equipped with speed sensors that alarm and
stop the conveyors in the event of low speed. All transfer chutes are equipped with
blocked chute detectors and will stop the conveyor in the event of a blocked chute.
o Belt rip detectors (11-RIPD-01/2) are incorporated in the crushing circuit on the stockpile
feed conveyor (11-CONV-01) and stockpile reclaim conveyor (11-CONV-02). These
detectors help to minimise the damage done to the conveyor belts through early
detection of a ripped belt, therefore reducing the maintenance costs to repair and the
downtime of the circuit.
o Belt drift switches are installed on the stockpile feed (11-CONV-02) and stockpile reclaim
(11-CONV-03) conveyors to detect if the belt is tracking off its rollers (i.e. the belt is no
longer running centrally on the troughing idlers). There are two sensors (one on each
side of the belt) installed for each conveyor at each end of the conveyor. The sensor

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consists of a vertical roller attached to a movable arm. The arm is attached to a sensor
box which is calibrated for position. If the sensor arm is pushed outside of its limits by
the belt, an alarm will sound for a period to be determined (typically 30 seconds) and
trip conveyor if alarm conditions still exists after this period.
o Belt tear detectors are also installed on the stockpile feed (11-CONV-01) and stockpile
reclaim (11-CONV-03) conveyor for early detection of a tear on the conveyor belt.
o Chute block detectors are installed on all transfer chutes.

The following information and control commands for the Crushing circuit are indicated on SCADA:

 local or remote operation of drives

 ready /run /fault indication on all drives.
 Underspeed alarms for all conveyors.
 Blocked chute detector alarms for all transfer chutes
 Rom Bin (11-BIN-01) level (%)
 Apron Feeder (11-APRF-01) variable speed drive output
 Reclaim feeders (11-FEDR-01/2/3) variable speed drive output (%)
 pull wire/ lanyard alarms for all conveyors and the apron feeder
 starting and stopping of all drives when in remote operation
 interlocking of equipment with up stream process equipment as per sequence start/stop
operation
 Instantaneous and totallised tonnage on weightometers (11-WEIG-01/2)

4.3.1.1 Alarms
 ROM Bin (11-BIN-01) low level alarm PID1110-LALL-01
 ROM Bin (11-BIN-01) high level alarm PID1110-LAHH-01
 11-CONV-01 low speed alarm PID1110-SAL-01
 11-CONV-02 low speed alarm PID1110-SAL-02
 11-CONV-03 low speed alarm PID1110-SAL-3.0
 11-CONV-01 chute high level alarm PID1110-LAH-01
 11-CONV-03 chute high level alarm PID1110-LAH-03
 11-CONV-02 belt ripped/torn alarm PID1110-ZAH-05
 11-CONV-03 belt ripped/torn alarm PID1110-ZAH-06/03

4.3.2 Interlocks:
Certain interlocks are incorporated in the control system for the purpose of protecting the equipment
from physical damage, and to avoid/reduce operational problems caused by unusual situations. The
interlocks are such that equipment will automatically trip or will not be started if a condition or a set of
conditions are not met.

 Apron feeder (11-APF-01) will be stopped when jaw crusher (11-CRUS-01) stops.

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 Apron feeder (11-APF-01) will be stopped when conveyor (11-CONV-01) stops.

4.3.2.1 Lanyard (Pull) Switches

 An unhealthy pull switch on the Mill feed Conveyor (11-CONV-03) will also stop all the stockpile
reclaim feeders (11-FEDR-01/2/3).
 An unhealthy lanyard switch on the stockpile feed conveyor (11-CONV-02) will stop the crusher
discharge conveyor (11-CONV-01) with subsequent back trips of the apron feeder and vibrating
grizzly.
 An unhealthy lanyard switch on the Primary crusher discharge (11-CONV-01) will stop Vibratory
Grizzly (11-VGRZ-01) & the Apron feeder (11-APRF-01). The rest of the equipment will continue
to run.

4.3.2.2 Underspeed Switches

 Underspeed switches are located on a non drive pulley of each of the conveyors. A detection is
usually an indication of belt slippage/breakage and/or drive fault. A detection will stop the
associated conveyor and stop other upstream drives as detailed for the lanyard switch faults.

4.3.2.3 Drive Faults

 An Apron feeder stoppage (11-APRF-01), caused by vendor interlocks, is alarmed and indicated
on SCADA display and alarm summary pages. All other drives continue to operate.
 A Vibrating grizzly stoppage will alarm and be indicated in the SCADA display and alarm summary
pages. A vibrating grizzly fault will stop the apron feeder only. All other drives will continue to
operate.
 A Jaw crusher stoppage will alarm and be indicated on the SCADA display and alarm summary
pages. A jaw crusher fault will stop the apron feeder and vibrating grizzly while all other drives
will continue to operate.
 A drive fault on any conveyor is also displayed on the SCADA display page. Each conveyor drive
is interlocked as previous detailed for the lanyard switches.

4.3.2.4 Level Transmitter/Switch

 Rom Bin (11-BIN-01) LALL stops Apron Feeder (11-APRF-01).
 Rom Bin LAH stops feed from dump trucks (red light switched on).
 Crusher discharge conveyor transfer chute LAH stops the crusher discharge conveyor ,apron
feeder and vibrating grizzly.
 LAH on the mill feed chute stops the mill feed (11-CONV-03) conveyor and subsequently the
stockpile reclaim conveyors.

Note: The Primary crushing area dust suppression continues to run throughput crushing plant
operation. Dust suppression spray solenoid valves are interlocked to the apron feeder. ROM bin dust
suppression is a manual operation & requires the operator to open the manual valve whenever there is
dumping to reduce water usage and buildup.

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4.3.3 Interlocks Summary

Equipment Interlock Condition
Mill feed conveyor A. SAG Mill feed conveyor cannot start or run
(11-CONV-03) if SAG Mill is not running
B. Interlocks that will prevent or stop the
operation of the mill feed conveyor:
− Mill feed chute high level alarm
− Pull wire switches
− Under speed switch
− Belt rip switch
− Belt tear switch
− Motor over current
C. Alarms
− Belt Drift
Stockpile feed conveyor A. Interlocks that will prevent or stop
(11-CONV-02) operation of stockpile feed conveyor:
− Stockpile high level alarm
− Pull wire switches
− Under speed switch
− Belt rip switch
− Belt tear switch
− Metal detector
− Motor over current
B. Alarms
− Belt Drift
Primary Jaw crusher A. Jaw crusher cannot start or run if primary
(11-CRUS-01) crusher discharge conveyor is not running.
B. Interlocks that will prevent operation of
the Jaw crusher:
− Motor over current
− High bearing temperature

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Crusher Discharge Conveyor A. Primary crusher discharge conveyor

(11-CONV-01) cannot start or run unless stockpile feed
conveyor is running
B. Primary crusher discharge conveyor
cannot start or run if blocked chute
detector is active
C. Interlocks that will prevent or stop
operation of primary crusher discharge
conveyor:
− Transfer Chute high level alarm
− Under speed switch
− Motor over current

Vibrating grizzly A. Vibrating grizzly cannot start or run if jaw

(11-VGRZ-01) crusher is not running.
B. Interlocks that will prevent operation of
the Grizzly:
− Motor over current
Apron feeder A. Apron feeder cannot start or run if
(11-APRF-01) vibrating grizzly is not running.
B. Interlocks that will prevent operation of
the Apron feeder:
− ROM bin level is too low
− Pull wire switches
− Hydraulic pressure
− Oil temperature is high.
− Motor over current

4.4 OPERATING GUIDELINES

4.4.1 Pre-start Checks
 no personnel in area whose safety may be endangered.
 all isolators in the MCC are free of tags and have a ready status.
 Stockpile is ready to receive ore
 all local stop station buttons are unlatched (‘out’) and selector switches are on remote.
 all lanyard switches are healthy.
 all safety guards and cages are in place, secured and not damaged.
 all chutes are clean & blockages have been cleared.
 the jaw crusher is well lubricated.
 oil levels in the apron feeder hydraulic pack are to vendor’s recommendations.
 raw water pump is running for dust suppression sprays.
 crusher feed available at the ROM pad and loader operator notified.
 dust extraction system is ready to operate.
 check status of all equipment on the SCADA display.
 tramp magnet is free of metal/debris.

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4.4.2 Normal Start-up Procedure

The crushing circuit start-up will be performed as per the following:

4.4.2.1 Primary Crushing

 start the Jaw crusher lube system according to vendor recommendations.
 Start the Apron Feeder lube pack according to Vendor recommendations.
 open the manual isolation valve (PID1110-v-01) for raw water feed to the dust suppression
system (11-DUSP-01)
 start the crushing plant dust suppression system (11-DUSP-01) locally at the start/stop station.
 start the tramp metal magnet( 11-MAGT-01) rectifier at the local control station.
 start the jaw crusher (11-CRUS-01) from the SCADA display page.
 Press the start Primary crusher circuit sequence on SCADA then the following will occur in
sequence as controlled by PLC:
o the stockpile feed conveyor (11-CONV-02) starts after a preliminary siren;
o the crusher discharge conveyor (11-CONV-01) starts after a preliminary siren & a ten
seconds delay.
o the vibrating grizzly starts after another ten second delay.
 start the apron feeder (11-APRF-01) at a designated output in manual mode from the SCADA .
 manually balance the crusher feed and the crushing circuit production throughput before
attempting to switch the apron feeder speed from manual to automatic control.

4.4.3 Normal Shutdown Procedure

A normal shutdown procedure is implemented for:

 Routine shift shutdown.

 Scheduled crushing circuit maintenance.
 High Level on crushed ore stockpile.
 Lack of crusher feed.
 Unscheduled crushing circuit maintenance.

The normal shutdown procedure is as follows:

 notify the loader operator of the intended shutdown (lights can be switched to “red” for no
dump to ROM bin).
 stop the apron feeder (11-APRF-01) and allow the load of the conveyor belts to empty.
 press the Primary crushing circuit sequence stop icon on the SCADA display page which will stop
in sequence;
o the vibrating grizzly; (11-VGRZ-01)
o crusher discharge conveyor (11-CONV-01);
o Stockpile feed conveyor (11-CONV-02) after a time delay.

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If the downtime duration is short (less than 15 minutes) the crushers can be allowed to continue to
operate. If the shutdown duration is substantial then:

 stop the jaw crusher using the icon on the SCADA display page
 stop the Apron Feeder lube system.
 Stop the Jaw Crusher lube system.
 stop the dust suppression system ;
 manually close the process water valve supply to the dust suppression system
 stop the tramp magnet rectifier at the local control station.

4.4.4 Emergency Shutdown Procedure and Power Failure

 Emergency shutdown procedures.

In the event of equipment trip normal interlocks will kick in. The crusher will require stopping separately
from the SCADA display page or the local control stations. A general power failure will naturally stop all
equipment. The field operator must in both cases conduct a filed inspection right through the plant and
report on any problems which may damage equipment or affect plant performance when the plant is re-
started. In the case of a power outage, the jaw crusher should not be restarted if the cavities are full with
rock.

4.4.5 General Operation

 When the crushing plant is operating, monitor all equipment status and throughput. Following
are some general operating guidelines:

4.4.5.1 ROM Bin Level

 A low level of 15% will cause the apron feeder to stop. This is to ensure a bed of ore remains on
the apron feeder protecting it from impact when ore is tipped into the ROM bin. When a high
level is reached (at least 85%), the red traffic light is activated and the loader driver or truck
driver will stop feeding ore to the ROM bin. It is necessary for the crushing plant operator to
maintain contact with the loader driver to advise on throughput requirements and ore blend
ratios.

4.4.5.2 Process Interruption

 The crushing circuit operation may be interrupted due to device detection, equipment fault,
process imbalance, metal detection and blockages. When the fault has been rectified crushing
can be recommenced by re-initiation of the crusher start sequence on the SCADA display page
and restart of the apron feeder in manual mode.

4.4.5.3 Adjusting Crusher Gaps

 The jaw crusher closed side setting should be checked daily by dropping a compacted aluminium
foil or lead ball through the crusher whilst it is operating with the feed off. The gap should be
maintained at the setting nominated by the plant metallurgist.

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4.4.5.4 Tramp Metal Removal

 A metal detector (11-METD-01) is located on the stockpile feed conveyor (11-CONV-02). A
detection of tramp metal will stop this conveyor, the vibrating grizzly and the apron feeder. The
Primary crusher will continue to operate. A sequence restart is only permissible after removal of
the offending tramp metal and a local reset on the detector.

4.4.5.5 Jaw Crusher Blockages

 Blockages of the jaw crusher opening are possible due to slabby type ore and/or bridging by near
sized materials. When this occurs wedges and the overhead hoist may be used to turn rocks and
move rocks into the cavity.

Note if the jaw is to be manually cleared, the apron feeder, the vibrating grizzly and the jaw crusher
must be isolated and appropriate harnessing is to be worn. A “no dump” red light should also be given
to the loader operator. The task should be assessed for hazards before commencement and may
require supervision.

4.4.5.6 Operator Routine Inspections

The field operator is in radio contact with the control room at all times and must report any findings of
his inspection immediately. He may under special circumstances execute an emergency field stop of
major equipment to prevent a major breakdown. Routine inspections of the crushing circuit by the
crusher operator(s) is required and should include the following:

 chutes are clear and not damaged;

 lanyards (pull wire switches) have sufficient tension on them;
 gearboxes for noises, oil leaks and/or overheating;
 unusual noises from any equipment;
 unusual or excessive vibrations;
 conveyor belts for wear, cuts, fraying and tracking;
 idlers for build up or jamming;
 walkways for spillages and trip hazards;
 visual judgement of crusher product sizes;
 conveyor belt scraper adjustment;
 spillages due to worn liners or skirts, or blockages;

Report on any oil/grease or chemicals spillages immediately to the safety officer and the shift supervisor.
These must be removed from the circuit and dumped in the dedicated dumping site. Oil and grease
spillages must never be pumped in circuit as it may cause significant Gold losses by preventing Gold
adsorption onto the activated carbon granules.

House keeping: Ore spillages are collected with shovels and loaded onto the feed belt conveyor, if free of
oil/grease contaminants. The plant is hosed down on a regular basis and water is pumped back into
circuit using the floor spillage pumps.

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 Clear belt scale frame of any spillage which may affect reading accuracy
 visual inspection of jaw crusher lubrication;
 oil levels in apron feeder hydraulic pack remain acceptable;
 build up on the head and tails drums of conveyors;
 oil level in Apron Feeder lube pack remains acceptable;
 dust suppression system operating efficiency.
 water sprays are adequate to minimise dust;
 metal is routinely removed from the static belt magnet;
 vibrating scalping grizzly for build up and excessive vibration.
 Observe crusher feed rate and chains smoothing effect on crusher feed rate.

4.4.6 Trouble shooting:

 Blockage at Apron Feeder discharge:

Cause Symptoms Consequences Solution

Large granite rocks Jamming of Apron  Bending of bin steel.  Clear blockages in
Tree trunks Feeder discharge  Apron Feeder trips crusher feed chute.
Steel liners on overload  Dig out.

 Blockage in crusher feed chute.

Cause Symptoms Consequences Solution

Large granite rocks  Crusher trips in  Major blockage and  Clear blockages in
Tree trunks overload. plant stoppage. crusher feed chute
Sticky clays lumps from  Feed chute fills up.  Long shut down using overhead hoist
wet ROM ore required. if necessary
Labour intensive and  Discharge tramp
dangerous work. material on
stockpile.

 Belt drift

Cause Symptoms Consequences Solution

Buildup on pulleys and  Frequent belt off Spillage on conveyor  Check and clean for
rollers tracking structure build up on pulleys
Conveyor cuts and rollers
Structural problem  Check structure and
rectify

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5. MILLING PLANT
5.1 MILLING SAFETY PROCEDURES:
Strict safety procedures must be followed in milling operations. It is important to note that safety
procedures are important for both the personnel and the equipment they are operating. If proper safety
procedures are not followed mill circuits can pose a great deal of hazards to operators and personnel in
general. Main dangers result from rotating machinery (i.e.Sag mill, ball mill), accidental fall from heights
and injury from falling objects being lifted. Operators working in the mill area must be alert at all times,
wear the required personal protective equipment and avoid direct contact with slurries as these contain
toxic and corrosive products be it in dilute form.

5.2 GENERAL PPE (PERSONAL PROTECTIVE EQUIPMENT)

The PPE requirements normally include:

 Steel capped safety boots

 Hard hat
 Full overall with reflective material strips
 Safety glasses
 Gloves
 Dust masks must be worn when required
 Ear protection

In addition, operators shall ensure that Fire Extinguishers and High Pressure Hosing Equipment are
readily available when working around the area.

5.3 THE MAIN ISSUES OF CONCERN ARE HIGHLIGHTED BELOW:

5.3.1 Cyanide
The milling area uses recycled process water which has low levels of cyanide in it from the downstream
processing of the ore. The amount of cyanide present is at low levels, however to minimise risk of
cyanide poisoning, personnel shall avoid direct contact with slurry or process water through correct use
of PPE.

5.3.2 SAG and Ball Mill

All moving components on the SAG and Ball mills including the mills themselves are guarded.

Most work around the mills during operation relates to operation, lubrication and condition monitoring,
such as:

• Sampling Mill discharge for metallurgical samples and densities.

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Note: Provision for sampling the trommel underflow will need to be made. A sample of the
underflow will enable the determination of gold distribution to be made between the two mining
operations

• Visual inspection of the lubrication systems around the SAG/Ball mills.

• Assessment and reporting of the operation of the SAG/Ball mills through visual and audible
assessments
• Charging of the mill ball load
• No attempt shall be made to remove or repair damaged components or to remove blockages in
chutes or the like on an operating SAG/Ball mill.
• No guard shall be removed from the SAG/Ball mill whilst it is operating. No equipment shall be
operated with any of the guards removed.
• No person shall remove or go beyond the mill safety barriers whilst the mills are turning.
• The inside of any mill is considered an enclosed space, and all relevant safety measures shall be
implemented when working inside the mill. Working on top of the mill shall require the use of
safety lanyards and fall arrest equipment.
• Prior to working within a mill a confined space permit must be obtained and signed by an
appropriate supervisor and will include provision for the testing of:
o Presence of Hydrogen cyanide gas.
o Sufficient oxygen in the air within the mill.
• No electrical or mechanical work shall commence on any piece of equipment in the plant
without first isolating and tagging the equipment.

5.3.3 Conveyor belts

Belt conveying systems are commonly used equipment in many industrial and mining applications. Yet,
the conveyor is responsible for many serious injuries in the mining industry. The reason for these injuries
is that in most cases employees working around the conveyor area either were not aware or were
complacent about the safety aspects of the area or disregarded safety procedures. Most work around
belt conveyors during operation relates to lubrication and condition monitoring, such as:

• Greasing bearings on conveyor pulleys.

• Assessment and reporting of the operation of the systems and of seized and damaged idlers,
belts and other items through visual and audible assessments.
• Sampling of gearbox oils for analysis.
• Adjusting belt cleaner position, but not replacement of cleaners.
• Vibration and other condition monitoring.

Operators to observe the following:

• No attempt shall be made to remove or repair damaged components or to remove blockages in

chutes or the like on an operating conveyor.

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• No guard shall be removed from a conveyor whilst it is operating. No equipment shall be

operated with any of the guards removed.
• No electrical or mechanical work shall be completed on any piece of equipment in the plant
without first isolating and tagging the equipment.
• Watch, but do not touch, any part of the moving belt or the ore on the belt. Normally sirens will
warn that a conveyor is about to start. Sirens can fail or not be heard. Stay clear of conveyors
unless isolated.

Emergency pull-wire switch is one of the protective devices on a belt conveyor. Stop the belt if a
situation arises which could endanger life or property. Red lock-stop button pushes have the same
function, and allow anyone to override control systems and stop the plant in the shortest possible time.

Conveyor Belt Fires

The belt on conveyors is manufactured from a rubber compound that is flammable. Although not a
common occurrence, these belts can catch alight usually due to sparks from cutting, welding or similar
activities, or from heat generated by friction when the belt rubs continuously against a fixed component.
It is preferable that fires are not caused in the first place and most will be prevented through good
practices. During operations observe whether the conveyor belt tracks centrally on the idlers and that it
does not run off and contact the support structure, chutes or other items. Skirts can be a fire hazard if
not adjusted or if they are damaged. Apart from the possibility of fire, the amount of damage to the belt
and structures etc. that can occur is a safety issue. Safety devices are incorporated to stop the conveyor
if this happens. If these devices fail, stop the conveyor and report.

When any work is commenced on or around conveyor belts that involves generation of sparks or flame
or hot metal fragments, i.e. cutting, welding, etc. ensure that there is a trained observer close by with
ready access to fire extinguishers a fire blanket and a good supply of water. Fires are best controlled by
prevention.

If you come across a conveyor belt that has already started to burn, stop the conveyor immediately, to
prevent the fire spreading, and advise security. Start the conveyor fire control sprinkler system if
installed. If you are confident, and have access to a good water supply, flood the belt with water from a
safe distance. Large volumes of water are required to suppress a belt fire.

In most instances however one item such as a rubber impact idler which has seized will be the cause of
the fire and the conveyor belt itself will not be burning. In this case it is better to leave the conveyor
running and to put out the fire on the particular item of equipment – if safe to do so. A fast moving
conveyor will not be in the vicinity of the fire for long enough to catch fire itself and stopping the belt
will escalate rather than reduce the impact of the fire.

Remember – Only fight a fire if you are trained and feel it is safe to do so.

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5.3.4 Transfer Points and Discharge Chutes

Transfer points are commonly located at the head and tail of conveyors or between equipment, and
include bins, hoppers and chutes. Cleaning and un-bogging are common tasks for operators after ore
flow has been interrupted in these areas. Common causes of bogging are increased ore flow rates, poor
chute design, worn or loose chute lining materials, oversize rocks and ore that is too wet or too fine.
Often these are seasonal or pit issues with more problems occurring in the wet season or with ore from
specific parts of the pit. Most work around bins, hoppers and chutes during operation relates to
monitoring and observing the operation, such as:

• Visual inspection of ore flow where possible.

• Visual inspection of liner condition where possible.

Watch, but do not touch, the moving ore streams. Do not attempt to dislodge hung material in a chute
unless the system is isolated correctly.

In the milling area, the only transfer chutes are those feeding the SAG mill and on the scats recycle
circuit. The SAG mill feed chute has a blocked chute detector, which will indicate when the chutes is
blocked and will automatically shut down the feed conveyor.

The following procedure shall be followed by operations personnel when carrying out cleaning or un-
bogging tasks, especially if entering hoppers, bins, or chutes.

• Tasks shall be discussed before beginning work and initiate actions to ensure they are protected
from possible injury, the supervisor shall monitor safety controls for effectiveness.
• Completion of Job Safety Analysis is mandatory for this work.
• Safety harnesses and fall arrest equipment shall be worn and lanyards shall be securely
anchored if working in a chute, bin or hopper.
• No person shall be allowed to work under hanging material to minimise risk of injury from falling
rock. All hanging material shall be barred down, or a safety shelter shall be installed.
• Work in bins, chutes and hoppers shall be considered as work in an enclosed space and a
confined space permit should be obtained and signed by an appropriate supervisor. At least one
person shall be immediately available outside the area to provide assistance.

5.3.5 Pebble Crusher / Scats Storage Bin

The pebble crusher will be a future installation at Bisha, if scats are found to contain economic gold
values. Initially all scats will be returned directly to the mills and a by-pass chute will be installed where
the crusher or bin would be located. If scats are found to be barren, then they will be stockpiled for
disposal.

All moving components on the crusher will be guarded.

Most work around the crusher, bin or by-pass chute during operation relates to lubrication, monitoring
and observing the operation, such as:

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• Assessment and reporting of the operation of the crusher through visual and audible
• assessments
• Assessment of bin / chute operation and wear condition.

Operator to ensure the following:

• Ensure the area around the crusher is always clean and that lighting is sufficient to avoid
accidents.
• Rocks can be ejected out of the crushing chamber of the machine during operation.
• The crusher and associated conveyors and bins shall be clear of people and equipment before
starting.
• Scats will be removed periodically from the storage bin if used, and personnel shall avoid this
area when loaders and trucks are operating. High visibility clothing is required in this area.

5.3.6 Forklifts and Bobcats

Forklifts and Skid Steer Loaders (Bobcats) and similar small mobile equipment will be used in and around
the milling area for transfer of spares and reagents, for cleaning up and for other duties. This type of
mobile equipment shall be only be operated by trained and certified personnel.

Personnel shall assume that the mobile equipment has right of way at all times and that the operator
may not be able to see other people and therefore may not stop or avoid damage or an incident.

5.3.7 Centrifugal Slurry Pumps

This area of the plant has two centrifugal slurry pumps. These are used to circulate milled solids in a
slurry format to other areas of the process. The centrifugal pumps and their associated gland water
service systems normally operate automatically from the control room. Flush water is controlled locally,
and operation of the isolation and flush valves is interlocked with the pump motor. Work around the
centrifugal pumps will mainly involve:

• Visible inspection of the pumps for leaks and correct operation during start up and shut down.

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• Inspection of the couplings and other drive components on the pumps for high temperatures,
vibration, loose wedge belts, unusual noises etc.
• Inspection of the electric motors for high temperature, vibration and other unusual issues.
• Flushing out pumps and pipelines that become blocked during operating, which will involve
manual connection of flush water to various flushing points and opening the manual sluice /
dump valves.
• Confirmation of valve operation during a pump changeover.

Operators to observe the following:

• No attempt shall be made to flush a pump or pipeline unless the suction isolation valve is closed
and the pumps are isolated. Particularly in the case of the cyclone pumps, operators shall note
that a large volume of slurry may run back from a blocked pipe once the blockage is cleared.
• No attempt shall be made to remove or repair damaged components or to remove blockages or
the like on an operating pump.
• WARNING: If the pump has been running with a blockage in the discharge line and with slurry in
the pump casing and suction lines the slurry can be very hot and can be ejected with force and
the risk of severe scalding exists.
• No guard shall be removed from a pump whilst it is operating. No equipment shall be operated
with any of the guards removed.
• No electrical or mechanical work shall commence on any piece of equipment in the plant
without first isolating and tagging the equipment.
• Maintenance or other work on a standby pump that requires disconnection of the piping shall
not commence until both the suction and delivery isolation valves are closed.

5.3.8 Sumps and Pumps

This area of the plant has two spillage sumps with sump pumps. These are used to collect hosed spillage
in a slurry format, washing from the various items of equipment and to transfer the spillage to the
correct area of the process. The spillage pumps are significant size and normally operate automatically
from a level control in the sump.

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• Because they are likely to contain water they form a slip- trip and drowning hazard for the
unwary. Operators shall not enter a sump without good reason. Work in the sumps shall be
considered as work in an enclosed space. At least one person shall be immediately available
outside the area to provide assistance.
• Any sampling equipment provided for the area shall always be replaced in its dedicated holding
or storage point and not left lying on walkways (which would create a trip hazard).
• Cyclones also require regular maintenance, so tools and used cyclone components shall be
removed from the area after maintenance has been completed.
• Cyclones are high pressure operating units; the most likely danger to personnel in the vicinity of
an over-pressurised cyclone is a high pressure slurry leak (spurt) which could damage
unprotected eyes.

5.3.9 Automated valves

Automated valves are commonly used for process control or where manual operation is not viable, such
as with the larger valves in use. The milling and cyclone circuit has a selection of automated valves.

• Personnel shall not touch automated valves unless they have been isolated, as dangerous nip
points may be present.

5.3.10 Mill Start Up

Observance of proper safety procedures are critical is mill start up, as it is during this phase that most
accidents happen. Proper checks and inspections must be done to ensure that personnel and equipment
are not in danger in the process of mill start up.

The following is required safety procedure for mill start up.

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• Make sure the safety guards and barriers are in place prior to start up and that all work has been
completed and where possible housekeeping done.
• Make sure all lock out tags have been removed and signed off by the relevant personnel.
Personal danger tags have the following information on them: the full name of the person, time
and date, and the signature of the person. After confirming the person is safe, the supervisor
can give the signal to start up the mill.
• Make sure all personnel are clear of the mill. It is important that during start up at least two
people be positioned on either side of the mill they will move around the mill at least twice to
make sure there are no personnel close to the mill at start up.
• Recheck and confirm if the mill is clear of personnel before pushing the start button.

5.3.11 Normal/ Emergency Shutdown

It is important to follow proper safety procedures during a mill shut down. If proper shut down
procedures are not followed, damage to equipment and personnel may occur. A normal shutdown is
usually carried out for the purpose of mill maintenance or inspections whereas an emergency shutdown
is a result of a problem that requires immediate stoppage of the mill or a result of a power trip. In both
cases of shutdowns safety procedures must be followed where applicable.

A normal shutdown will normally involve cutting the feed to the mill and allowing the mill to run without
new feed for the required grind out time (usually about 10-20 minutes). This is dictated by the power
draw required at shut down. Once the grind out time or the required shutdown power draw is reached
the mill is switched off by using the normal start/stop station.

The following safety procedures must be followed during any normal mill shut down:

• Allow the mill to go to a complete stop before any personnel are allowed to go within an unsafe
distance of the mill
• Once the mill is completely stopped, the shift electrician must isolate the mill electrically in the
MCC and put an isolation tag with his name, the date and isolation time, the equipment
number, and his signature.
• The isolation tag must be put onto the lock for the mill main breaker, and the electrician keeps
the key to the lock.
• Once the shift electrician has put his isolation tag on the mill isolation point, all the operators,
and personnel who will be working in and around the mill must then put their personal danger
tags.
• Under no circumstances will any person climb inside the mill or start working on any component
of the mill without completing and hanging a personal danger tag on the mill isolation point.

5.4 THE COMMINUTION THEORY

Gold minerals in mined ores are intimately associated with gangue and must be unlocked or liberated
before efficient separation can be undertaken.

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This process of size reduction is called comminution. In the comminution process, the physical particle
size of the ore is progressively reduced in size to permit subsequent separation of the valuable
component from the gangue.

The comminution process is in three stages with:

• The first stage is blasting (explosives) the ore in the pit so it can be transported by the mine
dump trucks,
• The second stage is crushing where the mined material is reduced from about 650mm to less
than 150mm in size;
• The third and final stage of comminution takes place in the grinding circuit where the crushed
ore size is reduced to less than 150 microns.

Crushing is carried out by compression of the ore against rigid surfaces (jaw and cone crushers) and
autominously (rock on rock), it is a dry process carried out in 3 stages with small reduction ratios across
each stage (3 - 6 to 1).

Grinding is carried out in a tumbling mill with grinding media (steel balls); it is the last stage of
comminution and is carried wet to provide slurry for cyanidation processes in CIL. Particle breakage
occurs by impact, abrasion, and to a lesser extent chipping.

The grinding media is loose and heavy in comparison to the crushed ore product. Due to the rotation of
the mill shell, the grinding media is lifted along the rising side of the mill until a point is reached where
the media falls down (cascade / cataract) the surface of the rest of the media in the mill. Cascading
media produces size reduction by abrasion, whilst cataracting media produces size reduction by impact.

Mill speed is measured in rpm (revolutions per minute), and the mill operates at between 70 and 80% its
critical speed depending on the size of the mill. The critical speed is the speed of the mill at which
grinding media, ore and water will stick to the mill shell by centrifugal force. At mill speeds in the range
of 70% to 80% of the critical mill speed, the cataracting grinding media should strike the toe of the
charge to create impact. At these speeds, breakage is mostly due to impact compared to abrasion and
attrition. This gives the best utilization of energy.

5.4.1 SAG/ Ball Milling:

The SAG/Ball mill consists essentially of a horizontal rotating steel cylinder containing a grinding
medium. Ore and water enter through the opening at one end of the mill (the mill feed end), and the
ground product is discharged through a corresponding opening at the other end (the mill discharge
end).

The mill and associated equipment comprises of:

• Mill shell, with trunnions, mill shell liners, mill lifter bars, trommel, and ball charge
• Drive Train – mill motor, mill gearbox, drive pinion and girth gear

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• Trommel and mill feed spout

• Lubrication system
• Trunnion bearings and bearing housings.

The mill internals are protected from wear by rubber mill shell plates, these plates are held in place by
the lifter bars which are bolted to the mill shell in rows along the length of the mill.

The trunnions (2 of, one at each end of the mill) support the total weight of the mill (that is mill shell,
shell liners / lifters, ball charge and pulp); and allow the mill to rotate through the trunnion bearings.
The trunnions are hollow and allow pulp to feed into and out of the grinding mill.

The mill drive train is transmits energy from the motor to the mill, giving the mill the required rotation.
The power to rotate the mill comes from an electric motor. To allow a smooth start up, the liquid
resistance starter controls the current flow to the motor. The starter allows a gradual increase in power
supply to the motor until the mill attains maximum speed of rotation, when the starter maintains the
required power draw. This regulation of power to the mill allows a gradual increase in the motor torque
to the mill gearbox from zero to the maximum, enabling a smooth mill start up to maximum speed of
rotation. The mill motor couples to the mill gearbox by a flexible coupling. The coupling cushions the
shock/ impact to the gearbox at start up and during steady running conditions. The gearbox gives a
mechanical advantage and reduces the output speed from the motor to the mill by using a helical gear
reducer.

The output shaft of the gearbox drives the mill pinion shaft, which in turn drives the mill shell through
the girth gear.

The gearbox is fully enclosed and is splash lubricated by oil. Lubrication oil is pumped and circulates
between the reservoir and the gearbox. An external cooling unit cools down the oil as it circulates
between the gearbox and the reservoir. Oil gets hot due to heat produced by wearing parts in the
gearbox and cooling is necessary to keep the oil temperature within the acceptable temperatures
ranges. A fine spray of grease lubricates the girth gear and the mill pinion coupling. The greasing system
is automatically controlled and grease sprays finely onto the girth gear-pinion contacts at preset time
intervals.

Temperature probes are installed in the mill motor, mill gearbox and on mill drive pinion bearings which
report to the SCADA system in the control room.

An inching drive is installed, so that for mill maintenance purposes when the mill has been stopped, the
mill can be turned slowly. A chain is attached to the inching drive motor from the mill gearbox and it is
operated in manual mode when required. The inching drive chain must be removed before the ball mill
is started.

The power draw is a crucial parameter in milling operations and is used as a reference for process
control and optimisation.

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The relationships between mill load and power draw are discussed below:

• The power draw at constant rotational speed is directly proportional to the mill charge, i.e. the
sum of the masses of the grinding media (ball charge) and the slurry (ore and water) retained in
the mill.
• As the ball charge remains constant during the milling operation changes in power
consumptions are due only to the variations in ore tonnages retained in the mill.
• Under normal operating conditions as the ore load decreases so does the power draw and vice
versa.
• However when the mill feed rate increases beyond the safe operating level the charge becomes
affected by the “centrifuging” effect. At this point, the power draw drops rapidly with increasing
mill charge, indicating an overload condition.

Figure 5-1: Ball mill Power Draft as a Function of the Charge

• The bulk density of the ball charge amounts to ± 4.4t/m3 and. therefore. The ball charge has a
major effect on the power draw.
• The mass of grinding media is determined for each type of ore as a volumetric percentage of the
mill inner volume occupied by the charge at rest.
• Steel balls wear over time at a known rate of ore milled. The actual consumption will depend on
the variations in the ore hardness and the conditions the mill will be operated (the mill charge,
and the speed of rotation). Grinding media must be topped up at regular intervals in order to
maintain a constant ball charge. If the grinding media is allowed to drop too far, and mill feed is
maintained, mill charge will gradually increase resulting in high mill power draw.
• Mill liners also wear over time and it is necessary to regularly measure the inner shell diameter
as well as the charge level during liner inspections. The ball charge can be adjusted to maintain a
constant volumetric percentage as the shell liners wear. This results in increased power draw.

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5.5 CLASSIFICATION THEORY

Most process circuits operate mills in closed circuit with classifying hydro-cyclones. The hydro-cyclones
regulate the progressive size reduction of particles within the milling circuit, allowing particles, which
have reached the required size, to leave the circuit, while particles that are too coarse are sent back to
the mill for further grinding.

Classification or size separation in a suspension of fine non-settling solids is carried out by hydro-
cyclones. Separation is achieved in hydro-cyclone classification under the action of centrifugal,
buoyancy, and drag forces. Depending on their size, density and shape, particles are separated into
coarse and fine fractions. Fine, light and irregularly shaped particles are more influenced by the effects
of buoyancy and drag compared to the centrifugal forces. This will result in such particles reporting to
the cyclone overflow. Large, heavy and spherical particles, including the larger gold nuggets, are more
influenced by the centrifugal forces compared to the drag and buoyancy forces. These move and down
and are discharged from the spigot.

The efficiency of the separation process depends on the solids density; slurry viscosity; and cyclone
operating/inlet pressure. The controls over the cyclone operating parameters form part of the overall
milling/classification process control philosophy, which will be addressed in detail below. Hydro-cyclone
classification cannot achieve a perfect separation and a certain amount of misplaced material is always
present in the two fractions.

Figure 5-2: Typical Hydro cyclone Cluster Arrangement

The cyclone overflow constitutes the final product from the mill/classification section and must conform
to the CIL feed slurry requirements.

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5.6 MILLING PROCESS DESCRIPTION

5.6.1 Introduction
The grinding circuit will use the SAG Mill as the primary mill and ball mill for regrinding. The milling
circuit has been designed to handle 250 tph of oxide ore but this can be increased to 300 tph for
supergene and 450 tph for primary ore. Design criteria around the milling area thus takes into account
the increased throughput.

5.6.2 Milling Major Equipment

Equipment code Equipment name kW Description Supplier
21-MILL-01 SAG Mill 2000 6.1m D x 3.0m EGL, Polysius
22% max ball load,
76% Critical speed,
VSD motor
21-TRSC-01 SAG Mill trommel screen 1.517m IDx1.536m L
12mmx50mm slots,
Polyurethane
21-BUNK-01 Media reclaim bunker
21-CONV-01 Scats discharge conveyor 3
21-CONV-02 Pebble crusher feed conveyor 11
21-MAGT-01 Media reclaim magnet 10
21-MREL-01 Mill reline machine
21-BRET-01 Bolt removal tool 15
21-WEIG-01 Pebble weightometer
21-METD-01 Pebble metal detector
21-CONV-03 Pebble crusher feed conveyor 4
21-MILL-02 Ball Mill 4500 5.5m D x 8.3m EGL, Polysius
40% max ball load,
75% Critical speed,
Fixed speed motor
21-HYST-02 Ball loading tower crane 0.55 Kroll K100 Tower Tradehouse
crane, 4000kq @
R35m, H35m
21-SKIP-01 Ball loading skip
21-BUNK-02 Ball mill discharge ball bunker
21-BOX-01 U/flow velocity breaker
21-BUNK-03 Grinding media storage
bunker
21-TANK-01 Mill discharge sump
21-PUMP-01/2 Cyclone feed pump 01/2 250
21-PUMP-03 Feed end spillage pump 7.5
21-PUMP-04 D. End spillage pump 5.5
21-RECV-01 Pinch valve air receiver
21-HYST-03/4 Cyclone F/ pump hoist 1/2
21-CYCL-01 Cyclone cluster 12 way qMax 15-10 Krebs
cluster, 8 cyclones, 4
blanked

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5.6.3 Process Description

Step 1: Crushed ore (80% passing 125mm) is stored on a 9000 ton live capacity open stockpile (11-STPL-
01).Crushed ore is reclaimed at a target of 250 dry tons per hour, from the stockpile using variable speed
pan feeders (11-FEDR-01/2/3) located under the stockpile and discharged onto the mill feed conveyor
(11-CONV-03) which then conveys the ore to the SAG mill (21-MIL-01). Ore tonnages (wet) are
measured and recorded using a weightometer (11-WEIG-02) installed on mill feed conveyor (11-CONV-
03).

Fresh ore is mixed with cyclone underflow (Circulating Load) and feed water in the feed conveyor head
chute to achieve the required 72% solids concentration for optimum milling efficiency. The mill feed
dilution water is ratio controlled to the mill feed rate by using the reading from the magnetic flow meter
(2110-FT-01) and controlling the actuated flow-control valve (2110-FCV-01). The ratio control constant
can be adjusted from the relevant SCADA screen to account for varying ore moistures and cyclone
underflow solids concentrations but it is password protected.

The 6.1 m diameter x 3.0m long (Inside liners) SAG mill has a grate discharge with 60mm apertures. The
mill is driven by a variable speed high voltage motor rated at 2000 kW through a reduction gearbox,
pinion shaft and girth gear and rotates at 76% of critical speed for optimum milling efficiency.

Bearings and gears are lubricated with oil or grease under pressure. Oil is pumped in closed circuit and is
air cooled by use of cooling fans on the low pressure oil feed lines to the fixed (21-FAN-01/2/3) and
floating (21-FAN-04) sides of the mill. Temperatures, pressures and flow rates are monitored for
protection of the critical mechanical components.

Step 2: The SAG mill discharge, at 72% solids and 80% passing 2000um, flows through the SAG mill
trommel (21-TRSC-01). The trommel has polyurethane panels with 12x50mm apertures to protect
pumps and cyclones from oversize scats. The trommel oversize (scats, max lump size 60mm) is returned
to the SAG mill feed conveyor (11-CONV-03) via a series of conveyors (21-CONV-01/2/3). A future scats
crusher (sometimes called a pebble crusher), will be added if the scats are found to build up to the
extent that they affect SAG mill throughput. The trommel undersize gravitates to the mill sump (21-
TANK-01) where it is diluted to 55% solids by weight to suit the hydro-cyclones operating conditions.

Step 3: The trommel undersize is then pumped to the cyclone cluster (21-CYCL-01) by one of the cyclone
feed pumps (21-PUMP-01/2). The slurry pumps are fitted with variable speed drives and a gland seal
water supply system. The discharge pipe work of the duty and standby cyclone feed pumps combine at a
bi-directional valve (PID3110-V-09) and the pulp is delivered to the cyclone cluster distribution box,
located at the top of the mill building. The bi-directional valve allows both cyclone feed pumps to be run
simultaneously to facilitate pump change over without stopping the plant.

Step 4: Only four of the available six cyclones (21-CYCL-01A/B/C/D/E/F) in the cluster are utilised at
normal operating condition with the cyclones operating pressure is 70KPa. Cyclone underflow, at 72%
solids by weight, gravitates to the ball mill (21-MIL-02) feed chute via a velocity breaker (21-BOX-01)

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lined with mill balls. The ball mill of 5.5m diameter and 8.30m EGL, is overflow type and runs at 75% of
the critical speed. The mill is driven by a 4500kw fixed speed motor.

Bearings and gears are lubricated with oil or grease under pressure. Oil is pumped in closed circuit and is
air cooled by use of cooling fans on the low pressure oil feed lines to the fixed (21-FAN-05/6/7) and
floating (21-FAN-08) sides of the mill. Temperatures, pressures and flow rates are monitored for
protection of the critical mechanical components.

Step 5: Ball mill (21-MILL-02) discharge also flows into the common mill sump (21-TANK-01) and forms
part of the cyclone feed, closing the secondary milling circuit.

Figure 5-3: Typical Overflow Ball Mill Cutoff.

Step 6: Cyclone overflow, at 35% solids by weight and a grind of 80% passing 75 microns, reports to an
overflow launder from where it gravitates to the linear trash screen (31-LISC-01) via a splitter box (31-
SPLT-01). The linear screen is for tramp oversize removal such as misplaced oversize particles, vegetal
debris and trash such as plastic fragments, fuses, copper wires from the overflow stream prior to
thickening and downstream processing. The splitter box installed ahead of the trash screen allows for
future splitting of feed to two linear screens when throughput is increased. Allowance has been made in
the layout for an additional screen linear screen installation in future together with the screen undersize
pumps.

A belt magnet (21-MAGT-01), is placed on the scats return conveyor to recover undersize balls, which
are dumped in the recovered media bunker (21-BUNK-01) before being added to the ball mill, if
suitable. The reuse of mill balls reduces the cost of the process. Provision for future installation of a
metal detector (21-METD-01) on the scats conveyor (21-CONV-02) has also been made in the design.

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Provision has been made in the design for future installation of a scats weightometer (21-WEIG-02) on
scats conveyor (21-CONV-02).

Balls that escape from the ball mill (21-MILL-02) report as report as trommel (21-TRSC-02) oversize into
a bunker (21-BUNK-03) from where they can be recovered and reused in the ball mill.

The Mill area is bunded to contain spillage which gravitates to a sump pumps, one on the mill feed end
side (21-PUMP-03) and one on the discharge end side (21-PUMP-04), from where it is pumped to the
mill sump (21-TANK-01).

5.6.4 Addition of Grinding Media

A tower crane (21-HYST-02) is situated in the Milling area to assist with maintenance and addition of
grinding media to the mill. Grinding media is laid down on the ball bunker (21-BUNK-03). Balls are
loaded into the ball kibble (21-SKIP-01) and lifted by the crane to the mill feed chute and the balls
allowed to roll into the mill.

5.7 MILLING CONTROL PHILOSOPHY

The milling and classification must be regarded as one unit operation as any change in operating
parameters of the mill affects the cyclones operation and vice versa. The unit is designed to operate at
steady state as near as possible to optimum conditions. Effective and practical controls and proper
instrumentation are therefore designed to allow the milling circuit to operate at steady state and as
close to optimum as possible in order to attain the following objectives:

• Achieve maximum throughput of 250 tph whilst keeping mill discharge density of 72% solids.
• Achieve optimum mesh-of grind (80% passing size 75 um) whilst maintaining a plant design
throughput of 2.0 million tons per annum.
• Achieve consistently optimum cyclone overflow slurry solids concentration of 35% solids by
weight for optimum preleach thickening performance whilst satisfying all other requirements.

5.7.1 Control
A weightometer (11-WEIG-02) installed on the SAG mill feed conveyor (11-CONV-03) as previously noted
will allow for control of SAG mill feed tonnage, process water addition into the SAG mill feed and
discharge sump for dilution purposes; lime addition to the milling circuit and metallurgical accounting
purposes.

Magnetic flow meters and air-actuated valves installed on the process water lines in the milling section
will be used to control water addition to the SAG/Ball discharge sump to maintain set densities in the
mill discharge and feed to the cyclone cluster respectively.

SAG mill feed dilution process water flow will be measured by a magnetic flow meter (PID2110- on the
feed water pipe line and adjusted by varying the position of the air actuated valve to match the set point
calculated from a ratio applied to the feed tonnage measured by the weightometer (11-WEIG-02) and
desired slurry discharge solids content of 72 % solids by weight.

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The mill discharge sump (21-TANK-01) will be equipped with an ultrasonic level transmitter to control
the sump level by varying the speed of the mill pumps (21-PUMP-01/2).

The feed pressure to the cyclone cluster will be controlled automatically through SCADA by opening and
closing the cyclone feed actuated pressure control valves (PID2140-PV- 01A/B/C/D/E/F) to achieve the
set pressure (to be specified by the vendor) in the feed distributor (21-CYCL-01) measured by a pressure
transmitter (PID2140-PT-01).

The SAG & Ball mill control philosophy will be part of the vendor supply. The control philosophy will
encompass instrumentation that monitors mill drive motors, gear sprays and trunnion bearings. The
control philosophy will provide permissive signals as well as alarms and mills trip signals.

• The mill motor is equipped with temperature detectors (RTD’s) for the stator windings and
motor bearings. These will enable monitoring of windings and bearings temperatures. Alarms
and trip signals are included as part of the temperature monitoring and control system.
• The gear spray system has a count monitor that will send a fault signal in response to incorrect
amount of counts which could be a result of low grease pump air pressure, low level in the
grease drum or defective solenoid valve.
• The trunnion bearings are fitted with temperature detectors (RTD’s) to monitor the surface
temperature of the trunnions and provide start permissive signals and alarm & trip mill when
limits are exceeded. A temperature transmitter in the trunnion lube system tank monitors the
oil temperature while a level switch will provide an alarm when oil level in the tank drops to
below allowable minimum. Both the temperature transmitter and low level switch located in
this tank provide the start permissive for the low and high pressure oil pumps.
• A differential pressure switch installed on the lube oil filter assembly will alarm on high pressure
indicating dirty filter.
• Flow switches fitted on trunnion low and high pressure oil systems will alarm on low oil flow and
trip the mill on low -low flow.

Lime addition to mill feed will be controlled as a cascade loop. Under normal circumstances lime slurry
flow will be measured by a magnetic flow meter (PID2110-FT-04) on the feed lime line and adjusted by
varying the position of the air actuated flow control valve (PID2110-FCV-04) to match the set point
calculated from a ratio applied to the feed tonnage measured by the weightometer (11-WEIG-02) and
desired lime slurry flow rate. A pH probe (PID3210-AE-01) located in the conditioning tank (32-TANK-01)
will be used to monitor the pH levels reporting to leach. In the event of this falling below certain set
point; the position of the lime feed valve will be controlled using output from the pH probe until the pH
rises to the required values; by which time the other loop described above takes control. In the event
that the lime feed valve in the milling area (PID2110-FCV-04) is fully open and the pH is still less than the
minimum set point; then an ON/OFF valve in the leach area (PID3210-FCV-03) opens up to spike lime
into the system until the pH is above the set-point.

A siren located at the head pulley of the mill feed conveyor (11-CONV-03) will sound at the start of the
conveyor. This conveyor will be equipped with low speed sensor and belt drift switches.

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A siren will also sound when the start button to start each of the SAG mill (21-MILL-01) and Ball mill (21-
MILL-02) is activated and a light will rotate on mill start-up.

A Flow switch (PID2130-FSL-06) fitted on gland water service lines feeding the cyclone feed pumps will
alarm the operator in the event of low gland water flow. Pressure gauges (PID2130-PI-01/2) are installed
on the individual gland service lines to the cyclone feed pumps to give a visual indication of gland water
pressure while a pressure switch (PID2130-PSL-03) installed on the common line will give an alarm
(PID2130-PAL-03) in the event of low gland water pressure. Gland service water pressure is regulated
down by a pressure regulation valve (PID2130-PCV-02) fitted on the common pipeline feeding gland
water to the pumps.

Mill spillage pump (21-PUMP-03/4) is started manually on high sump level and is fitted with low level
switch (21-LSL-03/4) which stops the pump automatically on low sump level.

5.7.2 Control Loops

• Mill Feed Rate:

Ore will normally be fed at about 250 dry t/h. Tonnage rates are controlled by a set point which can be
modified from the relevant SCADA screen. The tonnage rate set point must take ore moisture into
account, however. Feed rate is measured and recorded via a weightometer (11-WEIG-02), installed on
mill feed conveyor (11-CONV-03). The feed rate is controlled by a PLC adjusting the speed of the variable
speed stockpile reclaim using the weightometer feedback signal as a reference.

• Mill Feed Dilution Water:

The ore is ground wet at 70% solids by weight for optimum milling efficiency. SAG mill (21-MILL-01) feed
dilution water will be added to the mill in ratio to ore feed rate. The ratio can be modified using the
SCADA system to suit different types of ores. Using the reading from a magnetic flowmeter (PID2110-FT-
01) and controlling the actuated flow-control valve (PID2110-FCV-01) process water flow rate is adjusted
to achieve the required mill discharge density.

Process water can also be added to the Ball mill (21-MILL-02) in ratio to ore feed rate to the SAG mill
(21-MILL-01) to achieve optimum mill densities in response to varying ore types being fed to the milling
circuit. Using the reading from a magnetic flowmeter (PID2120-FT-02) and controlling the actuated flow-
control valve (PID2120-FCV-02) process water flow rate is adjusted to achieve the required mill
discharge density.

• Mill Sump Dilution Water:

Under normal circumstances process water flow will be measured by a magnetic flow meter (PID2130-
FT-03) on the sump (21-TANK-01) process water feed line and adjusted by varying the position of the air
actuated flow control valve (PID2130-FCV-03) to match the set point calculated from a ratio applied to
the feed tonnage measured by the weightometer (11-WEIG-02) and process water flow rate. A density
meter (PID2130-DE-01) on the cluster distributor feed line will be used to monitor the cyclone feed

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density. In the event of this falling below certain set point; the position of the process water flow control
valve (PID2130-FCV-03) will be controlled using output from the density transmitter (PID2130-DT-01)
until the density rises to the required values; by which time the other loop described above takes
control.

• Mill Sump Level:

The mill discharge sump (21-TANK-01) is equipped with an ultrasonic level transmitter (PID2130-LT-01)
to control the sump level. The sump level is maintained by varying the speed of the mill discharge
pumps (21-PUMP-01/2): slowing down the pumps if the sump level goes below the set point and
speeding up the pumps if the level rises above the set point.

• Cyclones Inlet Pressures:

The classification performance is highly dependent on the cyclone inlet pressure which controls the
magnitude of the centrifugal forces generated in the cyclone. Inlet pressure of between 75 and 100 kPa
are required to achieve efficient separations. Pressure is measured by a pressure transmitter (PID2140-
PT-01) mounted on the radial distributor (21-CYCL-01). Normally four cyclones are functioning, with two
cyclones on standby. Four cyclones normally maintain the cyclone feed pressure within range, provided
the spigot sizes are maintained within working limits. When necessary cyclone feed pressure is
regulated by opening or closing valves to cyclones (PID2140-PV-01A/B/C/D/E/F), increasing or reducing
the duty cyclones. Pressure shall be monitored in field by the field operator by regularly checking the
field pressure indicator (PID2140-PI-04). Cyclone feed valves must only be fully open or fully closed –
there is no part opening.

• Mill motor current monitoring:

The mill motor power draw (KW) is measured and displayed on the relevant SCADA screen. This is a
critical operating parameter as it represents the power consumed in the comminution process.
Although not used in any automatic control loop the mill power serves as reference for the adjustment
of other important operating parameters, such as mill feed rate, ball charge and mill discharge solids
concentration.

5.7.3 Milling SCADA Display

The milling area has a number of dedicated SCADA pages notably, general milling; mill gearbox and
trunnion bearings and mill motor lubrication systems. The items displayed on each milling SCADA page
are:

5.7.3.1 General Milling Page

Sag Mill

• Status (stopped/running) of all drives.

• Instantaneous and totalised mill feed tonnage
• Variable speed output (%) of the Stockpile reclaim feeders(11-FEDR-01/2/3)

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• The ratio control constant for mill discharge density.

• Instantaneous and totalised SAG mill feed dilution water flow rate as measured by the magnetic
flowmeter (PID2110-FT-01)
• Instantaneous and totalised Sag mill lime slurry flow rate as measured by the magnetic
flowmeter (PID2110-FT-04)

Ball mill

• Position of mill dilution water flow control valve (PID2120-FCV-02).

• Instantaneous and totalised Mill sump dilution water as measured by the magnetic flowmeter
(PID2130-FT-03)
• Position of mill sump dilution water flow control valve (PID2130-FCV-03).
• Level of the mill sump (21-TANK-01) %
• Open or closed position indication of the mill discharge pump (21-PUMP-01/2) suction valves
(PID2130-V-06 & 10)
• Variable speed output (%) of the duty mill discharge pump
• Instantaneous and totallised tonnage pumped to cyclones
• Open/Close position of individual cyclone feed valves (PID2140-PV-01A/B/C/D/E/F)
• Open/Close position of gland water valves (PID2130-XV-04/03)
• Mill motor power draw
• Status (stopped/running) of all drives.
• The ratio control constant for mill discharge density.
• Mill motor power draw.

5.7.3.2 Mill Lubrication Page (Sag and Ball Mills)

• Status (stopped /running) of all drives
• Trunnion bearing lube tank oil temperature
• Feed end trunnion bearing temperature
• Discharge end trunnion bearing temperatures
• Trunnion bearing low pressure oil cooler exit oil temperature
• Gearbox oil temperature
• High pressure oil to mill feed end trunnion bearing
• High pressure oil to mill discharge end trunnion bearing
• Gearbox temperature
• Pinion drive and non drive end temperatures
• Pinion bearings low pressure oil cooler exit temperature
• Pinion bearing lube tank oil temperature

5.7.3.3 The Mill Motor Page

• Status (stopped/running) of all drives
• Motor stator winding temperature
• Motor drive and non drive end temperatures

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5.7.3.4 Alarms
• Low gland water pressure; PID2130-PAL-03 to the cyclone feed pumps 21-PUMP-01/2
• Low gland water flow PID2130-FAL-06 to 21-PUMP-01/2
• Low mill discharge sump level; PID2130-LALL-01
• Conveyor (21-CONV-01/2/3) low speed (PID2110-SAL-01/2/3)
• Low pressure in pinch valve receiver (PID2130-PAL-02)

5.7.4 Interlocks
Interlocks are put in place to protect the mill and its ancillary equipment from mechanical and other
forms of damage and to avoid some serious operational problems/ complications. The interlocks are
such that the mill will immediately trip and stop if some condition is detected that would cause damage
or other operational complications if the mill were to continue running. Similarly an interlock will
prevent the mill from starting up if correct start up conditions are not met:

5.7.4.1 Interlock Summary

Equipment Interlock Condition
SAG Mill A. SAG Mill cannot start or run if downstream processing
(21-MILL-01) equipment and the lubrication systems are not running
- Scats discharge conveyor (21-CONV-01)
- Ball mill (21-MILL-02)
B. Locked charge system (Main drive only) SAG Mill cannot
start if:
− The mill has been shut down for 2 Hours AND the
mill has not been inch driven for one complete
revolution.
C. SAG Mill cannot start or aborts the start if:
− The girth gear lubrication system is not ready
− The individual lubrication systems on the
gearbox or trunnions indicate:
High or High High oil temperature
High filter differential pressure
Low or High oil pressure
Low or Low Low oil flow
Low oil pressure
Low pinion oil levels
High motor currents or temperature
− The individual temperature sensors on the
trunnion bearing pads, pinion bearings or motor
bearings indicate:
High or High High.
− High Pressure ‘jacking’ oil not high enough (to
unseat the mill).
− Low pressure ‘flood’ lubrication oil flow is too
low
− The barring drive interlock is not closed.
− Main motors
Thermal overload
Bearing temperatures or winding temperatures

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are too high

Motor start attempted within 30 minutes of
previous start
Secondary resistance system fault
D. SAG Mill will shut down when operating if:
Girth Gear
− Girth gear fault has not cleared AND the
lubrication cycle is not complete within 30
minutes of a fault occurring.
− Faults include:
1. Low air pressure
2. Lubricant reservoir empty, broken or
blocked lines or nozzle
3. Interval or timing over-run − As the
lubrication system operates
intermittently this allows up to 25
minutes maintenance time before the
mill shuts down.
There is no feed to the mill for more
than 10 minutes.
E. Inching drive
− Inching drive cannot engage until main motor
drive is isolated at HV controls
− Main motor isolating switch cannot engage until
inching drive clutch is disengaged.

Ball Mill A. Ball Mill cannot start or run if downstream processing

(21-MILL-02) equipment and the lubrication systems are not running
B. Locked charge system (Main drive only)
− The mill has been shut down for 2 Hours AND the
mill has not been inch driven for one complete
revolution.
C. Ball Mill cannot start or aborts the start if:
− Mill discharge sump level is high (21-LAHH-01)
− The girth gear lubrication system is not ready
− The individual lubrication systems on the
gearbox, trunnions, pinions or motor indicate:
High or High High oil temperature
High filter differential pressure
Low or High oil pressure
Low oil flow
Low trunnion cooling water flow
Low oil pressure
Low pinion oil levels
High motor currents or temperature
− The individual temperature sensors on the
trunnion bearing pads, pinion bearings or motor
bearings indicate:
High or High High.
− High Pressure ‘jacking’ oil not high enough (to
unseat the mill).
− Low pressure ‘flood’ lubrication oil flow is too

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low
− The barring drive interlock is not closed.
− Main motors
Thermal overload
Bearing temperatures or winding temperatures
are too high
Motor start attempted within 30 minutes of
previous start
Secondary resistance system fault
D. Ball Mill will shut down when operating if:
− The girth gear lubrication system has faulted
E. Ball Mill will shut down when operating if:
Girth Gear
− Girth gear fault has not cleared AND the
lubrication cycle is not complete within 30
minutes of a fault occurring.
− Faults include:
1. Low air pressure
2. Lubricant reservoir empty, broken or blocked
lines or nozzle
3. Interval or timing over-run
− As the lubrication system operates intermittently
this allows up to 25 minutes maintenance time
before the mill shuts down.
There is no ore into the SAG mill for more than
10min (11-WALL-02)
F. Inching drive
− Inching drive cannot engage until main motor
drive is isolated at HV controls
− Main motor isolating switch cannot engage until
inching drive clutch is disengaged.
Mill alarms A. Alarms for SAG and Ball Mills when running. These alarms
will indicate in the control room but will not shut the mill
down as there are back ups. The alarm gives time to rectify
fault without stopping production:
− Girth gear lubrication fault
− High temperature alarms on gearbox oil,
trunnion oil, trunnion bearing temperature,
pinion bearing temperature, motor bearing and
winding temperature. All are backed by high high
trip outs.
− Filter differential pressure
− Low oil flow to SAG mill trunnions, backed by low
low flow trip out
− Other instruments are continuously monitored in
the control room and trends indicate whether
there are potential problems with the mills.
Scats discharge conveyor A. Scats discharge conveyor cannot start or run unless the
(21-CONV-01) media reclaim magnet (21-MAGT-01) is running
B. Scats discharge conveyor cannot start or run unless
Pebble crusher feed Conveyor (21-CONV-02) is running

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C. Interlocks that will prevent or stop operation of Scats

discharge conveyor:
− Pull wire switches
− Under speed switch (21-SAL-01)
Pebble crusher feed conveyor 1 A. Conveyor 21-CONV-01 cannot start or run unless
(21-CONV-02) Conveyor 21-CONV- 02 is running
B. Interlocks that will prevent or stop operation of Conveyor
21-CONV-01
− Pull wire switches
− Under speed switch (21-SAL-02)
− Belt drift switch (21-ZAH-01)
− Metal detector (21-AAH-01)
Pebble crusher feed conveyor 2 A. Conveyor 21-CONV-02 cannot start or run unless
(21-CONV-03) Conveyor 11-CONV-03 or the pebble crusher (11-CRUS-02)
is running or both are running.
B. Interlocks that will prevent or stop operation of SAG Mill
Discharge Conveyor:
− Pull wire switches
− Under speed switch (21-SAL-03)

Equipment Interlock Condition

Mill Feed side spillage pump A. Mill sump pump is started manually when sump level is
21-PUMP-03 high and stops when sump level is low (21-LSL -02).
Mill Discharge side spillage pump A. Mill sump pump is started manually when sump level is
21-PUMP-04 high and stops when sump level is low (21-LSL-03).
Cyclone Feed pump 1 Cyclone feed pump can not start or run unless:
21-PUMP-01 − Drain valve (21-XV-05) is closed.
− Suction valve (21-XV-01) is open
− Gland water valve (21q-XV-03) is open
− Suction valve n(21-XV-02) is open
− Gland water valve (21-XV-04) is closed
− There is sufficient pulp in the mill sump (21-TANK-
01). Low sump level (21-LALL-01) will stop the
pump if running.
− There is sufficient flow in the gland service line to
pump. Low flow (21-FAL-06) will stop the CF pump
if running.
− There is sufficient gland water pressure. Low gland
water pressure (21-PAL-03) will stop the CF pump
if running.
− The trash linear screen (31-LISC-01) is running
− Thickener feed tank (31-TANK-01) level is low.
− At least one of the cyclone feed valves ( 21-PV-
01A/B/C/D/E/F) is open
− Lime dosing pump (53-PUMP-03/04) is running
Process water pump (61-PUMP-01/02) is running
Cyclone Feed pump 2 Cyclone feed pump can not start or run unless:
21-PUMP-02 − Drain valve (21-XV-06) is closed.
− Suction valve (21-XV-02) is open

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− Gland water valve (21-XV-04) is open

− Suction valve n(21-XV-01) is open
− Gland water valve (21-XV-04) is closed
− There is sufficient pulp in the mill sump (21-TANK-
01). Low sump level (21-LALL-01) will stop the
pump if running.
− There is sufficient flow in the gland service line to
pump. Low flow (21-FAL-06) will stop the CF pump
if running.
− There is sufficient gland water pressure. Low gland
water pressure (21-PAL-03) will stop the CF pump
if running.
− The trash linear screen (31-LISC-01) is running
− Thickenner feed tank (31-TANK-01) level is low.
− At least one of the cyclone feed valves ( 21-PV-
01A/B/C/D/E/F) is open
− Lime dosing pump (53-PUMP-03/04) is running
− Process water pump (61-PUMP-01/02) is running

5.8 OPERATING PROCEDURES IN MILLING

The ball mills are usually the first mills to be started in the mill start up sequence. –

Prerequisites for start-up of the ball mill are the same as the comprehensive pre-start checks that need
to be conducted for the start up of the SAG mills and the same prerequisites met.

Normally the ball mills will be operational prior to the SAG mills being started so that the slurry
discharge from the SAG mill can be pumped to the cyclones and returned to an operating ball mill thus
completing the grinding circuit

5.8.1 Start-up procedures

• Start the mill cooling system
• Start the ball mill lube system-from SCADA (sequence start)
• Barring/ inching the ball mill for a minimum period of 10 min is required.
• During the barring/inching period establish mill main slurry circuit water flow by:
o Starting trash screen 31-LISC-01
o Opening spray valves for the trash screen (PID3110-V-01 & 02)
o Opening the mill trommel spray water valve (PID2120-V-05)
o Starting gland service pump 62-PUMP-12/13
o Opening duty cyclone feed pump gland service valve (PID2130-V-16 for 21-PUMP-01 or
PID2130-V-19 for (21-PUMP-02)
o Opening from SCADA the suction valve of the duty cyclone feed pump (PID2130-XV-01
for 21-PUMP-01 and PID2130-XV-02 for 21-PUMP-02)
o Opening the required number of cyclones
o Starting the process water pump 61-PUMP-01/02

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o Instructing the control room operator to manually open the mill feed water valve
PID2120-FCV-02 to 10% from SCADA.
o Instructing the control room operator to manually open the mill sump dilution valve
P2130-FCV-03 to 20% from SCADA.
• Starting the duty cyclone feed pump 21-PUMP-01/2 once sump level is close to 60%;
• Disengage barring gear at the end of 10 minutes
• Switch off and disengage the barring gear. Isolate it from MCC
• Energise the mill motor switch gear; green light will appear in field to indicate that mill is ready
to start
• Mill operator to ensure that no one is in close proximity of the mill
• The field operator can now activate the start push button on the local control station. After
activation of the start push button, an audible alarm and orange/red flashing light will first be
activated for approximately 30 seconds before the mill starts to turn.

5.8.1.1 SAG Mill

The following process should be done concurrently with the same steps outlined above for the ball mill.

• Start the mill cooling system

• Start the SAG mill lube system-from SCADA (sequence start
• Instruct the control room operator to manually open the mill feed water valve PID2110-FCV-01
to 10% from SCADA
• Barring/ inching the SAG mill for a minimum period of 10 min is required.
• During the barring/inching period establish mill main slurry circuit water flow by:
• Disengage barring gear at the end of 10 minutes
• Switch off and disengage the barring gear. Isolate it from MCC
• Energise the mill motor switch gear; green light will appear in field to indicate that mill is ready
to start
• Start the scats recycle system starting with the scats crusher (11-CRUS-01), 21-CONV-03, 21-
CONV-02, 21-CONV-01. Ensure the pebble metal detector and the media reclaim magnet are
running.
• Mill operator to ensure that no one is in close proximity of the mill. The SAG mill should only be
started once the ball mill has started and attained full speed.
• The field operator can now activate the start push button on the local control station. After
activation of the start push button, an audible alarm and orange/red flashing light will first be
activated for approximately 30 seconds before the mill starts to turn.
• Open the mill lime feed valve (PID2110-V-13) to 100% and the lime automatic valve (PID2110-
FCV-04) to about 10% and ensure lime bypass valve (PID2110-V-09) is closed, ensure lime is
being delivered into the Sag mill feed chute.
• Once mill has attained full speed the mill operator should give the control room operator the go
ahead to start the mill feed conveyor 11-CONV-03. The control room operator should start two
stockpile reclaim feeders at about 20% speed and gradually increase the speed until about 100

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tph is registered on the mill feed mass meter 11-WEGH-02, by which time he should put the mill
feed tonnage; mill feed dilution water; mill sump level; mill discharge sump dilution water; lime
and pH controllers in AUTO mode in SCADA which will automatically control the parameters to
achieve set points.

5.8.2 Field operator duties

The field operator is in radio contact with the control room at all times and must report any findings of
his inspection immediately. He may under special circumstances execute an emergency field stop of
major equipment to prevent a major breakdown.

Following are some of the duties that a field operator is expected to execute during normal mill run
operations:

• Inspection of motors, gearboxes, bearings and any moving machinery for undue temperature,
noise, smoke emissions and leakages that would indicate some damage that may result in a
major breakdown.
• Inspection of ball mill for liner bolt leakages, feed spout spillage or leaks in high wear areas.
• Taking sample of mill discharge and test slurry density using a “Marcy” type density scale.
• Checking level in mill discharge sump.
• Inspecting integrity of trommel screen panels.
• Checking mill discharge pumps gland service water supply. A small amount of water should
weep from the gland at all times. The gland must be tightened if it leaks excessive amounts of
water.
• Reporting on any oil/grease or chemicals spillages immediately to the shift supervisor. These
must be removed from the circuit and dumped in the dedicated dumping site. Oil and grease
spillages must never be pumped in circuit as it may cause significant gold losses by preventing
gold adsorption onto the activated carbon granules.
• Reading cyclone pressure.
• Checking cyclones for leaks which may indicate wear through the liners.
• Checking launders and boxes for sediments and blockages.
• Loading grinding media in the mill. The shift foreman instructs the field operator to load a
number of kibbles with steel balls of a specified size. These are lifted with a crane and placed on
the loading chute opening for discharge.
• Ensuring that scats are removed from the scats bunker.
• Ensuring good housekeeping with the milling area by attending to the spillage as soon as it
occurs.

5.8.3 Planned shutdown procedures

A planned shutdown achieved by an Operator will:

• Minimise spillage which is labour intensive to clean

• Ensure no damage to the equipment and smooth and rapid start up of the plant

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• Minimise dilution in the CIL area which would otherwise result in high reagent consumption.

For these reasons mill operators are to follow procedures given below during planned shutdowns:

• Stop the stockpile reclaim feeders (11-FEDR-01/2/3)

• Allow mill feed conveyor 11-CONV-03 to run empty
• Close the lime mill feed valve (PID-2110-V-13) and put the lime control valve PID2110-V-08 at
0% in manual
• Start the HP lube pump (SAG and Ball Mills) and check jacking oil pressure is sufficient.
• Allow the mills to grind out for the required time if ball charge is to be measured
• After grinding out, the control room operator should manually close mill feed dilution control
valve (PID2110-FCV-01) for the SAG mill and PID2120-FCV-02 for the ball mill.
• The control room operator should manually close mill discharge sump dilution control valve
(PID2130-FCV-03) to maintain a drop in level in the sump.
• At the end of grind out, field operator must stop the mill by the stop/start centre (SAG mill first
the Ball mill after.)This also stops the mill feed conveyor. The scats recycle system is then
stopped from SCADA.
• Close the mill trommel screen wash water valve (PID2110-V-05) for the Sag and (PID2120-V-05)
for the ball mill.
• Close the trash screen spray water valves
• Allow the mill discharge pump to run until the mill discharge sump 21-TANK-01 is almost empty
• Stop the duty cyclone feed pump (21-PUMP-01/2)
• Close the duty cyclone feed pump suction valve PID2130-V-06/10
• Open the cyclone feed pump suction dump valve PID2130-XV-05/06
• Close the duty gland water valve (PID2130-XV-03/4)
• Stop the trash screen 31-LISC-01
• Flush the duty pump
• The mill girth gear, trunnion bearing and motor lubrication systems should be left running all the
time. In the event where these are required to be shutdown; this can be affected as in the
vendor manual operating and maintenance manual.

5.8.4 Emergency Shutdown

It may be necessary at times to perform an emergency shut-down on one or more of the components of
the milling circuit (eg conveyor belt rip, jaw crusher wear plate loose, presence of tramp metal etc.). The
entire milling circuit will shut down in the event of a power failure or through an emergency stop. All
conveyors feeding the mills should stop along with the crusher apron feeders. Downstream operations
will not be affected. The Emergency stop buttons are in the mill control room on the control panel. Once
pressed, all equipment will stop. An emergency stop ignores all sequencing and stops all equipment in
the shortest time possible and may lead to spillage at chutes and some other issues that will need to be
rectified prior to restarting. The emergency stop shall be used only for emergencies and not as a quick
method of stopping the plant for routine purposes. More often it may be necessary to stop or isolate
just one piece of equipment. The operator shall determine whether it is possible to leave a part of the

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circuit running or shut down the entire section. Other emergency shut downs can be initiated in the field
through pull wire switches and automatic safety interlocks. All stops will shutdown associated
interlocked equipment. It is important that the location of the milling circuit emergency stop buttons is
familiar, and the outcome of their use is understood.

5.9 Operation of Barring Gear

The SAG and Ball mills have individual barring gear drives which will be used to inch the mill to enable
mill liner replacement and/or barring after extended shutdowns to loosen charge. The barring drive is
operated from a pushbutton in the field, which has a non-maintained contact.

When the mill is stopped for a long period of time, it may be possible that the material (charge) in the
mill becomes “frozen” and difficult to move. Starting the mill under these conditions could result in the
damage to the gearbox and thus it is imperative that the mill be barred/ inched for a period of 10
minutes before mill start up. In general the mill should be barred for 10 minutes prior to start up after a
stoppage length of more than 1hr.

In the case of the mill, the PLC/SCADA will be programmed in such a way that if the mill is stopped for
more than 1 hour; then it will not be possible to start the mill main drive before barring is carried out.

For safety reasons the barring drive can ONLY be operated:

• Using field control switches that have a non-maintained contact (in reverse or forward modes
depending on the operator requirements). During barring session the operator needs to press
the forward or reverse buttons all the time and releasing it will stop the mill.
• When main drive contact breaker (in the substation) is in an open position to prevent
simultaneous engaging of the main motor which could have disastrous consequences.
• When mill lubrication system (gearbox and trunnion bearings) is healthy to prevent damage of
bearings.

As an added safety feature to the barring drive mechanism; a stop button is supplied so that in the event
of releasing the forward or reverse button the mill does not stop this STOP button can be utilised.

5.9.1 Preconditions for starting barring drive

All the conditions listed below have to be satisfied for permission to start the barring drive to be
granted:

• Mill feed trunnion bearing temperature displayed < 700 C

• Low pressure lubrication system starting condition for the mill trunnion bearings is healthy
• High pressure lubrication system starting condition for the mill trunnion bearings is healthy
• Lubrication system starting condition for the mill motor is healthy
• Main drive is OFF. The main drive will be hard wire interlocked to the starter of the barring
drive and conversely the barring drive will be hard wired back to the main drive to ensure that
the main drive cannot be started.

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• Barring drive coupling is ENGAGED as indicated by the limit switch

5.10 Trouble shooting:

Trouble shooting for various classification problems is tabled in table below:

Item
No
Observation Possible Problem Action Required

1 Cyclone pressure gauge Mill pump cavitating Check mill sump level and dilution water
surges up and down addition
2 Cyclones blocking Tramp material entering Check apertures on mill discharge
cyclones trommel screen
Spigot torn Replace spigot
3 Low underflow density Cyclone inlet worn or too Replace cyclone inlet
large
Spigots worn or too large Replace spigots
Cyclone pressure too high Close one cyclone feed valve
4 High underflow density Spigots too small Replace with larger spigots during shut
down
Spigot is torn Take cyclone off line and replace spigot
Cyclone pressure Automatic pressure controller is failing.
continuously too high Open one more cyclone manually
5 Cyclones vibrate Feed pressure too high Open one cyclone feed valve
Partially blocked cyclone Isolate and open each cyclone for
inspection
6 High wear on spigots, High feed pressure Open up more cyclones to operate at a
inlets, vortex finders lower pressure if classification is
acceptable

7 Coarse cyclone overflow High re-circulating load Check mass flowmeter.

Feed density high Check feed density and dilute if required
Cyclone lining worn Isolate and open each cyclone for
inspection. Replace damaged section

Cyclone pressure high Open one cyclone feed valve

8 Underflow overflowing Downstream blockage Investigate and remove obstruction
9 Poor mill grind Low ball charge Add more steel balls.
Check mass flow meter

10 Low cyclone feed flow rate Pump / pipe restriction Switch to standby pumps and investigate
Water imbalance Check process water supply

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6. PRE-LEACH THICKENING
This section should be read in conjunction with the PRELEACH THICKENING PFD FD 3100 and P&ID
PD3110, PID3120)

6.1 INTRODUCTION

This manual covers the trash removal and thickening area of the Bisha Gold project. The trash removal
and thickening area is closely linked to the leaching and adsorption section as the thickeners provide the
feed for this circuit. Trash material must be removed since it can cause serious production and
metallurgical problems in the thickening and leaching circuit such as pegging of inter-stage screens in
the adsorption tanks and blocking of strainers in the elution circuit. Pegging the screens may cause
adsorption tank overflows, which result in undesired spillage and throughput rate reduction. The
thickening area is utilised to thicken slurry to a higher density thereby recovering process water and
reducing the volume of slurry in the downstream processing area.

6.1.1 General Area Safety Policies and Procedures

6.1.1.1 General PPE (Personal Protective Equipment)

The PPE requirements normally include:

• Steel capped safety boots

• Hard hat
• Full overall with reflective material strips
• Safety glasses
• Gloves
• Dust masks must be worn when required
• Ear protection

In addition, operators shall ensure that Fire Extinguishers and High Pressure Hosing Equipment are
readily available when working around the area.

The main issues of concern are highlighted below:

Cyanide

• Recycled process water containing residual cyanide from downstream processing is found within
the thickening area. Though the cyanide levels are low caution must be exercised minimise any
risk of poisoning. Personnel shall minimise direct contact with slurry (wet or dry) or process
water through correct use of PPE.

Flocculant

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• Flocculant is non-flammable, and is incompatible with oxidising agents and acids. Do not inhale
dust from solid flocculant. Where a dust hazard exists, mechanical explosion proof extraction
ventilation is recommended. Spillage of liquid flocculant should be cleaned up by hosing at the
earliest opportunity, as the spillage will create a significant slip hazard.
• If flocculant contacts the eyes apply the standard procedure of flushing the eyes for 20 minutes
with water from an Eye Wash Station should be carried out followed by medical examination at
the site Medical Centre.

Trash Screens

• Avoid loose clothing or long hair when working in the trash screen area. If a belt or a rotating
roller gets a grip on a piece of your clothing or hair, it will pull you in quickly.
• Be aware of your clothing when working around trash screens or motors. Change or secure
loose personal items (including long hair) when in the vicinity of trash screens.
• Remember the safety pull-wire alongside the screens. Stop the screens if a situation arises
which could endanger life or property. Local stop station activation has the same function, and
will override control systems and stop the plant in the shortest possible time.

Thickener

• Hard hats should be removed when on the thickener bridge, due to the risk of them falling into
the thickener and being raked into the center cone causing a blockage. Hard hats should be
stored in the container provided at the entrance to the bridge.
• Ensure the thickener area is always clean and that lighting is sufficient to avoid accidents.
• Underflow and process water pumps will start and stop under automatic control and therefore
must be isolated and tagged out prior to commencing any work.
• No attempt shall be made to flush a pump or pipeline unless the suction isolation valve is closed
and the pumps are isolated. Operators should be aware that a large volume of slurry could run
back from a blocked pipe once the blockage is cleared.
• No attempt shall be made to remove or repair damaged components or to remove blockages, or
the like, on an operating pump.
• WARNING: Pumps that are blocked and continue to run can build up large amounts of heat and
care must be taken when draining these pumps, as hot slurry can be ejected under pressure.
Maintenance or other work on a pump that requires disconnection of the piping shall not
commence until both the suction and delivery isolation valves are closed.

Major Pre-Leach Thickening Equipment

Equipment code Equipment name kW Description Supplier

31-SPLT-01 Cyclone overflow splitter
31-LISC-01 Trash Linear Screen 3.0 12m2 HBS unit, Delkor
600x700um
aperture
31-BSKT-01 Linear Screen Basket

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31-TANK-01 Preleach thickener Feed tank

31-PUMP-01 Preleach thickener feed pump 1 45
31-PUMP-02 Preleach thickener feed pump 2 45
31-TANK-02 Preleach thickener external SENET
dilution tank
31-MIXR-01 Dilution tank mixer 55 SENET
31-THCK-01 Preleach thickener mechanism 22
31-PUMP-03 Thickener UF pump 1/2 55
31-PUMP-04
31-PUMP-05 Preleach thickener spillage 7.5
pump
31-PUMP-06 Trash screen spillage pump 11
31-TANK-04 Preleach thickener OF tank
31-PUMP-07 Preleach Thickener OF pump 1 22
31-PUMP-08 Preleach thickener OF pump 2 22

6.2 PROCESS DESCRIPTION

Step 1: Cyclone overflow gravitates from the cyclone overflow launder via the cyclone overflow splitter
(31-SPLT-01) to the linear trash screen (31-LISC-01). The feed slurry is distributed over the screen and
drains through the cloth into the underpan, from which it gravitates to the releach thickener feed
sump(31-TANK-01). Trash material retained by the screen is dewatered on a linear screen basket (31-
BSKT-01) before falling into the storage bunker prior to being transferred to the tailings sump for
disposal. The dirty water gravitates to trash screen sump from where it is pumped together with the
other spillage in this area using sump pump (31-PUMP-06) to the preleach feed splitter.

Figure 6-1: GKD Delkor Linear Screen Typical Installation.

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The screen requires the following services for operation:

• Instrument quality air supply at a 6 Bar (Maximum) for the operation of the automatic belt
tracking system.
• Clean water supply at a pressure of 4 Bar for the cloth washing sprays.

The linear screen arrangement and operation are illustrated in the sketches below:

Figure 6-2: Linear Screen Operating Principles.

A complete description of the operation and maintenance of the linear screen is given in the vendor
(GKD Delkor) Operating and maintenance manual in Appendix).

Step 2: The screened pulp from the trash screen then gravitates into the preleach thickener feed sump
(31-SUMP-01) from where it is pumped by one of the thickener feed pumps (31-PUMP-01/2) to the
thickener external dilution tank (31-TANK-02).The slurry pumps (31-PUMP-01/2) are fitted with variable
speed drives and a gland seal water supply system. The discharge pipe work of the duty and standby
thickener feed pumps combine at a bi-directional valve (PID3110-V-09), which allows both thickener
feed pumps to be run simultaneously to facilitate pump change over without stopping the plant.

Step 3: The screened trash screen underflow, process water, flocculant spillage and the thickening
sump discharge enter the thickener feed external dilution tank and flows to the preleach thickener (31-
THCK-01). An optimum concentration exists for each and every application at which the highest
sedimentation rate is achieved at the lowest flocculant dosage rate. This is often in the 12 to 14 %
solids range for Gold ores and the optimum concentration is determined by ongoing optimisation test
work. The mixer (31-MIXR-01) in the dilution tank ensures adequate mixing of the streams entering the
tank before gravitating to the thickener.

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The purpose of the thickener is to thicken slurry to a higher density (50% solids by weight) and reduce
the volume for downstream processing. This maximises leach and adsorption retention time (and
possibly recovery) and reduces reagent quantities.

Principle of Operation

The high rate thickener is large settling tank where diluted slurry enters a feed well in the centre, with
thickened slurry being withdrawn from the bottom and clean water overflowing the top. The thickeners
work with the aid of flocculants which are long chain polymers that cause the slurry particles to be
attracted to each end of the chain and rejecting interstitial water between them. The particles then
settle to the bottom of the thickening tank. This process is known as flocculation. The rejection of the
water causes the slurry to increase its solids percentage and this is known as thickening.

Figure 6-3: Flocculation Mechanism.

The picture in Figure below shows a typical thickener installation.

Figure 6-4: GKD Delkor Thickener.

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There are three settling zones in the high rate thickener which are known as the clear zone, hindered
settling zone and compacted (or settled) zone.

• The clear zone contains clear water which overflows the thickener via the thickener overflow
launder and gravitates to the process water pond.
• The hindered settling zone contains flocculated solids which are settling under gravity and water
which is rising through the solids to the clear zone.
• The compacted zone contains solids which have largely settled resulting in thickened slurry
which is ready for discharge. The thickeners are equipped with rakes which direct the thickened
slurry into the underflow cone from where it is drawn from the thickener and pumped to the
leach circuit.

Figure 6-5: Settling Zones in “High Rate” Thickening.

A: Clear solution.

B: “Hindered settling”/”Compaction” intermediate zone.

C: Compression zone.

Each thickener consists of the following main components :

Main thickener tank

The tank is 35 meters in diameter with a sloping bottom. The rake drive and feed well are supported by
a bridge and a walkway which spans the tank.

Feedwell and feed pipe

The feed pipe delivers slurry from the thickener distributor box across the top of the thickener to the
feed well. Thickener by pass is not installed. Incoming feed enters the circular feed well tangentially,

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promoting a gentle mixing of the slurry and diluted flocculant. The feed well is sized to allow for de-
aeration of the incoming slurry feed. Flocculant can also be injected into the feed well from sparge
pipes. A deflector cone at the bottom of the feed well allows the mixed slurry to discharge steadily into
the main body of the thickener, at the hindered settling zone, from where the solid particles settle to
the bed whilst clear liquid rises towards the surface where it overflows via the circumferential overflow
launder.

Rake drive

The thickener is equipped with four rake arms. Two long arms extend to the edge of the tank. Two
shorter arms are installed at 90° to the long arms. The arms are fitted with rakes arranged to sweep the
entire floor of the thickener twice per revolution. The rakes move solids towards the centre cone, as the
rake arms rotate, and also help to keep the bed mobile and thicken the solids in the bed. The rake drive
configuration is a hydraulic driven motor equipped with a reduction gearbox connected to a pinion
driving a slew ring gear coupled to a torque tube. The torque tube in turn drives the rakes. The drive has
an automated lift facility that raises the rake arm assembly to a maximum 600mm if the bed offers too
much resistance to movement.

Underflow withdrawal

Underflow is withdrawn from the discharge cone via one of two 250 NB nozzles each connected to a
separate underflow pump.

Pulp bed level control system

This sensor indicates when the pulp water interface (bed depth) rises and adjusts flocculant addition
accordingly.

Torque transmitter

This is a pressure transducer measuring the pressure applied by the hydraulic drive motor. This pressure
is proportional to torque and hence, the 4-20 mA signal transmitted is proportional to torque. The
torque is displayed as a percentage of full load torque on the control panel. If the torque becomes too
high an alarm sounds and the rakes will automatically lift to prevent them from being damaged or
bogging down. If the torque exceeds the maximum, the drive will shut down automatically to prevent
rake damage.

The thickener underflow pumps feed into a common pipe through a Tech Taylor Valve. This valve
automatically allows the flow-source to change from the duty pipe to the standby pipe without any
operator input. The standby pump is started up while the duty pump is being shut down, and the
pressure change moves a rubber ball in the valve from one entry port to another. Thickener underflow
may be recirculated to thickener feed; routing is controlled by pneumatically operated 200mm knife-

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gate valves. (Recirculation is normally practiced during temporary or short-term stoppage of thickener
feed, or when building up underflow densities during start-up or if the thickener has been pumped out.
It may also occur if feed to leach has to be stopped for a period)

Overflow from the thickener is directed to the thickener overflow tank (31-TANK-04) from where it is
pumped to the process water pond (61-POND-02) by one of the fixed speed thickener overflow pumps
(31-PUMP-07/8).

Thickener underflow at the target density of 50% solids is pumped to the CIL section.

Specific Issues for Thickeners

The following issues are likely to require observation on the thickeners:

1. Monitor the overflow water for clarity.

2. Monitor top surface of thickeners for build up of foam, flocculant, waste etc.
3. Watch rake arm wand for erratic or jerky movement – the rakes should move smoothly at all
times.
4. Monitor all slurry and flocculant feed lines for leaks etc.
5. Check oil level in hydraulic tank
6. Check oil temperature
7. Visually check hydraulic hoses and system for leaks and report any leaks found.
8. Check gearbox for undue noise or vibration and report.
9. Monitor underflow area for leakage, keep clean at all times.

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6.2.1 Controls

6.2.1.1 Linear screen

The screen is fitted with an automatic cloth tracking system operated with instrument air. The cloth runs
between alignment switched and an alarm is triggered if the cloth runs out of alignment.

Instrument air at 6 Bar and raw water at 4 Bar are required to operate the linear screen.

For further details please refer to the O & M Manual in Appendix

The pre-leach thickener feed sump (31-TANK-01) will be equipped with an ultrasonic level transmitter
(31-LT-01) to control the sump level by varying the speed of the thickener feed pumps (31-PUMP-01/2).

6.2.1.2 Thickener
Please refer to the O & M Manual in Appendix

Feed slurry dilution

The thickener has an external feed dilution system to ensure the correct feed density to the thickener is
attained ( about 11% solids by weight).

Local panel

A local panel is mounted on the thickener bridge. The panel consists of the following:

• Audible alarm (Siren).

• Visual alarm (Flash light).
• Torque indication.
• Alarm lights for high torque and main drive trip.
• Start and emergency stop buttons.
• Local alarm reset button.

Torque control and automatic rake lift system

The rakes and the rake lifting systems are powered by a hydraulic power pack which is controlled from
the central PLC and. The rake lift system operates automatically according to the vendor control
philosophy (See appendix). The control philosophy is summarised below:

• A pressure transducer (31-NT-01) fitted to the hydraulic power pack will provide thickener
torque indication. If an increase in solids loading raises the torque to 55 % of the installed
torque, the pressure transducer activates the high torque alarm at the SCADA and a siren
sounds. This warns the operator to take corrective action to prevent an excessively high torque
in the thickener (31-THCK-01). The alarm will continue to sound until the operator accepts the
alarm condition.

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• If the torque continues to rise to 65 % of the maximum torque, the rake lifting action will start
and the system alarms as previously described. The rake will rise until the torque drops below
55 %. The rake will then stop rising. If the torque drops below 50 % of the installed torque, the
rake will begin to drop. If the torque rises to 100 % of the installed torque, the hydraulic motor
will trip and the very high torque alarm will be activated

Bed level monitoring and control

Bed level indication in the thickener will be provided to alert operators of any build up in inventory in
the thickener. This mud ball (31-LT-02) will be used to regulate flocculant addition rate by varying the
speed of the flocculant dosing pumps (52-PUMP-05/6).

Bed mass monitoring and control

A combination of pressure transmitter (31-PT-01) located at the bottom of the thickener (to measure
bed mass) and the nuclear density meter (31-DT-01) will enable the underflow variable speed pumps
(31-PUMP-01/2) to be operated in a cascade loop as a means of controlling the underflow density (50%
solids) to the Leach circuit for optimum water recovery.

On low density measurement the density control valve 1A (31-DV-01A) will close and density control
valve 1B (31-DV-01B) will open to re-circulate the underflow at minimum speed until the required
density is achieved. See simplified P&ID in Figure below:

Mass flow monitoring and recording:

The magnetic mass flow meter (31-FT-01) will be used together with the nuclear density meter (31-DT-
01) as a mass flow meter. The instrumentation will give a local and Scada display of instantaneous slurry
density and instantaneous and totalized volumetric flow and integrated dry tonnage. The flow will only
be totalized when the forward valve is open.

A Flow switch (PID3110-FSL-01) fitted on gland water service lines feeding the preleach thickener feed
pumps will alarm the operator in the event of low gland water flow. Pressure gauges (PID3110-PI-01/2)
are installed on the individual gland service lines to the preleach thickener feed pumps to give a visual
indication of gland water pressure while a pressure switch (PID3110-PSL-03) installed on the common
line will give an alarm (PID3110-PAL-03) in the event of low gland water pressure. Gland service water
pressure is regulated down by a pressure regulation valve (PID3110-V-04) fitted on the common pipeline
feeding gland water to the pumps.

A flow switch (31-FSL-02) and pressure switch (31-PSL-05) are also installed on the common gland
service line feeding the thickener underflow pumps (31-PUMP-03/4) together with pressure gauges (31-
PI-03/4) are installed on the individual gland service lines.

The preleach thickener overflow pump (31-PUMP-07/8) will stop on low level in the overflow tank (31-
TANK-04).

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The trash screen spillage pump and preleach spillage pumps (31-PUMP-06/5) are started manually on
high sump level and is fitted with low level switch (21-LSL-03/4) which stops the pump automatically on
low sump level.

6.3 PRELEACH THICKENER SCADA DISPLAY

The items displayed on the preleach thickener SCADA page are:

• Status (stopped/running) of all drives.

• Instantaneous bed level %
• Instantaneous torque level %
• Instantaneous bed mass
• Instantaneous and totalised CIL slurry flow rate as measured by the magnetic flowmeter
(PID3120-FT-01). This will only totalise when underflow is being pumped to tailings dam.
• Instantaneous tailings slurry density as measured by the nuclear density meter (PID3120-DT-01)
• Instantaneous and totalised integrated tailings dry solids tonnes
• Position of recycle valve (PID3120-V-19).
• Position of Leach feed valve (PID3120-V-18).
• Variable speed output (%) of the duty tailings VSD pump (31-PUMP-03/4)

6.3.1 Alarms
• Low gland water flow PID3120-FAL-02 to 31-PUMP-03/4
• Low gland water flow PID3110-FAL-01 to 31-PUMP-01/2
• Low gland water pressure PID3110-PAL-03 to 31-PUMP-01/2
• Low gland water pressure PID3120-PAL-05 to 31-PUMP-03/4
• High and high-high torque level alarms
• High and high-high bed level alarms
• High underflow density alarm
• Low preleach overflow tank level alarm (31-LALL-05)

6.3.2 Interlocks
Interlocks are put in place to protect the thickener drive from damage and to minimise
interruptions caused by equipment failure.

• Linear screen (31-LSC-01) cannot start unless:

o Instrument air pressure switch healthy (6 Bar G).
o Spray water pressure switch healthy (4 Bar G).
• Linear screen (31-LSC-01) stops if belt alignment switches made contact.
• Trash screen spillage pump (31-PUMP-06) cannot start or run if
o Sump level is low (31-LSL-03)
o Preleach thickener feed sump level is high (31-LAHH-01)
• Thickener (31-THCK-01) rake drive stops on torque alarm (31-NT-01) “High-High”.

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• Preleach thickener underflow pumps (31-PUMP-03/4) will be stopped when gland water pumps
(62-PUMP-12/13) stop.
• Preleach thickener feed pumps (31-PUMP-01/2) will stop on
o Preleach thickener feed sump low level (31-LALL-01)
o Gland water flow low (31-FAL-01)
o Gland water pressure low (31-PAL-03)
o Preleach thickener drive torque alarm (31-NAHH-01)
o Thickener overflow tank high level (31-LAHH-05)
• Preleach thickener feed pump 1 (31-PUMP-01) can not start or run unless:
o Suction valve (31-XV-01) must be open
o Gland water valve (XV-03) must be open
o Suction valve (31-XV-02) must be closed
o Gland water valve (31-XV-04) must be closed
o Dilution tank mixer (31-MIXR-01) must be running
• Preleach thickener feed pump 1 (31-PUMP-02) can not start or run unless:
o Suction valve (31-XV-02) must be open
o Gland water valve (31-XV-04) must be open
o Suction valve (31-XV-01) must be closed
o Gland water valve (31-XV-03) must be closed
o Dilution tank mixer (31-MIXR-01) must be running
• Preleach thickener underflow pump1 (31-PUMP-03) can not start or run unless:
o Gland water valve (31-XV-05) is open
o Gland water valve (31-XV-06) is closed
o Discharge valve (31-XV-10) is open
o Discharge valve (31-XV-09) is closed.
o Suction valve (31-XV-08) is open
o Suction valve (31-XV-07) is closed.
o Either density valve (31-DV-01A/B) is open
• Preleach thickener underflow pump1 (31-PUMP-04) cannot start or run unless:
o Gland water valve (31-XV-06) is open
o Gland water valve (31-XV-05) is closed
o Discharge valve (31-XV-09) is open
o Discharge valve (31-XV-10) is closed.
o Suction valve (31-XV-07) is open
o Suction valve (31-XV-08) is closed.
o Either density valve (31-DV-01A/B) is open
• Preleach thickener U/F pumps (31-PUMP-03/4) will stop on:
o Gland water low flow (31-FAL-02)
o Gland water low pressure (31-PAL-05)

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• Preleach thickener U/F pumping forward to CIL will stop if:

o Tails screen (34-LISC-01) stops
o Detox feed sump level is high (34-LAHH-01)

• Preleach thickener overflow pump (31-PUMP-07/08) will stop on:

o Low level in the thickener overflow tank (31-LALL-05)
o High level in the process water pond level (61-LAHH-01)
• Preleach thickener spillage pump (31-PUMP-05) will stop on sump level low (31-LSL-04)

6.4 PLANT OPERATING PROCEDURES

Refer to the Vendor O & M Manuals for detailed operating and maintenance procedures for the linear
screen and the thickener.

• Linear screen.
• Thickener.
• Slurry pumping system.
• Flocculant addition.

6.4.1 Start up procedures: After extended period.

Start-up after an extended shut down period involves the following:

The field operator will perform the following checks:

• Preleach thickener feed and U/F pumps inspection.

• Abnormal spillages.
• Oil spillages.
• Set manual valves in correct positions.
• Gland Service Water pressure on the pressure gauge.
• Adjust pressure regulating valve, if necessary.
• Flocculant solution available and dozing pump ready to start.
• Operation of linear screen (31-LISC-01).
• Linear screen cloth alignment.
• Linear screen sprays operating correctly.
• Linear screen basket clean (no pegging or blocking of slots).
• Spillage pumps are operating correctly.

The operator should ensure the downstream sections (tailings ,CIL) are ready to receive material from
the preleach thickening section. Upstream ,the milling section should be ready to start and supply pulp
for preleach thickening.

• Fill the thickener with water and start the drive racks
• Open the recircuilation valve (31-DV-01B)
• Open suction valve for selected duty pump

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• Start the thickener U/F pump in recircuilation mode, pumping back to the dilution tank and back
into the thickener.
• Start the mixer (31-MIXR-01) in the dilution tank (31-TANK-02)
• Check the operation of the flocculant dosing pump
• Start feed and flocculant dosing (dilute flocculant)
• Open dilution water valve into the dilution tank and ensure target thickener feed density is
attained.
• The thickener can now receive feed from the preleach thickener feed pump (31-PUMP-01/2)
once the level in the preleach thickener feed sump (31-SUMP-01) is high.
• Set flocculant dosage according to solids feed rate
• Switch the drives in this section to Auto mode.
• The thickener underflow slurry density will increase steadily until the “High RD” set point is
reached at which point the bypass valve closes and the slurry is pumped forward to the Leach
circuit.
• The preleach thickener U/F pumps are left running for short plant shut downs. When the slurry
density reaches the “Low RD” set point the bypass valve (31-DV-01B) opens automatically and
the slurry is pumped back to the thickener feed dilution tank in closed circuit.

The same applies for the change over of thickener U/F pumps set.

6.4.2 Planned shutdown procedures.

Shutdown is usually one that is planned, i.e. maintenance on a circuit to be performed at a designated
time and shutting the plant down to ensure it is available at this specific time. The sequence for
shutdown at the thickening circuit is as follows:

• Shut off the feed

• Stop the flocculant dosing pump
• Pump down the bed in manual control until the underflow is basically water.
• Stop the U/F withdrawal (Close duty pump suction valve and stop gland service)
• Shut off dilution water.
• Allow the rakes to operate at low torque
• Open the dump valve on the duty pump and drain the delivery line.

6.4.3 Emergency procedures.

If a power failure occurs, causing a pro-longed shutdown and the rakes will not restart, Rake “jogging”
can be tried. Jogging is performed at the local control panel, ensuring the thickener has first been
switched to manual. If the rakes fail to start and still cannot move do not continue to jog them as severe
damage can result. Inform the supervisor. Do not allow new feed to enter the thickener until the rakes
are moving normally

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6.4.4 Trouble shooting:

6.4.4.1 Linear screen

WHAT IS THE
WHAT CAUSED IT? WHAT SHOULD I DO
PROBLEM?
Cloth keeps on  Deltracker air supply is Connect deltracker air supply
running off to one connected incorrectly, or the correctly.
side valve is closed

 Cloth sensor paddle is jammed Free cloth sensor paddle.

 Head and /or tail pulleys are not Level head and tail pulleys.
horizontal

 Screen installation is not level Level screen.

 There is a build-up of waste on Clean rollers.

rollers

WHAT IS THE
WHAT CAUSED IT? WHAT SHOULD I DO
PROBLEM?
Carry over of oversize  Cloth wash spray bar nozzles are Clean nozzles.
material blocked

 Cloth wash spray bar angle is Rotate spray bar to spray 90º to
incorrect cloth.

 Wash water supply is Check wash water supply eg inline

inadequate. strainer.

Motor not starting  There is an electrical power Identify problem and correct it.
supply problem

 Screen tripped on the cloth limit Lift cloth tensioner, slide cloth back
switches to centre and check tracking
system.

Cloth tearing in a  Sharp objects are in contact with Check screen for sharp objects in
particular area the cloth cloth travel path.
 Excessive wear on the cloth Check screen for items rubbing
onto cloth in wear path.

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6.4.4.2 Thickener:
WHAT IS THE
WHAT CAUSED IT? WHAT SHOULD I DO
PROBLEM?
No flocculation of the  Blocked flocculent pipes Unblock the pipes and clear with
feed water at full volume.
 Over- flocculent Check the control system.
 Under- flocculent Check the control system.
Underflow density is  Decrease in feed solids Reduce underflow pump speed
too low loading Underflow pumps OR
running too fast throttle underflow discharge
valve.
 No flocculent Check that flocculent plant is
delivering flocculent.
 Rat-holing - normally caused Reduce flocculent dose rate, OR
by over-flocculation or underflow discharge rate.
excessive underflow
pumping
 Stalled rakes Stop feed. Investigate cause and
take corrective measures.

WHAT IS THE
WHAT CAUSED IT? WHAT SHOULD I DO
PROBLEM?
Underflow density is  Underflow pumps running Increase underflow pump
too high too slow speed, OR
open underflow discharge valve.

 Increase in feed solids Reduce flocculent dosage rate.

loading
 Excessive flocculent Reduce flocculent dose rate.
High torque  Over- flocculent causing a Reduce flocculent dose rate.
jelly-like substance.
 Excessively high feed solids Reduce feed to thickener.
loads
 Excessively coarse feed Reduce feed to thickener.
Investigate and correct cause of
coarse feed.
 Underflow too low Increase underflow discharge
rate.
 Mud build-up on rakes – Decrease flocculent.
typically caused by over-
flocculation
Rakes do not turn  The electric motor is Check rotation of electric motor.
running in the wrong
direction

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 Flow control valve Close flow control valve

completely or partially open completely

 Pressure relief valve setting Raise pressure setting on relief

too low valve.
 WARNING: Do not screw in
the adjustment screw
completely.

WHAT IS THE WHAT CAUSED IT? WHAT SHOULD I DO

PROBLEM?
Rakes do not  Trip pressure switch has Check operation of and adjust if
turn….cont. been activated necessary.

Rakes turn too slowly  Flow control valve too far Adjust flow control valve (close).
open.
 Leaking pipework Check pipework for leaks and
repair or replace.
Rake lifting cylinder  Faulty solenoids are not Manually check operation of
does not operate activating directional control DCV. Replace solenoids if
valve necessary.
 Pressure relief valve set too Raise pressure setting on relief
low valve
 Electric motor turning in Check rotation of electric motor
wrong direction
Rake lifting cylinders  Faulty PRV Re-adjust PRV cartridge or adjust
do not lower setting.
Power pack  Pressure relief valve on Raise pressure setting on relief
overheating hydraulic motor portion set valve.
below trip alarm pressure  WARNING: Do not screw in
switch the adjustment screw
completely.
Check operation of (PSI) and
adjust if necessary.

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7. CARBON IN LEACH PLANT (CIL)

7.1 SAFETY
Dangerous reagents used in CIL plant such as sodium cyanide solution, lime slurry, caustic cyanide,
liquors from elution /electrowinning, require strict adherence to safety procedures.

For detailed safety procedures on sodium cyanide, lime slurry and caustic soda, refer to the material
safety data sheets contained in Appendix

7.1.1 General PPE (Personal Protective Equipment)

• Steel capped safety boots
• Hard hat
• Full overall with reflective material strips for better illumination
• Safety goggles
• Elbow length PVC gloves

7.2 LEACHING & CIL PRINCIPLES

Gold is extracted from ore in a series of agitated tanks through a process called cyanidation. The
cyanidation process takes place when dilute sodium cyanide solution is added to the agitated gold slurry
according to the equation

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

From the above equation, it can be noted that cyanide and oxygen play a very important role. It is
important to maintain cyanide levels in the first and last CIL tanks at about 300 ppm and 100 ppm
respectively, below which the leach kinetics will slow down and high solid ore gold losses encountered.

In less complex ores, injection of compressed air through the agitator shafts will provide sufficient
dissolved oxygen for the cyanidation reaction to take place. Peroxide or pure oxygen can be added to
the leach circuit in the event where the ore contains high oxygen consumers.

Cyanidation of gold takes place at pH values greater than 10.5 and hence lime is added to achieve this
pH and to prevent formation of hydrogen cyanide gas according to the equation:

NaCN + H2O = HCN + NaOH

The ore at times tends to be associated with “pregrobbers”, which tend to adsorb gold soon as it is
leached out. To counter this problem, carbon in leach (CIL) techniques are employed. This involves
addition of activated carbon in the tanks to adsorb gold as soon as it is leached. Slurry flow is thus
counter current to carbon movement which will promote incremental loading of carbon, with the
highest loadings in the first CIL tank.

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Small micron size Gold particles dissolve rapidly in the first CIL tanks and the recovery rate is very fast
(See steep section of the curve in Figure 1 below). Extraction rates tend to decrease with time as:

• Fewer larger Gold particles take longer to dissolve.

• Partially or totally locked particle’s dissolution rates are also slower by nature.

Figure 7-1: Gold dissolution rate versus time.

The typical variation of extraction rate with time is illustrated in the figure above.

Carbon particles are maintained in suspension in the CIL tanks by the action of the agitator blades and
are retained by inter-stage screens. Slurry on the other hand flows through the inter-stage screens from
one tank to the other and is eventually discharged onto a carbon recovery screen from where it feeds
the detoxification section before moving to tailings thickener. Thickened barren tailings are pumped to
the slimes dams.

As the slurry overflows the last CIL tank in line more than 95% of the Gold in the feed has been leached
out and recovered on the carbon granules. Gold losses can be characterized as follows:

• Insoluble losses due to un-dissolved Gold values, which can be attributed to :

o Insufficient retention time.
o Locked Gold particles or Gold in solid form in sulphide minerals.
o Abraded fine loaded carbon particles passing through the screen meshes.
• Soluble losses due to adsorption process inefficiencies. High soluble losses generally indicate
fouling of the carbon surfaces (e.g. carbonaceous deposits due to inefficient acid wash or
coating with carbohydrates (Gearbox oil, etc…).

Gold loading onto the carbon particles in each tank naturally increases with time and an amount of
carbon is periodically moved counter-current to the slurry flow to end up in the second CIL tank at
carbon loadings of ±4 060 g Au/t carbon. This loading is ideal for optimum adsorption/elution
efficiencies. A batch of loaded carbon, sized to fill the elution column, is transferred to the carbon

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screen for slurry removal and cleaning with spray water prior to discharging into the acid wash tank. An
equal amount of regenerated carbon is added to the last CIL tank at the same time.

Carbon inventory movement is done using vertical spindle recessed impellor slurry pumps, installed at
the top of each CIL tank. The carbon movement operations are carefully monitored and controlled and
form part of the carbon management operating procedures, which will be described in detail below. All
carbon transfer and handling systems have been designed for minimum abrasion in order to limit Gold
losses on fine carbon particles passing through the screen meshes.

The main objectives of these procedures are as follows:

• Prevent carbon size degradation by minimizing transfer times and duration to the minimum
required.
• Maintain constant carbon concentration in each tank.
• Control carbon loading grades to suit optimum adsorption/elution performances.
• Control and minimise carbon consumption.

Major CIL equipment

Equipment code Equipment name kW Description Supplier

32-SAMP-01 Leach feed sampler 0.75 2 in 0ne sampler, Multotec
300-TIO-20/2/20
32-BOX-01 Leach feed splitter box
32-TANK-01 Preleach tank
32-MIXR-01 Preleach Tank agitator 55 AMX 7500, 2 blades, Kemix
12.3mDx 12.6mH
32-CNAC-01 Auto CN analyser
32-TANK-02 CIL tank 1 - 8
32-MIXR-02 to 09 CIL tank 2-8 agitator 55 AMX 5500, 2 blades, Kemix
10.84mDx11.24mH
tank
32-PUMP-01 Loaded carbon transfer pump 30
32-INSC-01 to 08 Interstage screen 15 MPS 700 P, 7m2, Kemix
800um aperture,
304ss
32-INSC-09 Spare interstage C screen 15
32-PUMP-02 Interstage C transfer pump 1 30
32-PUMP-03 Interstage C transfer pump 2 18.5
32-PUMP-04 Interstage C transfer pump 3 18.5
32-PUMP-05 Interstage C transfer pump 4 15
32-PUMP-06/07/08 Interstage C transfer pump 18.5
5/6/7
32-PUMP-09 Leack spillage pump 15
32-LISC-01 Loaded carbon screen 3.0 12m2 HBS unit, Delkor
800x800um aperture
32-HYST-01 CIL gantry hoist
32-FRAM-01 Interstage screen wash frame

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32-PUMP-10 Interstage screen wash pump 3.0

32-SASH-01 Leach safety shower U-type, double Delta health &
column, platform Safety
activated cw hand
operated side
mounted eyewash
32-HCND-01 HCN gas detector
32-PUMP-11 CIL spillage pump 11

7.3 CIL PROCESS DESCRIPTION

This section has to be read in conjunction with CIL PFD (PFD 3200), P&ID PD 3210, 3220, PD3230

The preleach thickener underflow, at about 50% solids by weight is pumped by the duty thickener U/F
pump to the Leach feed splitter box (32-BOX-01).

The splitter distributes slurry to either the Pre-Leach Tank (32-TANK-01) or CIL Tank 1 (32-TNK-02) if CIL
Tank 1 is offline. Barren electrolyte from the recycle tank (43-TANK-01), Spillage from the cyanide &
caustic make-up and dosing area and lime slurry from the ringmain are also directed to this splitter box.

The CIL section consists of nine tanks comprising one 1 430m3 Pre-leach Tank ( 32-TANK-01) and eight
CIL tanks (32-TANK-01 to 32-TANK-09), each with an effective volume of 894m3 giving a total
(preleach/CIL) residence time of 24 hours to ensure complete dissolution of gold and its subsequent
adsorption onto activated carbon. The slurry and carbon particles are maintained in suspension and
agitated by the action of dual impeller mixers (32-MIXR-01 and 32-MIXR-01/2/3/4/5/6/7/8/9).

Flow of slurry from one CIL tank to the other is through an interconnecting launder system. As the CIL
process is continuous in nature provision has been made in the design for easy isolation and bypassing
of each tank in the event of major equipment break-down (e.g. agitator, inter-stage screen, tank
sanding, etc…). Each tank outlet launder is fitted with two gate valves where the first gate valve feeding
the next tank in line is normally open and the second connects to the bypass launder and is normally in
closed.

Each CIL tank is equipped with one Kemix interstage wedge wire cylindrical screen mechanisms, 32-
INSC-01 to 32-INSC-08 which prevent migration of carbon from one tank to another. Tank slurry levels
are the same for all the CIL tanks and transfer of slurry from tank to tank is achieved by the pumping
action of the internal impeller mechanism of the inter-stage screens. The interstage wedge wire
cylindrical screen pegs with near size carbon and periodically one interstage screen is lifted from the
tank onto an interstage screen wash frame 32-FRAM-02/3 for cleaning. A spare screen (32-INSC-09) is
provided on another interstage screen wash frame (32-FRAM-01) to replace other screens during clean-
up or maintenance operations. A high pressure low volume wash pump (32-PUMP-10) is provided to
clean blocked screens. Mobile cranes (client) will be used in the CIL area for the lifting of interstage
screens and general maintenance purposes.

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Compressed air, for oxygen supply, is fed to the agitator shafts of all the tanks (32-TANK-01 to 09) and
dispensed at the bottom of the shaft ensuring maximum dispersion throughout the pulp.

Cyanide solution is pumped through a ring main from which it can be dosed into the the preleach tank
(32-TANK-01). In the event where the determined concentrations are low, addition to other CIL tanks
(32-TANK-02 and/or 32-TANK-03/4) can be done.

There is provision to add lime slurry from the lime ring main in the CIL splitter box (32-BOX-01) in the
event where pH values determined in Pre-leach Tank (32-TANK-01) being low by the pH meter (32-AE-
03).

Loaded carbon in the CIL slurry is pumped using loaded carbon pump, 32-PUMP-01, from CIL Tank 1 (32-
TANK-02) or loaded carbon pump, 32-PUMP-02, in CIL Tank 2 (32-TANK-03) onto loaded carbon screen,
32-LISC-01. The slurry returns to either CIL Tank 1 or CIL Tank 2 while water sprays on this screen ensure
that clean carbon is discharged as screen oversize product into the acid wash tank 41-COLM-01. Other
recessed impeller vertical spindle pumps (32-PUMP-03 to 32-PUMP-08) are installed in CIL tanks 3 to 8
(32-TANK-03 to 32-TANK-09) to transfer carbon upstream at intermittent intervals. Regenerated or
eluted carbon is added to the last CIL tank (32-TANK-09 or 32-TANK-08) if last tank is on bypass.

Pulp from the last CIL tank gravitates to the detoxification section of the plant.

Spillage in the CIL area is contained in a bund that has two spillage pumps 32-PUMP-09 and 32-PUMP-
11. The first spillage pump (32-PUMP-09), pumps spillage to the leach feed splitter box (32-BOX-01)
while the second spillage pump (32-PUMP-11), pumps to CIL tank 5 (32-TANK-06).

7.4 LEACH CONTROL PHILOSOPHY

The CIL circuit will mostly be controlled manually by the operators. A cabin equipped as a shift
laboratory will be provided on top of the leach tanks. Manually taken slurry samples from the various
tanks will be filtered where necessary, and used for process control and accounting purposes. Regular
sampling and analysing of the following will ensure proper control and accounting of the circuit:

• Slurry feed
• Lime concentration
• Cyanide concentration
• Carbon concentration

The CIL feed sampler (32-SAMP-01), installed above the leach feeder splitter box, will periodically take a
sample from the slurry feed to the CIL circuit. This sample will be analysed and used for control and
metallurgical accounting purposes.

Inter-tank flow will be controlled manually by opening and closing the respective gate valves feeding
each tank. Carbon transfer will be started manually and the installed timers will stop the pump/s
automatically.

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Cyanide addition is ratio controlled to the totalised tonnage fed forward (31-WIQR-01).Cyanide
concentrations in the first tank (32-TANK-02 or 32-TANK-02)) are analysed “on-line” by the automatic
cyanide analyser (32-CNAC-01) and automatically controlled to the required strength by automatic
dosing of cyanide solution via a control valve (32-FCV-01) mounted on a ring main. Cyanide can also be
added to the other tanks via manual valves mounted on the ring main with the concentrations
determined on a regular basis using titration.

Airflow to the CIL tanks will be manually set. Pressure of compressed air into the CIL agitators is
manually regulated using pressure regulators (50-V-22/25/27/11/14/17/11/13/16) fitted on the piping
feeding each tank.

A pH probe (32-AE-01), installed in the Pre-Leach Tank (32-TANK-01) to monitor pH, enables automatic
lime addition into the leach feed splitter box (32-BOX-01) through the flow control valve (32-FCV-03) in
order to maintain required pH. A portable pH meter is used to measure pH in the rest of the CIL tanks
and lime will be manually added in CIL Tank 1 should the need arise. Primary PH control is however in
the ratio control of lime slurry addition to the SAG mill.

Spillage pumps (32-PUMP09/11) can only be started manually in the field but stop automatically on low
level when the low level switch (32-LSL-01/2) is activated.

Other controls employed relate to manual determinations of slurry pulp density, dissolved oxygen levels
and carbon concentrations. Oxygen concentrations will be monitored using a hand held dissolved
oxygen meter.

Details of procedures of how these measurements are done are given in the “Detailed Procedures” of
this manual.

A hydrogen gas detector (32-HCND-01) is installed in the CIL circuit with SCADA indication. High levels of
hydrogen cyanide gas will alarm (32-AAH-02) on SCADA and a siren sounds in the CIL area.

A safety shower (32-SASH-01) is installed in the leach area. The Safety shower is equipped with a flow
switch (32-FSH-04), which when activated will activate an audible siren and a flashing light. This is done
for safety reasons.

7.4.1 CIL Scada Page

• Status (stopped/running) of all drives.
• Instantaneous pH in the Pre-Leach tank
• Instantaneous cyanide strength in the Pre-Leach tank
• CIL lime slurry addition valve position 32-FCV-03
• CIL cyanide addition valve position 32-FCV-01
• CIL cyanide addition flow rate 32-FE-01

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7.4.2 CIL Alarms

• Low pH alarm
• Hydrogen cyanide gas level high (32-AAH-02)
• Safety shower high flow alarm (32-FA-04)

7.4.3 CIL Interlocks

• Loaded carbon transfer pumps 32-PUMP-01/2 cannot start or run if the loaded carbon screen
(32-LISC-01) is not running.
• Loaded carbon screen (32-LISC-01) will stop on high level in the Acid wash column (41-COLM-
01)
• Spillage pumps (32-PUMP09/11) can only be started manually in the field but stop automatically
on low level when the low level switch (32-LSL-01/2) is activated.
• Prestart conditions for the CIL circuit
o Spray water pump should be running (61-PUMP-03/4)
o Lime dosing pump (53-PUMP-03/4) should be running
o Cyanide dosing pump (51-PUMP-02/3) should be running
o Air compressors (56-COMP-01/2/3) should be running)

7.4.4 CIL Equipment

7.4.4.1 Linear Trash Screen (32-LISC-01)

The trash screen is a 6m2 GKD linear type, equipped with two water spray bars. The screen cloth is of
600X650um aperture while the spray bars have spray nozzles that ensure that fines are washed off from
the trash to give a clean screen oversize.

7.4.4.2 Kemix inter-stage screens (32-INSC-01 TO 32-INSC-08)

The Mineral Separating Pump Screens, MPS(P), is used to retain carbon in the CIL tanks. Each MPS(P)
screen consists of a geared drive, a screen for carbon and slurry separation and an internal mechanism.
The drive combines the two functions of driving the internal mechanism and screen cleaning. The
screen cleaning is carried out via a rotating cage attached to the bottom of the shaft, with a series of
vertical blades that sweep the screen.

The screen comprises a stainless steel wedge wire cylinder and a solid inner surface that serves as
housing for the internal mechanism. The screen and drive are mounted from a steel support frame that
includes a discharge launder.

For the original MPS screen the internal mechanism consists of a pitch blade turbine attached to the
shaft. The pitch blade turbine is driven by the shaft as it rotates, and the blades cause an upwards
movement of the slurry inside the screen, which maintains the solids in the slurry in suspension.

Since the slurry inside the screen is being moved by the mechanism, it also keeps the inside of the
wedge wire clean. This allows the MPS screen to operate under flow conditions from no flow to
maximum designed flow. Thus the screen will not clog up under variable flow conditions.

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The MPS (Pumping or P) screen is similar to the MPS screen but the internal mechanism of the MPS (P)
screen includes a pumping impeller. This impeller is attached to the shaft inside the volute. As the
impeller is driven, it generates centrifugal forces, which lifts the slurry and deposits it in the exit launder
above the slurry level in the tank. The impeller also provides the slurry with a velocity of between 0.5
and 2.0 m/second in the exit launder.

With MPS (P) screen installation, the slurry in the tank is below the height of the slurry in screen exit
launder. Height differential is typically 200mm. To use MPS (P) screens the tanks can be level with the
same slurry level throughput the plant.

The drive and screen form an integrated unit that can easily be cleaned and maintained. The screen is
attached to the interconnecting launders by a hook-on arrangement to facilitate easy screen removal for
cleaning.

A client mobile crane enables repairs and maintenance activities to be carried efficiently. Under normal
conditions the crane is used primarily for the removal and replacement of inter-stage screens for
cleaning or repair. An inter-stage screen is removed either periodically, for inspection, or as required for
cleaning or repair.

Identifiable operating problems indicating screen removal include the following:

• Increased tank level due to screen blinding.

• Loss of carbon (reduction in carbon concentration) due to worn out or holed screens.

The dirty or damaged screen is removed and placed on the cleaning platform (32-FRAM-02) fitted with a
spare inter-stage screen (32-INSC-09). The “dirty” screen is immediately replaced with the “clean” spare
screen. The dirty screen is cleaned with high pressure water from a dedicated WAP type pressure
washer (32-PUMP-10), inspected and readied for the next change over.

7.5 DETAILED PROCEDURES

Apart from a few instruments and controls the CIL circuit is controlled manually by the control room and
the field operators.

CIL operators will check slurry densities, slurry pH, dissolved oxygen (D.O.) levels and perform titrations
to check reagent level and prepare samples for the assay laboratory.

Samples are taken manually from the CIL tanks on a regular basis and analysed in the field laboratory for
process control purposes. Based on the results the field operator performs the necessary actions to
maintain the plant operating parameters as close as possible to the target values. All results are
recorded in a log book and used for trends analysis and test error identification.

7.5.1 Feed slurry pH control:

Slurry alkalinity must ideally be maintained at between pH 10.5 and pH 11.Lime slurry is added at the
Milling section. pH is monitored automatically through use of a pH probe located in the Pre-Leach Tank

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(32-TANK-01) and regulated by use of a control valve (32-FCV03) on the lime addition line coming off the
ringmain into the leach feed splitter box 932-BOX-01). pH set point of 10.5 is monitored on SCADA. It is
noted that this valve is for spiking ONLY.

In addition to the automatic pH monitoring described above, the section operator manually measures
pH levels in each tank on a two hour cycle. A hand held pH meter is provided for this duty. The meter is
provided with a full set of operating instructions that should be followed carefully. The pH meter should
be calibrated daily as per the procedure provided by the supplier.

7.5.2 CIL Feed Slurry Sampling

The CIL field operator is responsible for collecting above composite samples and preparing these prior to
dispatch to main laboratory. The samples serve to monitor gold recoveries and identify the causes of
eventual losses. The figures are used for accounting purposes.

7.5.3 Cyanide Concentration

Cyanide solutions are normally prepared to strength of 20% (NaCN), at high pH, in the reagents section
and pumped through a ring main. Cyanide is dosed in the preleach tank (32-TANK-01) via a control valve
(32-FCV-01) and can also be dosed to CIL Tanks 1, 2 & 3 (32-TANK-01/2/3) using manual valves. The
cyanide ratio control is adjusted to achieve target cyanide concentrations in the Pre-Leach Tank (32-
TANK-01),(this will vary depending on the type of ore, operator to seek guidance from metallurgist) .

One litre slurry samples are taken from selected CIL Tanks every 2 hours using the Marcy scale bucket.
The samples are filtered and the solution is titrated for free cyanide and corrective action can then be
taken to increase or decrease cyanide addition as needed.

Following is a brief outline for free cyanide:

• Filter about 200ml of slurry though a paper filter/ funnel into a 100ml beaker
• Collect 30-40ml of clear leach solution/ filtrate
• Measure exactly 10ml of filtrate into a clean and dry 100ml titration flask
• Add 3 drops of rhodaine/ Phenolphthalein indicator
• Ensure the burette with silver nitrate is zeroed
• Place the titration flask under the burette on top of a white background
• Carefully open the burette and silver nitrate drop by drop into the leach/CIL solution.
• Stopping after each drop, swirl the titration flask and check any slight colour change in the
titration flask contents
• Look for the appearance of the lightest pink colour in the flask and close the burette at this
moment.
• Calculate the volume of silver nitrate by change in burette volume

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7.5.3.1 Calculation:
Vt = Volume of silver nitrate titre to get to end point (ml)

Ct = Molar concentration of silver nitrate (typically 0.01M)

CNppm = 26 x (Vt x Ct)

= 26 x Vt (for a titre concentration of 0.01M)

7.5.4 CIL tanks carbon concentration:

• Take a 2-litre slurry sample from the CIL tank. Use a plastic bucket or a dip tube.
• Do not sample near the inter-stage screen - a biased result is often obtained there.
• Pour the sample into a bucket or container with a fine 0.6 mm mesh at the bottom.
• Wash the slurry through the mesh with water, retaining the carbon.
• Take another 2-litre sample from the opposite side of the tank and repeat the above washing
procedure.
• Using a plastic funnel, carefully wash the clean carbon into a 200 ml measuring cylinder.
• Read off the volume of settled carbon Vc (ml).
• Calculate carbon concentration Cc (g/l) as follows:

Vc (ml)
Cc( g / l ) 
4 
7.5.5 Slurry Density
The slurry density in all CIL tanks should be checked every 2 hours through use of a Marcy scale as
outlined below.

To check the slurry density, take a manual pulp density sample of the CIL feed and the CIL Tanks 1, 3, 5,
7 ,9 every 2 hours, as follows:

• Fill up the one litre slurry density container with CIL feed slurry while blocking the upper
drainage holes with fingers.
• Place the slurry density container on the slurry density scale and remove fingers to allow excess
pulp to drain from the container. Wait for the reading to stabilise.
• Read off the slurry density number corresponding to that shown by the needle on the 3.2 solids
density scale.

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Accurate measurement of pulp relative density relies on using exactly one litre of sample. It is
important to use only the container supplied with the scale and to calibrate the relative density scale
once a shift. This is done by taking a reading with the slurry density container full of water. Should the
needle not indicate 1.00 (i.e. positioned at “12 o’clock”), turn the adjusting screw until the needle
indicates 1.00.

7.5.6 Oxygen addition & monitoring

Oxygen is supplied in from compressed air, supplied from a header at constant pressure and is
connected to all CIL tank agitators’ hollow shafts. The air is discharged in the pulp at the bottom of the
shafts via air spurges. Air flow is controlled via a manually operated throttling valve to control the
dissolved oxygen levels in the CIL slurry. The dissolved oxygen levels are measured using a handheld
dissolved oxygen meter.

7.6 CARBON MANAGEMENT

Carbon is susceptible to size degradation by abrasion and small particles created in the CIL circuit are
likely to report to tailings causing gold losses. Any transfer of carbon is done in the shortest possible
time using specially designed equipment such as recessed impeller pumps running at low speed and air
lifters. The pipelines are designed to create minimum turbulence with large diameters and long radius
bends.

This applies in all areas where carbon is handled or processed in one way or another (e.g. elution,
carbon regeneration etc…). Great care is taken to handle the carbon as little as possible and therefore
the pumping of carbon in the CIL circuit is managed accordingly.

Good carbon management procedures are critical to achieving high gold recoveries in the CIL plant.
Insufficient adsorption due to depletion of the carbon inventory, excessive loadings or fouling of carbon
surfaces are the cause of unacceptable soluble gold losses. Surplus carbon generally results in excessive
carbon losses through abrasion and a reduction in the loaded carbon grade. This results in higher
elution costs.

The carbon inventory at any time is calculated from the individual carbon concentration tests performed
on each of the CIL tanks.

The test procedure is described below and an example of inventory calculation is shown in table below:

Carbon Concentrations (g/l) Carbon Inventory (t) for 894 Total Carbon
CIL Tank No 3
Sample 1 Sample 1 Average m Tank Volume Inventory (t)
1 11 12 11.5 10.28 55.43
2 14 12 13.0 11.62
3 15 14 14.5 12.96
4 9 12 10.5 9.39
5 12 13 12.5 11.18

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Carbon concentrations in each CIL tank must be maintained at the required concentration of ± 12g/l.
The concentrations may be revised from time to time as the adsorption process is optimised.

7.6.1 Counter current transfer of the 6.0 t batch:

The whole regenerated carbon batch is discharged into the last CIL tank (32-TANK-09) from the quench
screen.This increases the carbon inventory in the tank considerably. Some time is allowed to achieve a
homogenous dispersion of the carbon granules before the inventory test is carried out in CIL Tank 8.The
transfer time required to restore the required concentration of say 12g/l in tank No 8 is calculated, as
shown in table below:

Parameter Symbol
Tank volume Vt
Transfer Pump flow rate (CIL8-1) Q
Loaded Carbon Transfer rate Q
Tank 8 INITIAL concentration C8
Tank 8 FINAL concentration C7

The formula to calculate T is given below:

Carbon transfer pump 32-PUMP-08 runs for T minutes.

Vt  (C8  C 7)  120
T ( Min.) 
Q  (C8  C 7)
The operation is repeated upstream one tank at the time until correct carbon concentrations are
restored in CIL tank 1 (32-TANK-02). CIL Tank 1 holds a large inventory of loaded carbon which is
transferred to the elution circuit for gold stripping, as described in the next paragraph.

7.6.2 Loaded carbon transfer to Acid Wash Column

The CIL operators manage and perform the carbon transfer operations.

Loaded carbon is transferred to the carbon screen from CIL tank No 1 using transfer pump 32-PUMP-01
or from CIL tank 2 using transfer pump 32-PUMP-02.

• Check that acid wash column is ready to receive carbon.

• Check carbon level in column, if any, using graduated dip stick.
• Fill with water if necessary.
• Start loaded carbon screen (32-LISC-01).

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• Open water sprays valves (32-V-31/32).

• Check transfer pump delivery valves in correct positions.
• Start carbon transfer pump (31-PUMP-01) if transferring from CIL Tank 1.
• Start carbon transfer pump (31-PUMP-02) if transferring from CIL Tank 2.
• The level switch in the Acid Wash Column should stop the duty pump on high level.

7.6.3 Inter-stage carbon transfer procedures:

An inter-stage transfer to restore the normal carbon concentration in all CIL tanks is carried out as
follows:

• Following loaded carbon transfer operation.

• Once per shift as a standard procedure.

The objective is to control the carbon concentrations in each tank in order to:

• Achieve optimum gold recoveries.

• Identify any abnormal condition such as perforated inter-stage screens.

7.6.4 Cleaning Inter-stage screens

The CIL circuit uses Kemix MPS(700)P , 800m slotted wedge-wire screens for inter-stage screening. The
circuit is sensitive to platelet carbon. Platelet carbon has very high gold adsorptivity. Because of their
shape, platelets escape through the interstage screens, taking with them the adsorbed gold. This way
platelets act as preg-robbers.

Care is therefore taken to pre-screen any fresh or regenerated carbon fed to the circuit in order to
remove these platelets.

Wedge-wire screen material has good wear resistance and the screens are normally replaced when the
slots open up to ±1.0 mm.

It is necessary to clean inter-stage screens periodically as the apertures become either:

• Pegged with sharp edged or near size carbon particles.

• Blinded with fibrous trash.

In order to maintain the screen designed flux and avoid overflowing. Each screen is removed from circuit
for inspection on a regular schedule.

The procedure follows:

• The CIL tank is bypassed:

o Bypass plug valve is removed.
o Normal connection launder is plugged.
• The slurry now bypasses the isolated tank.
• Stop pump cell.

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• The level in the tank is lowered to below the level of the discharge launder.
• The screen is disconnected and lifted out of the slurry (Using the tower crane) until the bottom
of the screen is just above the level of the walkway grating.
• Slurry is hosed from the screen.
• The screen is removed from position and transported to the screen frame, adjacent to the tank
farm.
• The spare screen is immediately placed in position and the tank is put back on line as fast as
possible:
o The screen is lowered in position ensuring that it is adequately supported.
o All connections between the screen discharge launder and the tank discharge launder
are sealed.
• Once in position the pump cell is started.
• The feed to the tank is resumed:
o Normal feed plug is removed.
o Bypass plug is inserted.
• The whole operation will take between 20 and 30 minutes, under normal conditions.
• The screen placed on the frame for cleaning is thoroughly washed with high pressure sprays
from the WAP machine and wire brushed to remove any pegged particles and blinding material.
• The screen material as well as all mechanical parts is thoroughly inspected for any damage
during the cleaning operation and the apertures are measured for wear.
• The screen material is replaced when showing wear damage.
• Check for carbon losses from the refitted screen by taking a sample of slurry in the downstream
inter-tank launder.

The scheduled period between screen cleaning operations is determined by experience. Unscheduled
inspections must however be carried out at first sign of:

• Abnormal carbon concentrations detected by routine carbon concentration measurements as

this may signify a perforated screens.
• CIL tank level increases or overflows, signifying a blinded screen.
• Carbon is lost from the circuit by:
o Abrasion in the CIL process caused by the mixing process and during all transfer
operations.
o Escape through perforated screens in the final CIL tank or through gaps between the
incorrectly fitted inter-stage screen in the final CIL tank and corresponding launder.
o Fresh carbon present as platelets or used carbon breaking up in the shape of platelets
(Flakes).

Carbon losses and misplaced carbon arising from damaged or incorrectly installed inter-stage screens
can be detected from the routine carbon concentration tests and the trends shown in the recorded
figures.

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7.6.5 Detection of carbon losses through inter-stage screens

An operator checks for any carbon loses from the CIL. Regular checks are performed by taking slurry
samples after CIL 8 inter-stage screen, washing the slurry through 600µm test sieve. Presence of carbon
in the test sieve indicates carbon loses to tailings. The same method is used to check for carbon
migration in the CIL section.

Fine carbon particles lost in the tailings stream can only be detected from the tailings analyses
conducted in the central laboratory.

Low carbon inventory may result in increased solution losses.

Overall carbon consumption is measured by the amount of fresh carbon required to maintain the total
inventory to the required level. Fresh carbon must be conditioned and screened prior to discharging
into CIL No 8.

A quality control test is performed on the carbon deliveries and the platelet content is analysed. Platelet
contents below 8% are acceptable.

7.6.6 Carbon fouling

Gold adsorption onto carbon is directly proportional to the total available active surface of the carbon
particles in contact with the leach slurry. Under normal conditions active surfaces reduce slowly with
time. However, carbon particles disappear from the circuit by the natural abrasion process long before
they become totally inactive by ageing.

The carbon surface can however be rendered inactive when coated with certain products such as:

• Organic products such as oils coat the surface of carbon, preventing god adsorption onto carbon
to take place.
• Deposits of sulphates and carbonates onto the carbon surface close access to the active pores,
preventing Gold adsorption onto carbon.

Oil and grease spillages must be avoided at all cost and procedures must be instituted for the prevention
and emergency handling of such occurrences.

Carbon adsorption efficiency tests must be carried out on a regular basis to assess the performance of
the acid-wash process.

7.6.7 Trouble shooting:

No Symptom Possible Cause Action Required

Check mill control parameters, steel
1 High solid losses Poor mill grind
addition

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Insufficient cyanide addition Check by titration

Incorrect slurry pH Check with pH meter and titration

Persistent high solid CIL tanks partially sanded - residence

2 Sound tanks check for sanding
losses time is low
Low carbon activity Check carbon activity
3 High soluble loss
Low carbon inventory Add fresh/regenerated carbon
Slurry backup in feed Remove inter-stage screen for
4 Inter-stage screen is partially choked
launder cleaning
Low carbon Low slurry % solids Check slurry density
5
concentration in tanks Inter-stage screen holed Check screen discharge
Carbon concentration too high Transfer carbon out of tank
Check carbon Quality Assurance
High carbon Poor quality carbon
6 procedures
consumption
Check kiln operation and
Overheating in Regeneration kiln
temperature control

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8. TAILINGS DETOXIFICATION
8.1 SAFETY:
The major safety concerns in the tailings facilities:

• Possible generation of hydrogen cyanide gas in the trash screen (34-LISC-01) feed box when
residual hydrochloric acid from acid wash area comes into contact with cyanide in tailings slurry.
• Cyanide solution in the tailings slurries
• Acid solutions pumped from the acid wash sections. Disposal of acid wash solutions is the major
concern in the tailings facilities area. The acid effluents pumped into the tailings box can lower
pH of the cyanide containing LEACH tailings to the point where hydrogen cyanide gas formation
goes above acceptable exposure limit (Toxicity Limit Value-TLV: 4.7ppm). This can be a problem
when it happens without notice while people are working in the area without proper cyanide
gas protection.

Standard PPE

• Hard hat
• Steel capped boots
• Full overalls
• PVC gloves
• Chemical full face masks (when necessary)

8.2 CYANIDE DETOXIFICATION PRINCIPLES:

LEACH tailings and other barren effluents from various points of the processing plant (acid wash effluent,
Acid spillage, regeneration spillage , elutriation and rinse effluents, etc,) are disposed of to the tailings
dam through the tailings detoxification facility. Cyanide poses a great danger to human beings and
aquatics. Cyanides are highly toxic and short term exposure can cause severe health risks including
death. Cyanide must therefore be destroyed to acceptable levels before the tailings are pumped to the
final tailing holding facility.

Gold processing plants produce effluents with cyanide concentrations as high as 250ppm. This is a very
high cyanide concentration and the environmental RISK of pumping such effluents to the environment is
high. Cyanide destruction aims to reduce the residual cyanide in the effluents to minimum possible to
reduce this risk.

A number of methods are in use for the destruction of cyanide from mineral processing plants some of
which include: oxidation with ferric sulphate; oxidation with peroxides; oxidation with chlorine; chlorine
dioxide and sodium metabisulphite.

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8.2.1 Destruction of cyanide using Sodium Metabisulphite

8.2.1.1 General
The SO2/AIR Cyanide Detoxification Process oxidises both free cyanide (CN-) and cyanide weakly
complexed with metals such as copper, zinc and nickel to cyanate (OCN-). Cyanate is two orders of
magnitude less toxic than cyanide, (for example, if 1 gram of cyanide has a Toxicity of 100, then 1 gram
of cyanate will only have a toxicity of 1). The cyanide strongly complexed with iron can be removed as an
insoluble ferrocyanide salt by the process.

The oxidising agent is a combination of sulphur dioxide (SO2) plus oxygen in the presence of a soluble
copper catalyst. Temperature is ambient and the pH range is between 8.0 and 9.5. If soluble copper is
not present in the tailings solution in sufficient quantities as a product of the cyanidation process, then it
must be added as copper sulphate. Sodium hydroxide (NaOH) or lime is added to neutralise sulphuric
acid generated in the process and to maintain the desired pH level. In addition a small amount of
thiocyanate (SCN-) presents is oxidised.

The solution or slurry to be treated is contacted with the reagents in a simple mixing tank. Sodium
metabisulphite is used to supply the SO2. The oxygen requirement for the process is normally supplied
by adding large volumes of air. The copper catalyst is provided by copper sulphate addition if it is not
already present in the feed solution. Retention times vary depending on the solution composition being
treated, but generally range from 1 to 3 hours. Compressed air, for oxygen supply, is fed to the agitator
shafts of all the tanks (32-TANK-01 to 09) and dispensed at the bottom of the shaft ensuring maximum
dispersion throughout the pulp.

8.2.1.2 Chemistry
Sodium cyanide and other alkaline cyanides are extensively used to extract gold and silver from their
ores. Dissolution of these precious metals in alkaline cyanide solution to form stable complex cyanide
anions depends on excess cyanide in solution. This excess cyanide is referred to as dissociated or free
cyanide. The oxidation of free cyanide to cyanate in the Cyanide Destruction Process can be represented
by the equation:

CN- + SO2 + O2 + H2O  OCN- + H2SO4 (1)

Reaction (1) requires dissolved copper to act as a catalyst. The cyanidation leaching process frequently
provides sufficient soluble copper in the tailings solution as a copper cyanide complex to eliminate the
need to add it as copper sulphate. Actual dosage of SO2 is usually greater than the theoretical SO2
requirement due to its consumption by other chemical reactions. The best pH range for cyanide
destruction is 8.0 to 9.5 , and is normally controlled by lime or sodium hydroxide addition.

Temperature has little effect on the cyanide oxidation reaction, but the type of effluent, solution or
slurry, can have a large effect on the reaction (usually determined in laboratory test work).

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The oxygen for reaction (1) is obtained from air sparging. Owing to the low solubility of oxygen in water,
and its low transfer rate between gas phase and water, only a small fraction of the oxygen added at the
bottom of the reactor is actually transferred to the solution. Once in solution, oxygen readily reacts with
the SO2 and cyanide. Insufficient oxygen transfer will limit the destruction performance.

Sulphuric acid generated during cyanide oxidation and other oxidation reactions is neutralised with
sodium hydroxide in the reactor as follows:

H2 SO4 + NaOH  Na2 SO4 + H2 O (2)

In addition to gold and silver, variable amounts of other metals such as copper, zinc, nickel and iron are
leached during the cyanidation process.

Weakly complexed cyanides of say zinc, are dissociated as follows:

2- 2+ -
Zn(CN)4  Zn + 4CN (3)

The liberated metal ions precipitate as metal hydroxides (below) and the liberated cyanide is oxidised to
cyanate, according to equation (1):

2 Zn2+ + 2OH-  Zn(OH)2

The cyanate ion (OCN-) is unstable, and hydrolyses to ammonium and carbonate ions, as follows:

OCN- + 2H2O  CO32- + NH4+

This reaction is accelerated at low pH. The carbonate ion precipitates as calcium carbonate. The
ammonium (NH4+) ion is in equilibrium with ammonia (NH3) with some escaping the slurry as NH3 gas
and some reporting to the solid phases present.

Major Detoxification Equipment

Equipment code Equipment name kW Description Supplier

34-LISC-01 Tails screen 3.0 6m2 HBS unit, Roymec
600x600um aperture Technologies
34-BSKT-01 Tails oversize carbon basket
34-TANK-01 Detox feed sump
34-PUMP-01/2 Detox feed pump 1/2 55
34-SAMP-01 Final tails sampler 1.1 Two in one slurry Multotec
sampler, 300-TIO-
20/2/20
34-BOX-01 Detox splitter box
34-TANK-02 Detox Tank 1
34-MIXR-01/2 Detox mixer 1/2 45 AMX 4500, 2 blades, Kemix
10.1Dx10.5mH
34-TANK-03 Detox Tank 2
34-TANK-04 Tails thickener feed sump
34-PUMP-03/4 Tails thickener feed pump 1/2 55

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34-PUMP-05 Detox spillage pump 11

34-HCND-01 HCN gas detector
34-SASH-01 Detox safety shower U type double column, Delta health &
platform activated cw Safety
hand operated side
mounted eyewash

8.3 PROCESS AND PLANT DESCRIPTION:

This should be read in conjunction with TAILINGS DETOX PFD FD3400 in Appendix

The CIL tailings detox section consists of the carbon safety screen (34-LISC-01), two stage detoxification
(34-TANK-02.3), two detox feed pumps (34-PUMP-01/2) and two tailings thickener feed pumps (34-
PUMP-03/4). This section fulfills the following:

• Recover any large carbon in the event of damage, wear or incorrect installation of the final inter-
stage screen.
• Collect all barren effluent streams from the various sections of the plant for final disposal in the
tailings dam
• Destruction of residual cyanide to levels acceptable levels before pumping to tailings
containment facility
• Pumping of plant tailings to the tailings storage facility.
• Obtain a representative tailings sample for the purpose of plant control and metallurgical
accounting

CIL slurry tails gravitate to the carbon safety screen (34-LISC-01) feed box where large carbon is removed
from the tailings. Carbon safety screen oversize gravitates into the tails oversize carbon basket (34-BSKT-
01). Other effluents that join the Leach tailings in the detox section include:

• Acid wash spillage pump

• Spent acid from acid wash plant
• Undersize/fines from regeneration quench screen
• Spillage from the cyanide make-up area
• Spillage from the detox reagents makeup area

The carbon safety screen (34-LISC-01) underflow gravitates into the detoxification feed sump (34-TANK-
01) from where it is pumped by the duty detox feed pump (34-PUMP-01/2) to the detox splitter box (34-
BOX-01) before gravitating into the first detox tank (34-TANK-02) or Detox tank 2 (34-TANK-03) if the first
tank is offline. Detox consists of two agitated tanks (34-TANK-01/2) each 810m3 volume , thus giving a

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total residence time of 3hrs in this section. Copper sulphate and sodium metabisulphite solutions are
pumped into the detox splitter box (34-BOX-01) to mix with the linear screen underflow and thus
commence the cyanide destruction process.

Compressed air, for oxygen supply, is fed to the agitator shafts of the detox tanks (34-TANK-02 and 03)
and dispensed at the bottom of the shaft ensuring maximum dispersion throughout the pulp.

Overflow from detox tank 1 gravitates into detox 2 (34-TANK-03) where the destruction of cyanide is
completed. Pulp from the last detox tank (34-TANK-03) overflows into the tailings thickener feed sump
(34-TANK-04) from where it is pumped by the duty tailings thickener feed pump (34-PUMP-03/4) to tails
thickener dilution tank. It is required that the residual cyanide in the final tail must be lower than
10mg/L. This is achieved by the following controls:

• Regulating the residual cyanide from CIL tailings

• Control of the detox process reagents addition to get optimum reduction of cyanide
• Control of detox process pH

pH control is very critical in the detox process. A protective pH of above 9.0 must be maintained to
prevent the evolution of highly toxic HCN gas. A pH analyser (34-AE-02/04) is used to measure the pH in
the first stage detox tank (34-TANK-02) and last stage (34-TANK-03). The pH probe controls the addition
of lime to detox by controlling the opening of the lime flow control valve (34-FCV-05) for 34-TANK-02 and
Flow control valve (34-FCV-08) for 34-TANK-03 to maintain the required pH as set on SCADA.

Cyanide concentrations in the last detox tank (34-TANK-03) will be analysed “on-line” using the cyanide
analyser (34-AE-03) located in leach area.

Primary dosage of sodium metabisulphite and copper sulphate is in ratio to totalised tonnage pumped
to detox as indicated by 34-WIQR-01. Secondary control is effected in response to the cyanide
concentration in the pulp in Detox tank (34-TANK-03) through the online cyanide analyser (34-AE-03) in a
feedback control loop. The online cyanide analyser measures the instantaneous cyanide concentration
in detox tank 2 pulp and sends a feedback signal to the PLC such that the speed of the dosing pumps
increases and decreases with cyanide concentration in the pulp in detox tank 2.

The detox feed sump (34-TANK-01) will be equipped with an ultrasonic level transmitter to control the
sump level by varying the speed of the thickener feed pumps (34-PUMP-01/2).

A nuclear density meter (34-DE-01) will be installed on the line feeding detox which will enable
automatic addition of process water (by varying the opening on density control valve , 34-DCV-01) to the
detox feed sump in order to dilute the slurry from 50% to 40% solids by weight.

The magnetic flow meter (34-FE-01) will be used together with the nuclear density meter (34-DE-01) as
a mass flow meter, a useful output that will be used for the purpose of metallurgical accounting and to
control addition of sodium metabisulphite and copper sulphate; both being critical in the cyanide
destruction step.

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The tailings thickener feed sump (34-TANK-04) is equipped with an ultrasonic level transmitter (34-LT-
03) to control the sump level by varying the speed of the thickener feed pumps (34-PUMP-03/4).

Airflow to DETOX tanks will be manually set.

8.4 DETOX CONTROL PHILOSOPHY

Tailings flow rate will be measured by flow meters (34-FT-01) installed on the detox feed line. The
density of the tailings will be measured by nuclear density gauge (34-DT-01) installed on the detox feed
line. Readings from the nuclear density gauge and volume flow meter will be computed in the mass flow
meters (34-WIQR-01) to give the instantaneous and totalised mass flow to the tailings dam. The mass
flow meter will be used for the purpose of both metallurgical accounting and process control.

Level in tailings thickener feed sump (34-TANK-04) is measured by the level transmitter (34-LT-03). The
level in the thickener feed sump is controlled by level controller (34-LIC-03) which is looped to the
variable speed pumps (34-PUMP-03/4). The level controller will speed up the pump if the level in the
detox tank rises above the set level and will slow the speed of the pump if the level drops below the set
point.

Dissolved oxygen measurements are taken in both detox tanks using the DO meter available for this
purpose.

A pH analyser (34-AE-02/04) is used to measure the pH in the first stage detox tank (34-TANK-02) and
last stage (34-TANK-03). The pH probe controls the addition of lime to detox by controlling the opening
of the lime flow control valve (34-FCV-05) for 34-TANK-02 and Flow control valve (34-FCV-08) for 34-
TANK-03 to maintain the required pH as set on SCADA.

Primary dosage of sodium metabisulphite and copper sulphate is in ratio to totalised tonnage pumped
to detox as indicated by 34-WIQR-01. Secondary control is effected in response to the cyanide
concentration in the pulp in Detox tank (34-TANK-03) through the online cyanide analyser (34-AE-03) in a
feedback control loop. The online cyanide analyser measures the instantaneous cyanide concentration
in detox tank 2 pulp and sends a feedback signal to the PLC such that the speed of the dosing pumps
increases and decreases with cyanide concentration in the pulp in detox tank 2.

Flow switches fitted on gland water service lines feeding the detox feed pumps (34-PUMP-01/2) and tails
thickener feed pumps (34-TANK-03/4) will alarm the operator in the event of low gland water flow.
Pressure switches fitted on gland water service lines feeding the detox feed pumps (34-PUMP-01/2) and
tails thickener feed pumps (34-TANK-03/4) will alarm the operator in the event of low gland water
pressure. Pressure gauges are installed on each gland service line to the detox feed and tails thickener
feed pumps to give a visual indication of gland water pressure. Gland service water pressure is regulated
by a pressure regulation valve fitted on each pipeline feeding gland water to the pumps.

Detox spillage pump (34-PUMP-05) is started manually on high sump level and is fitted with low level
switch (34-LSL-02), stopping the pump automatically on low sump level.

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The automatic tailings sampler (34-SAMP-01) will periodically take samples from the line discharging to
the tailings thickener to be analysed and used for process control and metallurgical accounting purposes.
Sample frequency can be adjusted by adjusting the sampler timer setting.

A hydrogen cyanide gas detector (34-HCND-01) is installed in the detox circuit with SCADA indication.
High levels of hydrogen cyanide gas will alarm (34-AAH-01) on SCADA and a siren sounds in the Detox
area.

8.4.1 Detox SCADA Display

The items displayed on the Detoxification SCADA page are:

• Status (stopped/running) of all drives.

• Opening of lime control valves (34-FCV-05) % and (34-FCV-08)%
• Instantaneous lime flow rate on lime flowmeter (34-FT-05/08) m3/hr
• Instantaneous and totalised sodium metabisulphite flow (m3/h m3)
• Level in detox detox feed sump (%)
• Level in tailings thickener feed sump (%)
• Open/close position of the detox feed pump suction valves (34-XV-01/2)
• Open/close position of the tailings thickener pump suction valves (34-XV-05/6)
• Instantaneous detox feed density shown on nuclear density gauges (34-De-01)
• Instantaneous tailings flow rate(m3/hr) and totalised flow (m3) measured by flowmeter (34-FT-
01)
• Instantaneous tailings flow rate (t/hr) and totalised material flow (t) measured by mass
flowmeter (34-WIQR-01)
• Instantaneous pH value in detox tank 1 and detox tank 2.
• Instantaneous cyanide concentration value

8.4.2 Alarms
• Low gland water flow 34-FAL-02 to detox feed pumps (34-PUMP-01/2)
• Low gland water flow 34-FAL-07 to tailings thickener feed pumps (34-PUMP-03/4)
• Low gland water pressure 34-PAL-03 to detox feed pumps (34-PUMP-01/2)
• Low gland water pressure 34-PAL-08 to tailings thickener feed pumps (34-PUMP-03/4)
• High HCN gas alarm (34-AAH-01)
• Detox safety shower (34-SASH-01)flow alarm (34-FA-09)

8.4.3 Interlocks
Interlocks are put in place to protect the equipment from damage and to minimise spillages and
interruptions caused by equipment failure.

Detox feed pump 1 (34-PUMP-01) will not start or run unless:

• Suction valve (34-XV-01) must be open

• Gland water valve (34-XV-03) must be open

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• Suction valve (34-XV-02) must be closed

• Gland water valve (34-XV-04) must be closed
• Process water pump (61-PUMP-01/2) must be running

Detox feed pump 1 (34-PUMP-02) will not start or run unless:

• Suction valve (34-XV-02) must be open

• Gland water valve (34-XV-04) must be open
• Suction valve (34-XV-01) must be closed
• Gland water valve (34-XV-03) must be closed
• Process water pump (61-PUMP-01/2) must be running

Detox feed pumps (34-PUMP-01/2) will stop on:

• Low gland water flow (34-FAL-02)

• Low gland water pressure (34-PAL-03)
• Tails thickener feed sump high level (34-LAHH-03)
• Operator must ensure that the spray water pump (61-PUMP-03/40 is running.

Detox spillage pump (34-PUMP-05) will stop on:

• Spillage sump level low (34-LSL-02)

• Tailings thickener feed sump level high (34-LAHH-03)

Tailings thickener feed pump (34-PUMP-03) will not start or run unless:

• Suction valve (34-XV-05) must be open

• Gland water valve (34-XV-07) must be open
• Suction valve (34-XV-06) must be closed
• Gland water valve (34-XV-08) must be closed
• Tails thickener dilution tank mixer (34-MIXR-01) must be running
• Tails thickener U/F pump (35-PUMP-01/2) must be running

Tailings thickener feed pump (34-PUMP-04) will not start or run unless:

• Suction valve (34-XV-05) must be open

• Gland water valve (34-XV-08) must be open
• Suction valve (34-XV-06) must be closed
• Gland water valve (34-XV-07) must be closed
• Tails thickener dilution tank mixer (34-MIXR-01) must be running
• Tails thickener U/F pump (35-PUMP-01/2) must be running

Tails thickener feed pumps will not start or run if:

• Gland water flow is low (34-FAL-07)

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• Gland water pressure is low (34-PAL-08)

• Tails thickener torque is high (35-NAHH-01)

Other prestart conditions for the detox section;

• Lime dosing pump (53-PUMP-03/4) must be running

• Air compressor (56-COMP-01/2/3) must be running for the supply if air to detox
• Plant air should have sufficient pressure
• Copper sulphate dosing pump (54-PUMP-5/6) must be running
• Sodium metabisulphite dosing pump (54-PUMP-05/6) must be running.

8.4.4 Detox Equipment

8.4.4.1 Carbon Safety Screen (34-LISC-01)

The tailings carbon safety screen is a Delkor Horizontal belt Screen. The screen is equipped with
pneumatic self tracking devices. Spray water is used to clean the oversize (carbon) and also to clean the
screen cloth (belt) from beneath. The oversize material, consisting mainly of carbon escaped from LEACH
and the regeneration, is collected in the oversize basket (34-BSKT-01), which can be moved for emptying
by use of a loader or a folk lift. The screen undersize becomes the final tailings and gravitates to cyanide
detox where it is treated with sodium metabisulphite and copper sulphate under controlled pH
conditions before pumping to the tailings thickener..

8.4.4.2 Detox Reactors

Detox consists of two agitated tanks (32-TNK-01/2) in which CIP tailings are treated with controlled
dosages of sodium metabisulphite under conditions of controlled pH. Hydrogen cyanide destruction
commences in detox tank 1 where lime addition is monitored using pH controller (34-AIC-02). Sodium
metabisulphite addition rate is controlled by varying the speed of the metabisulphite in response to
values given by the online cyanide analyser in 34-TANK-02.

8.4.4.3 Detox Feed Pumps

Each of Detox feed and Tailings thickener feed stages comprises two pumps (34-PUMP-01/2 AND 03/4)
with separate lines merging on a Tech Taylor valve into a common delivery. The speed of the pumps is
controlled by the level in feed sump for the pumps. The level controller will vary the speed of the pumps
to maintain a set operating level in the tank.

8.4.4.4 Detox Measuring and Control Devices

• Nuclear density gauges (34-DE-01) on the detox feed line measures the density of material being
pumped to the detox tanks..
• Flowmeters measure instantaneous and totalised flow of pulp ,reagents and water to the detox
• A mass flowmeter (34-WI-01) measures instantaneous and totalised mass flow to the detox
feed.
• Primary samplers (34-SAMP-01) takes samples from the tailings thickener feed line at set time
intervals.

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8.4.5 Detox Start-up procedures

DETOX section start up normally takes place just after mill start up. The time taken for slurry to move
through the Leach/CIL is often enough to allow some time to start up the Detox section after mill start
up. The operator should make sure that downstream section (Tailings thickening is ready to receive
material from the detox section).

• Start the carbon safety screen (34-LISC-01)

• Check to ensure sufficient instrument air pressure is available for the automatic tracking system
and observe the belt self tracking system functioning
• Open the linear screen spray water valves (34-V-01/02) and check if the spray water pressure is
sufficient
• CIL tails will gravitate onto the carbon safety screen and the underflow will flow into the detox
feed sump (34-TANK-01) up to about 60% level after which the selected detox feed pump (34-
PUMP-01/2) is started.
• Allow detox tank 1 (34-TANK-02) to fill above the first agitator blades (if the tanks have been
previously emptied) and start the agitator (34-MIXR-01).
• Manually open the lime addition valve (34-FCV-05) to 10% until the automatic pH probe is
immersed in slurry then switch the pH control to auto.
• Wait for pH to stabilise near the required set point before sodium metabisulphite addition
commences
• Start the sodium metabisulphite pump (54-PUMP-05/6) at 20% speed set in manual
• Start the copper sulphate pump (54-PUMP-02/3) at about 20% speed in manual
• Allow detox tank 1 to fill up and overflow into detox 2.
• Once the first set of agitator blades are immersed in slurry, start the agitator (34-MIXR-02)
• Allow the detox tank to fill up and overflow into the thickener feed sump to about 60% shown
on the level transmitter (34-LT-03)
• Open the suction valve of the duty pump (34-XV-05/6)
• Open the gland service water valves (34-V-41/27 OR 42/29) to selected tailings thickener feed
(34-PUMP-03/4)
• Start the duty pump (34-PUMP-03/4)
• Switch the sodium metabisulphite addition to auto

8.4.6 Normal operating procedures:

Most of the detox controls are automatic. The operator still has to do some manual checks to validate
the readings from control instruments. The following controls are done manually to complement the
automatic equipment installed in the section:

• Pulp density manual readings with a Marcy Scale provided

• Measurement of slurry pH in both detox 1 and 2
• Measurement of dissolved oxygen
• Collection of composite sample from the automatic sampler and preparing the sample for
submission to the main laboratory.

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• Ensuring there is enough sodium metabisulphite in the dosing tank

• Ensuring there is enough copper sulphate in the dosing tank
• Regularly check the tracking of the linear screen
• Ensure oversize carbon basket is regularly emptied.

8.4.7 Planned shutdown procedures

Normally slurry will continue to flow through the Leach to detox and then tailings for a while after the
mill has been shut down. It is important to note that tailings-detox shut down will wait until slurry stops
flowing from the Leach/CIP into the detox. After slurry flow has stopped from the Leach section, Detox
shutdown proceeds as follows:

• Leave the process water into the detox feed sump running until almost all solids are gone as
confirmed by the density meter readings. This allows the delivery lines to be flushed before
stopping.
• STOP the carbon catch screen (34-LISC-01)
• Close the spray water valves (34-V-01/2) to the carbon catch screen
• Close process water valve (34-DCV-01) and allow the level in detox feed tank (34-TANK-01) to
fall to almost empty as shown by the level indicator (34-LT-01) and stop the detox feed feed
pump (34-PUMP-01/2).
• Open the dump valve (34-V-07/11) on the duty line and dump the line contents.
• Close the suction valve for the duty detox feed pump (34-XV-01/2)
• When there is no overflow from detox tank 2 :
• Stop the sodium metabisulphite dosing pump (54-PUMP-05/6)
• Manually close the lime addition valve (34-FCV-05/08)
• Stop the copper sulphate dosing pump (54-PUMP-02/3)
• Close dosing pump suction valves for metabisulphite and copper sulphate
• When it is visible in the sump contents that almost all solids have been flushed ,Close process
water valve (34-V-47) and allow the level in tailings thickener feed tank (34-TANK-04) to fall to
almost empty as shown by the level indicator (34-LT-03) and stop the tailings thickener feed
pump (34-PUMP-03/4).
• Open the dump valve (34-V-19/23) on the duty line and empty the line contents to the floor.
• Close the duty tailings thickener feed pump suction valve (34-XV-05/6))
• Leave Detox tank agitators (34-MIXR-01/02) running

8.4.8 Trouble shooting:

8.4.8.1 Carbon safety screen:

WHAT IS THE PROBLEM? WHAT CAUSED IT? WHAT TO DO

 Carbon safety screen  Insufficient instrument air  Check and improve

losing tracking to self tracking device instrument air supply
pressure

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 Tracking Limit switch  Inspect and ensure all limit

jammed switches are free

 Guide rollers dirty  Clean all guide rollers

 Carbon Safety  Panels pegged in slots  Clean the slots

Screen Flooding
 Insufficient spray water  Check and improve spray
water supply

 Feed flashing through the  Install weir panels to reduce

screen the flow across the screen

 Manual pH differ too  Either of the pH meter out  Calibrate both pH meters
much from auto pH of calibration

8.5 APPENDICES

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9. TAILINGS HANDLING DEWATERING

9.1 SAFETY
The major safety concerns in the tailings facilities:

• Residual Cyanide solution in the tailings slurries

• Major safety issues in the flocculant mixing and distribution area are as follows:
o Flocculants are extremely slippery when wetted.
o Flocculants are slightly alkaline (have a high pH) and can cause skin irritation and burns
if not washed off immediately.
o If a spillage of flocculant occurs, the following steps should be taken to ensure no
personnel are injured:
• Take immediate action by barricading the area around the spillage.
• Sand should be used to absorb as much flocculant as possible.
• The sand / flocculant mixture should be shoveled up and removed.
• Small amounts of residual flocculant should be hosed up.
o If flocculant contacts the eyes apply the standard procedure of flushing the eyes for 20
minutes with water from an Eye Wash Station should be carried out followed by medical
examination at the site Medical Centre.

9.2 THICKENER
 Hard hats should be removed when on the thickener bridge, due to the risk of them falling into
the thickener and being raked into the center cone causing a blockage. Hard hats should be
stored in the container provided at the entrance to the bridge.
 Ensure the thickener area is always clean and that lighting is sufficient to avoid accidents.
 Underflow and process water pumps will start and stop under automatic control and therefore
must be isolated and tagged out prior to commencing any work.
 No attempt shall be made to flush a pump or pipeline unless the suction isolation valve is closed
and the pumps are isolated. Operators should be aware that a large volume of slurry could run
back from a blocked pipe once the blockage is cleared.
 No attempt shall be made to remove or repair damaged components or to remove blockages, or
the like, on an operating pump.
 WARNING: Pumps that are blocked and continue to run can build up large amounts of heat and
care must be taken when draining these pumps, as hot slurry can be ejected under pressure.
Maintenance or other work on a pump that requires disconnection of the piping shall not
commence until both the suction and delivery isolation valves are closed.
 Any electrical or mechanical faults should be immediately reported to the Maintenance
Department and equipment isolated as required.

9.2.1 Sumps and Pumps

This area of the plant has one spillage pump with a sump pump. This is used to collect hosed spillage in a
slurry format, washing from the various items of equipment and to transfer the spillage to the correct

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area of the process. The spillage pump is significant size and normally operate automatically from a level
control in the sump.

 Because they are likely to contain water they form a slip- trip and drowning hazard for the
unwary. Operators shall not enter a sump without good reason. Work in the sumps shall be
considered as work in an enclosed space. At least one person shall be immediately available
outside the area to provide assistance.

9.2.2 Automated valves

Automated valves are commonly used for process control or where manual operation is not viable, such
as with the larger valves in use. The tailings thickening circuit has a selection of automated valves.

 Personnel shall not touch automated valves unless they have been isolated, as dangerous nip
points may be present.

9.2.3 Standard PPE

 Hard hat
 Steel capped boots
 Full overalls
 PVC gloves
 Ear protection
 Safety glasses
 Chemical full face masks (when necessary)
In addition, operators shall ensure that Fire Extinguishers and High Pressure Hosing Equipment are
readily available when working around the area.

Major Tailings Equipment

Equipment code Equipment name kW Description Supplier

35-TANK-01 Tails thickener external dilution
tank
35-MIXR-01 Tails dilution tank mixer 55
35-TANK-02 Tails thickener tank
35-THCK-01 Tails thickener mechanism 30
35-PUMP-01 Tails thickener UF pump 1a 200
35-PUMP-02 Tails thickener UF pump 2a 200
35-PUMP-03 Tails thickener UF pump 1c 200
35-PUMP-04 Tails thickener UF pump 2c 200
3-PUMP-05 Tails spillage pump 7.5
35-PUMP-06 Tails thickener UF pump 1b
(Future)
35-PUMP-07 Tails thickener UF pump 2b
(Future0
35-PUMP-08 Tails gland water pump 1 45
35-PUMP-09 Tails gland water pump 2 45

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9.3 PROCESS AND PLANT DESCRIPTION:

This should be read in conjunction with TAILINGS PFD 3500 in Appendix

CIL tailings and other barren effluents from various points of the processing plant (acid wash effluent,
and rinse effluents, etc, which come through the detox section) are disposed of to the tailings dam
through the tailings facility. The tailings section consists of a tails dilution tank ,the tailings thickener and
thickener underflow pumps which fulfill the following tasks:

 Receive tailings from the detox section for final disposal in the tailings dam
 De-water tailings as far as practical to recover water and residual cyanide
 Pumping of plant tailings to the tailings dam storage facility.
 Obtain a representative tailings sample for the purpose of plant control and metallurgical
accounting
The following processes are used to achieve the above aims:

 Dilution of tailings for proper functioning of the High-Rate thickener.

 Thickening of the final tailings to 55% solids for economical and safe disposal in the slimes dams.
 Pumping of thickened tailings to the slimes dams.
 Automatic control of the thickener/pumping system in order to achieve optimum operating
conditions at all times.
 Automatic and accurate sampling of final plant tailings.
 Sedimentation in the slimes dam.

Tailings slurry (at a density of 40% solids by weight) pumped from the tailings thickener feed sump (34-
TANK-04), flows into the agitated (by 35-MIXR-01) tails thickener dilution tank (35-TANK-01) together
with dilute flocculant, tailings thickener overflow and tailings spillage from spillage pump (35-PUMP-05).
In the dilution tank, tailings are diluted to a density of 8 to 14% solids by weight, the target thickener
feed density.

The slurry from the thickener feed dilution tank overflows into a 45 metre diameter GDK-Delkor high
rate thickener (35-THCK-01), where solids material “settle” at the bottom and clarified water exits the
thickener as overflow. The thickened tails slurry at a solids density of 50-55% by weight is pumped to
the tailings storage facility (35-TLSF-01). Thickener overflow, which is clarified solution, reports to the
process water pond (61-POND-02)

The thickener underflow is pumped to the tailings dam using a two-stage pumping system (35-PUMP-
01/3 or 35-PUMP-02/4). All pumps are fitted with gland seal water. The first stage pumps are fitted with
variable speed drives while the second stage pumps are fixed speed. Provision has been included in the
design for future installation of third stage pumps (35-PUMP-06/7) on both trains.

Dilute flocculant solution is added to the tailings slurry in the tailings thickener feed sump (34-TANK-04),
thickener feed dilution tank (35-TANK-01) and thickener feed well at a controlled dosing rate from the
flocculant dosing plant.

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Spillage in the tailings area is contained in a bunded area fitted with a dedicated spillage pump 35-
PUMP-05. Spillage is pumped back to the tails thickener dilution tank

The slimes are deposited into a slimes containment dam (35-TLSF-01) especially designed for
environmental protection and fitted with a penstock for decant water recovery. Dam return water is
collected in a pond (61-POND-01/2) outside the dam and pumped to the various plant sections for reuse
as process water.

Emergency overflow pond

The emergency pond offers an emergency temporary diversion route for tailings in the event pumping
to tailings dam cannot be done for say, a pipe failure. The tailings can also be directed into an
emergency containment dam (35-POND-01) to prevent toxic spillages being discharged into nature while
the plant is being shut down.

9.3.1 Thickening Process

9.3.1.1 Principle of Operation

The high rate thickener is large settling tank where diluted slurry enters a feed well in the centre, with
thickened slurry being withdrawn from the bottom and clean water overflowing the top. The thickeners
work with the aid of flocculants which are long chain polymers that cause the slurry particles to be
attracted to each end of the chain and rejecting interstitial water between them. The formation of these
“flocs” increases the settling rate (Normally in the order of 5 to 8 m/h) to a point where it exceeds the
up-flow velocity of the clarified liquid. High-Rate” thickeners operate at up-flow velocities much higher
than those used in conventional thickeners and are therefore smaller in size. They are also more
susceptible to changing operating conditions due to shorter retention times and therefore require
sophisticated controls to achieve optimum operating conditions. The “flocs” settle at the bottom of the
tank, creating “thickened” slurry, which is raked to the centre of the thickener for discharge by the
underflow pumps. Flocculation of the ultra-fine particles creates a clear overflow. The rejection of the
water causes the slurry to increase its solids percentage and this is known as thickening.

Figure 9-1: Flocculation Mechanism

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The picture in the figure below shows a typical thickener installation.

Figure 9-2: GKD Delkor Thickener

There are three settling zones in the high rate thickener which are known as the clear zone, hindered
settling zone and compacted (or settled) zone.

 The clear zone contains clear water which overflows the thickener via the thickener overflow
launder and gravitates to the process water pond.
 The hindered settling zone contains flocculated solids which are settling under gravity and water
which is rising through the solids to the clear zone.
 The compacted zone contains solids which have largely settled resulting in thickened slurry
which is ready for discharge. The thickeners are equipped with rakes which direct the thickened
slurry into the underflow cone from where it is drawn from the thickener and pumped to the
leach circuit.

Figure 9-3: Settling Zones in “High Rate” Thickening

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A: Clear solution.

B: “Hindered settling”/”Compaction” intermediate zone.

C: Compression zone.

Each thickener consists of the following main components :

Main thickener tank (35-THCK-01)

The tank is 45 metres in diameter with a sloping bottom. The rake drive and feed well are supported by
a bridge and a walkway which spans the tank.

Feedwell and feed pipe

The feed pipe delivers slurry from the thickener dilution tank (35-TANK-01) across the top of the
thickener to the feed well. Thickener by pass is not installed. Incoming feed enters the circular feed well
tangentially, promoting a gentle mixing of the slurry and diluted flocculant. The feed well is sized to
allow for de-aeration of the incoming slurry feed. Flocculant can also be injected into the feedwell from
sparge pipes. A deflector cone at the bottom of the feed well allows the mixed slurry to discharge
steadily into the main body of the thickener, at the hindered settling zone, from where the solid
particles settle to the bed whilst clear liquid rises towards the surface where it overflows via the
circumferential overflow launder. Part of the overflow flows back as necessary into the dilution tank to
dilute the incoming feed to the target feed density.

Rake drive

The thickener is equipped with four rake arms. Two long arms extend to the edge of the tank. Two
shorter arms are installed at 90° to the long arms. The arms are fitted with rakes arranged to sweep the
entire floor of the thickener twice per revolution. The rakes move solids towards the centre cone, as the

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rake arms rotate, and also help to keep the bed mobile and thicken the solids in the bed. The rake drive
configuration is a hydraulic driven motor equipped with a reduction gearbox connected to a pinion
driving a slew ring gear coupled to a torque tube. The torque tube in turn drives the rakes. The drive
has an automated lift facility that raises the rake arm assembly to a maximum 600mm if the bed offers
too much resistance to movement. Top and bottom proximity switches sense that the rake is in the fully
raised or fully lowered position.

Pulp bed level control system

This sensor indicates when the pulp water interface (bed depth) rises and adjusts flocculant addition
accordingly.

Torque transmitter

This is a pressure transducer measuring the pressure applied by the hydraulic drive motor. This pressure
is proportional to torque and hence, the 4-20 mA signal transmitted is proportional to torque. The
torque is displayed as a percentage of full load torque on the control panel. If the torque becomes too
high an alarm sounds and the rakes will automatically lift to prevent them from being damaged or
bogging down. If the torque exceeds the maximum, the drive will shut down automatically to prevent
rake damage.

Underflow withdrawal

Underflow is withdrawn from the discharge cone via one of two 250 NB nozzles each connected to a
separate underflow pump train (35-PUMP-01/3 and 35-PUMP-02/4). The thickener underflow pump
trains feed into a common pipe line which carries the thickened slurry to the tailings dam. Actuated
valves are installed on the suction (35-XV-01/2) and discharge (35-XV-10/11) and manual valves 35-
V96/98)of each set of pumps which allows for isolation of the standby set. Thickener underflow may be
recirculated to thickener feed dilution tank (35-TANK-01); routing is controlled by pneumatically
operated valves (35-DV-01A/01B). (Recirculation is normally practiced during temporary or short-term
stoppage of thickener feed, or when building up underflow densities during start-up or if the thickener
has been pumped out. It may also occur if discharge to tailings dam has to be stopped for a short
period).

Thickener underflow at the target density of 65% solids is pumped to the tailings management facility.

Overflow from the thickener is directed to the process water pond (61-POND-02). Part of the overflow
flows back as necessary into the thickener dilution tank to dilute the incoming feed to the target feed
density

9.3.2 Specific Issues for Thickeners

The following issues are likely to require observation on the thickeners:

1. Monitor the overflow water for clarity.

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2. Monitor top surface of thickeners for buildup of foam, flocculant, waste etc.
3. Watch rake arm for erratic or jerky movement – the rakes should move smoothly at all
times.
4. Monitor all slurry and flocculant feed lines for leaks etc.
5. Check oil level in hydraulic tank
6. Check oil temperature
7. Visually check hydraulic hoses and system for leaks and report any leaks found.
8. Check gearbox for undue noise or vibration and report.
9. Monitor underflow area for leakage, keep clean at all times.

9.3.3 Controls

9.3.3.1 Thickener
Please refer to the OEM (GDK Delkor) Manual in Appendix

Feed slurry dilution

The thickener has an external feed dilution system to ensure the correct feed density to the thickener is
attained (8-14% solids by weight).

Local panel

A local panel is mounted on the thickener bridge. The panel consists of the following:

 Audible alarm (Siren).

 Visual alarm (Flash light).
 Torque indication.
 Alarm lights for high torque and main drive trip.
 Start and emergency stop buttons.
 Local alarm reset button.
 Rake up and rake down positions
 Main drive run and trip positions
 Low oil level
 Rake manual/off /auto selector
 Rake inch up and downs
 Main switch

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Torque control and automatic rake lift system

The rakes and the rake lifting systems are powered by a hydraulic power pack which is controlled from
the central PLC and. The rake lift system operates automatically according to the vendor control
philosophy (See appendix). The control philosophy is summarised below:

A pressure transducer (35-NT-01) fitted to the hydraulic power pack will provide thickener torque
indication. If an increase in solids loading raises the torque to 55 % of the installed torque, the pressure
transducer activates the high torque alarm at the SCADA and a siren sounds. This warns the operator to
take corrective action to prevent an excessively high torque in the thickener (31-THCK-01). The alarm
will continue to sound until the operator accepts the alarm condition.

If the torque continues to rise to 65 % of the maximum torque, the rake lifting action will start and the
system alarms as previously described. The rake will rise until the torque drops below 40 % or until it
reaches the top limit switch. If the torque drops below 40 % of the installed torque, the rake will begin
to drop. If the torque rises to 100 % of the installed torque, the hydraulic motor will trip and the very
high torque alarm will be activated.The operator should stop feed.

Bed level monitoring and control

Bed level indication in the thickener will be provided to alert operators of any build up in inventory in
the thickener. This mud ball (35-LT-02) will be used to regulate flocculant addition rate by varying the
speed of the flocculant dosing pumps (52-PUMP-01/2).

Bed mass monitoring and control

A combination of pressure transmitter (35-PT-01) located at the bottom of the thickener (to measure
bed mass) and the nuclear density meter (35-DT-01) will enable the underflow variable speed pumps
(35-PUMP-01/2) to be operated in a cascade loop as a means of controlling the underflow density (55%
solids) to the tailings management facility for optimum water recovery.

On low density measurement the density control valve 1A (35-DV-01A) will close and density control
valve 1B (35-DV-01B) will open to re-circulate the underflow at minimum speed until the required
density is achieved. See simplified P&ID in Figure below:

Mass flow monitoring and recording

The magnetic mass flow meter (35-FT-01) will be used together with the nuclear density meter (35-DT-
01) as a mass flow meter. The instrumentation will give a local and SCADA display of instantaneous
slurry density and instantaneous and totalized volumetric flow and integrated dry tonnage. The flow will
only be totalized when the forward valve is open.

A second flow meter (35-FIT-08) is fitted to the pipeline near its delivery point at the Tailings dam to
detect a pipeline failure. If this happens the tails pumps must be shut down immediately to limit
pollution of the environment.

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9.3.3.2 Gland service

Gland service water is supplied to all the thickener underflow pumps by gland service pumps (35-PUMP-
08/09) from dedicated tank (35-TANK-03).

Flow switches fitted on gland water service lines feeding the individual slurry pumps will alarm the
operator in the event of low gland water flow. Pressure gauges are also installed on the common and
individual gland service lines to the thickener underflow pumps to give a visual indication of gland water
pressure while a pressure switches installed on the common line will give an alarm in the event of low
gland water pressure. Gland service water pressure is regulated down by a pressure regulation valve
fitted on the individual lines feeding gland water to the pumps.

9.3.3.3 Spillage handling

The talings thickener area spillage pump (35-PUMP-05) starts automatically on high sump level (35-LSH-
01) and is fitted with low level switch (21-LSL-03/4) which stops the pump automatically on low sump
level.

9.4 TAILINGS THICKENER SCADA DISPLAY

The items displayed on the tailings thickener SCADA page are:

 Status (stopped/running) of all drives.

 Instantaneous bed level %
 Instantaneous torque level %
 Instantaneous bed mass
 Instantaneous and totalised tailings flow rate as measured by the magnetic flowmeter (35-FT-
01). This will only totalise when underflow is being pumped to tailings dam.
 Instantaneous tailings slurry density as measured by the nuclear density meter (35-DT-01)
 Instantaneous and totalised integrated tailings dry solids tones (35-WIQR-01)
 Position of recycle valve (35-DV-10).
 Position of tailings forward feed valve (35-DV-01A).
 Variable speed output (%) of the duty tailings VSD pump (35-PUMP-01/2)
 Open/Close position of all actuated valves in this tailings area

9.4.1 Alarms
 Low gland water flow 35-FAL-02 to 35-PUMP-01
 Low gland water flow 35-FAL-03 to 35-PUMP-02
 Low gland water flow 35-FAL-04 to 35-PUMP-03
 Low gland water flow 35-FAL-05 to 35-PUMP-04
 Low gland water pressure 35-PAL-02/03 to 35-PUMP-01/2/3/4
 Low gland water tank level alarm (35-LAL-03)
 Thickener alarms
o Thickener drive torque-55%

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o Thickener drive high torque -65%

o Thickener drive torque with rakes at top limit -100%..
o Thickener drive torque with rakes at top limit-105%.

9.4.2 Interlocks
Interlocks are put in place to protect the thickener drive from damage and to minimise interruptions
caused by equipment failure.

 Tailing spillage pump (35-PUMP-05) cannot start or run if

o Sump level is low (35-LSL-01)
 Thickener (35-THCK-01) rake drive stops on torque alarm (35-NT-01) “High-High”.
 Tails thickener U/F pump 1 (35-PUMP-01) cannot start or run unless:
o Suction valve (35-XV-01) must be open
o Gland water valve (35-XV-03) must be open
o Suction valve (35-XV-02) must be closed
o Gland water valve (35-XV-08) must be open
o Gland water valve (31-XV-07) must be open
o Discharge valve (35-XV-10) must be open
o Discharge valve (35-XV-11) must be closed
o Gland water has sufficient pressure and flow.
o Either gland water pump 35-PUMP-08/9) is running.
o Either density valve (35-DV-01A/01B) is open
o Flush valve (35-XV-12) is closed.
o Process water pump (35-PUMP-01/02) is running
 Tails thickener U/F pump 1 (35-PUMP-02) can not start or run unless:
o Suction valve (35-XV-02) must be open
o Gland water valve (35-XV-04) must be open
o Suction valve (35-XV-01) must be closed
o Gland water valve (35-XV-08) must be open
o Gland water valve (31-XV-07) must be closed
o Discharge valve (35-XV-11) must be open
o Discharge valve (35-XV-10) must be closed
o Gland water has sufficient pressure and flow.
o Either gland water pump 35-PUMP-08/9) is running.
o Either density valve (35-DV-01A/01B) is open
o Flush valve (35-XV-12) is closed.
o Process water pump (35-PUMP-01/02) is running
 Gland water pump (35-PUMP-08/09) will stop on Gland water tank level low (35-LALL-01)
 Tails thickener U/F pump 1 (35-PUMP-03) cannot start or run unless:
o Suction valve (35-XV-01) must be open
o Gland water valve (35-XV-05) must be open
o Suction valve (35-XV-02) must be closed

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o Gland water valve (35-XV-08) must be closed

o Gland water valve (31-XV-07) must be open
o Discharge valve (35-XV-10) must be open
o Discharge valve (35-XV-11) must be closed
o Gland water has sufficient pressure and flow.
o Either gland water pump 35-PUMP-08/9) is running.
o Either density valve (35-DV-01A/01B) is open
o Flush valve (35-XV-12) is closed.
 Tails thickener U/F pump 1 (35-PUMP-04) cannot start or run unless:
o Suction valve (35-XV-02) must be open
o Gland water valve (35-XV-06) must be open
o Suction valve (35-XV-01) must be closed
o Gland water valve (35-XV-08) must be open
o Gland water valve (31-XV-07) must be closed
o Discharge valve (35-XV-11) must be open
o Discharge valve (35-XV-10) must be closed
o Gland water has sufficient pressure and flow.
o Either gland water pump 35-PUMP-08/9) is running.
o Either density valve (35-DV-01A/01B) is open
o Flush valve (35-XV-12) is closed.
o Process water pump (35-PUMP-01/02) is running
 Gland water pump (35-PUMP-08/09) will stop on Gland water tank level low (35-LALL-01)

9.5 TAILINGS DAM

Tailings are distributed around the slimes dam (35-TLSF-01) using a ring main fitted with spigot points.
The spigots are spread around the dam to ensure equal rate of growth of the dam wall.

A second flow meter (35-FMTR-01) is fitted to the pipeline near its delivery point at the Tailings dam to
detect a pipeline failure resulting in a leak. If this happens the tails pumps must be shut down
immediately to limit pollution of the environment.

9.5.1 Plant operating procedures:

9.5.1.1 Start up procedures: After extended period.

The field operator will perform the following checks:

 Tailings thickener feed and U/F pumps inspection.

 Abnormal spillages.
 Oil spillages.
 Set manual valves in correct positions.
 Gland Service Water pressure on the pressure gauge.
 Adjust pressure regulating valve, if necessary.
 Flocculant solution available and dozing pump ready to start.

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 Spillage pump is operating correctly.

The operator should ensure the downstream sections (tailings dam , process water pond) are ready to
receive material from the preleach thickening section. Upstream, the detox, CIL, preleach thickening
and milling sections should be ready to start and supply pulp for thickening.

 Fill the thickener with water and start the drive racks
 Open the recircuilation valve (35-DV-01B)
 Open the delivery valve for the selected duty pump train
 Open suction valve for selected duty pump
 Start the thickener U/F pump in recircuilation mode, pumping back to the dilution tank and back
into the thickener.
 Start the mixer (35-MIXR-01) in the dilution tank (35-TANK-01)
 Check the operation of the flocculant dosing pump
 Start feed and flocculant dosing (dilute flocculant).
 Thickener overflow will act as dilution medium for the feed in the dilution tank.
 Set flocculant dosage according to solids feed rate
 Switch the drives in this section to Auto mode.
 The thickener underflow slurry density will increase steadily until the “High RD” set point is
reached at which point the recircuilation (35-DV-01B) valve closes and the slurry is pumped
forward (35-DV-01A opens) to the tailings management facility.
 The tailings thickener U/F pumps are left running for short plant shut downs. When the slurry
density reaches the “Low RD” set point the bypass valve (35-DV-01B) opens automatically and
the slurry is pumped back to the thickener feed dilution tank in closed circuit.

Apart from a few instruments and controls the tailings circuit is controlled manually by the field
operators. Tailings operators are expected to check slurry densities, slurry pH, and prepare samples for
the assay laboratory.

Samples are taken manually from the thickener underflow pipeline through use of valve on a regular
basis and analysed in the laboratory for slurry density and pH. The operator is expected to compare the
determined slurry densities against the readings from the nuclear density meter if significant differences
are noted then the nuclear density meter may need recalibration. All results are recorded in a log book
and used for trends analysis and test error identification.

The underflow slurry density should be checked every hour through use of a Marcy scale as outlined
below.

To check the slurry density, take a manual pulp density sample of the thickener underflow and:

 Fill up the one litre slurry density container with underflow slurry while blocking the upper
drainage holes with fingers.
 Place the slurry density container on the slurry density scale and remove fingers to allow excess
pulp to drain from the container. Wait for the reading to stabilise.

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 Read off the slurry density number corresponding to that shown by the needle on the 3.2 solids
density scale.

Accurate measurement of pulp relative density relies on using exactly one litre of sample. It is
important to use only the container supplied with the scale and to calibrate the relative density scale
once a shift. This is done by taking a reading with the slurry density container full of water. Should the
needle not indicate 1.00 (i.e. positioned at “12 o’clock”), turn the adjusting screw until the needle
indicates 1.00.

In addition the operator should check the thickener overflow clarity frequently.

9.5.1.2 Planned shutdown procedures

The following steps must be followed in normal shut down:

 Stop the milling section

 Leave the thickener in operation until CIL tails stop flowing into the detox section from where
tails thickener feed is pumped.
 Run the tailings pumps with dilution water until bed level and underflow density are minimal
and the thickener rakes are at the lowest point
 Stop dilution water when the thickener goes into circulation mode. The density is low enough to
leave the thickener in recycle mode.
 If the thickener has to be maintained, empty the thickener, stop the pumps and the rakes
 Put isolation tags on all the equipment to be maintained

9.5.1.3 Emergency procedures.

If a power failure occurs, causing a pro-longed shutdown and the rakes will not restart, Rake “jogging”
can be tried. Jogging is performed at the local control panel, ensuring the thickener has first been
switched to manual. If the rakes fail to start and still cannot move do not continue to jog them as severe
damage can result. Inform the supervisor. Do not allow new feed to enter the thickener until the rakes
are moving normally.

9.5.2 Trouble shooting: Thickener

WHAT IS THE WHAT CAUSED IT? WHAT SHOULD I DO
PROBLEM?
No flocculation of the  Blocked flocculant pipes Unblock the pipes and clear with
feed water at full volume.
 Over- flocculant Check the control system.

 Under- flocculant Check the control system.

Underflow density is  Decrease in feed solids Reduce underflow pump speed
too low loading
Underflow pumps
running too fast
 No flocculant Check that flocculant plant is
delivering flocculant.

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 Rat-holing - normally caused Reduce flocculant dose rate, OR

by over-flocculation or underflow discharge rate.
excessive underflow
pumping
 Stalled rakes Stop feed. Investigate cause and
take corrective measures.
Underflow density is  Underflow pumps running Increase underflow pump
too high too slow speed, OR
open underflow discharge valve.
 Increase in feed solids Reduce flocculant dosage rate.
loading
 Excessive flocculant Reduce flocculant dose rate.

High torque  Over- flocculant causing a Reduce flocculant dose rate.

jelly-like substance.
 Excessively high feed solids Reduce feed to thickener.
loads
 Excessively coarse feed Reduce feed to thickener.
Investigate and correct cause of
coarse feed.
 Underflow too low Increase underflow discharge
rate.
 Mud build-up on rakes – Decrease flocculant.
typically caused by over-
flocculation
Rakes do not turn  Trip pressure switch has Check operation of pressure
been activated switch and adjust if necessary.

Rakes turn too slowly  Flow control valve too far Adjust flow control valve (close).
open.

 Leaking pipework Check pipework for leaks and

repair or replace.

9.6 APPENDICES
 TAILINGS PFD FD 3500 Rev. 05
 WATER SUPPLY & TAILINGS DAM PFD FD
 TAILINGS P&ID PD 3510 Rev. 03.
 GKD Delkor Thickener O & M Manual.

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10. REGENERATION
10.1 PROCESS AND PLANT DESCRIPTION:
Read in conjunction with REGENERATION PFD 4400 (See Appendix).

10.1.1 Process description

A loaded carbon batch is normally transferred from CIL to elution on a daily basis. Batches are then
transferred from each downstream tank to its upstream neighbour leaving the last tank in line depleted
by a batch. This must be replaced immediately with a batch of regenerated carbon.

The regenerated carbon will normally be discharged directly by gravity to the last CIL vessel on line or
hydraulically transferred from an eductor tank holding the regenerated carbon.

Co-ordination and planning between the CIL and Regeneration operators will be crucial to ensure
optimum availability of regenerated carbon for transfer to the CIL.

Carbon particles loose a large proportion of their activity in the adsorption (CIL) and elution processes.
To maintain sufficient carbon activity it is necessary for the carbon to go through a reactivation process
before reuse in the CIL circuit. A thermal reactivation process is used in carbon regeneration.

The eluted carbon batch is transferred from the elution column to a storage tank through a pipeline
using clarified water as conveying medium. Excess water is drained off and reports to plant tailings. Wet
carbon from the barren carbon storage is fed via a screw feeder at constant feed rate to a rotary kiln.
The feeder speed can be varied in order to adjust the regeneration process retention time. The feeder is
also fitted with wedge wire screen material to eliminate water from entering the kiln. Excess water in
the kiln tends to damage the drum lining. However it is necessary that the carbon is fed with a minimum
amount of moisture to produce steam which is necessary for the regeneration process. The rotating kiln
is fired at ± 700o C and operates in a continuous process under mild reducing conditions. The kiln
temperatures are set in such a way that three distinct regions are formed along the kiln length. During
passage through the kiln carbon particles are subjected to a number of processes as it passes through
the different regions of the kiln as follows:

When the carbon enters the kiln, it passes through three stages, namely drying, baking and activation.
In the first section of the heating zone, the wet carbon achieves its maximum drying and baking
capabilities within the shortest possible time. The latter section of the heating zone allows the carbon
to soak at the specified operating temperature.

During the drying stage, the temperature of the carbon is increased to approximately 100C, during
which period the moisture evaporates.

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Steam, which is present in the carbon, distils the more volatile organic matter from the carbon. Any
organic compounds (from oil, grease etc.) attached to the carbon active surface by physical adsorption
will be removed.

The carbon temperature is then increased to approximately 650C (The baking stage), during which time
any cyanide compounds associated with the carbon will decompose to ammonia and carbon monoxide.
During the activation stage, char residue, which has been formed during the baking stage, is burnt off
according to the water gas reaction.

A steam atmosphere is present inside the retort tube by the water present in the carbon granules at the
feed stage. The steam provides a slightly positive pressure which excludes air from the tube and creates
the mild oxidizing environment required for the carbon surface reactivation.

As a result of the regeneration process the large surface area of the carbon particles has been cleaned
and reactivated.

The activation process and the retention time in the heating zone may be changed by varying either the
speed of the screw feeder, and/or the speed of rotation of the tube combined with different
temperature settings within the heating zones.

The carbon is quenched immediately at the kiln discharge before reaction with atmospheric oxygen can
take place.

During the transportation and regeneration processes carbon is subjected to severe thermal and
mechanical shocks and this generates a significant amount of fines. These must be removed prior to
recycling the batch to the CIL tanks. The quenched carbon is wet screened on a vibrating screen prior to
discharge directly into the last operating tank in the CIL circuit or via an eductor tank enroute to the last
CIL tank.

Fresh carbon in bulk bags maybe added to the quench screen to remove the fines prior to addition to
the CIL circuit. The virgin carbon together with raw water are added to a carbon attritioning tank before
being discharged onto the carbon fines screen where the carbon fines are washed off to the carbon
fines handling facility.

10.1.2 Safety
The following safety HAZARDS exist around the regeneration plant:

 Cyanide containing water during the carbon transfer process from the elution column
 Caustic containing solutions from the elution column
 Hot surfaces
 Ammonia and carbon monoxide gas emissions
 Hydrocyanic gas emissions
 Steam emissions

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It is important that gas measurements are regularly done to check any abnormal readings from the
areas around the regeneration plant. In cases where automatic gas detectors are installed, any alarms
from such devices must be investigated. If necessary evacuate the place immediately and corrective
action must be take to correct the problem.

10.1.3 Sodium Cyanide (NaCN):

Cyanide is the greatest danger around the regeneration plant. There are three ways of cyanide
poisoning:

Cyanide ingestion: when cyanide is taken through the mouth either as liquid cyanide, or in form of
contaminated slurries

Cyanide inhalation: this occurs when cyanide in the form of hydrocyanic gas (HCN) is inhaled through
breathing. Hydrocyanic gas (HCN) possibly poses the worst danger in a gold processing environment.

Absorption through the skin: cyanide in the form of liquid and in contaminated slurries can find its way
into human blood system by being absorbed through the skin.

It is important to note that prevention of cyanide poising constitutes the majority of the safety
procedures and standards for a typical CIL operating process. Proper Safe working procedures must
always put in place and must be made available and taught to all people working in cyanide working
environments.

WARNING!

ALL FORMS OF CYANIDE ARE POISONOUS WHETHER IT IS IN THE SOLID FORM, DISSOLVED AS A LIQUID
OR GIVEN OFF AS HYDROCYANIC (HCN) GAS.

DANGER SIGN FOR CYANIDE

Personnel shall take note of the location of the potable water safety shower and eye wash station
located in the area.

Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in Figure 3.4.1 below. The shower shall be used

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in all instances where any body part or clothing has been splashed or exposed in any way to the acid
solution.

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Figure 10-1: Safety Shower Features.

EYE-WASH BASIN AND

HANDLE

FOOT PEDAL

Material safety data sheet for cyanide is attached, which stipulates the properties, the proper handling
and storage conditions for the two major forms (liquid and solid) and recommended remedies are given
in case of cyanide poising. The material safety data sheet must be made available, accessible to and
understood by all the operators and supervisors before cyanide use commences on site.

10.2 PPE FOR CIL SECTION

10.2.1 Standard PPE
 Hard hat
 Steel caped boots
 Full overall
 PVC gloves and Leather gloves when necessary
 Dust masks (when necessary)

Beware of diesel leaks under pressure.

Beware of falls from slipping on greasy/oily surfaces.

A safety shower is available in the kiln area.

10.2.2 The following PPE must be used in addition to the normal CIL PPE:
 A gas detector must be used regularly to check the gas levels during the regeneration process.

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 Leather gloves must always be used when working on the hot surfaces of the kiln

Equipment code Equipment name kW Description Supplier

44-TANK-01 Eluted Carbon Holding tank
44-REGN-01 Regeneration kiln 15 Diesel fired kiln, 2.2KW Kemix
main drive, 600kg/h C
44-KEDC-01 Kiln emergency drive (DC) 1.1 Kiln emergency 24DC Kemix
drive
44-FEDR-01 Kiln screw feeder 0.75 Dewatering screw , Kemix
304SS
44-PAN-01 Quench pan
44-SCRN-01 Regenerated carbon screen 0.8
44-TANK-02 Eductor tank
44-TANK-03 Carbon transfer tank
44-PUMP-01/2 Carbon transfer pump 1/2 11
44-TANK-04 Carbon attrition tank
44-MIXR-01 Carbon attritioning mixer 1.10 AMX 25, 2 blades, Kemix
1.25mDx1.65mH tank
44-PUMP-03 Regen spillage pump 7.5
44-THCK-01 Carbon fines thickener 15
44-BSKT-01 Carbon fines basket

10.3 PLANT DESCRIPTION

The plant consists of the following equipment

 Carbon transfer pump in the elution circuit (44-PUMP-01/2).

 Piping to from the carbon transfer pump to the eluted carbon storage tank (44-TANK-01).
 Bypass piping to CIL (32-TANK-08/6).
 Eluted carbon storage tank (44-TNK-01) fitted with overflow and underflow filters. This has a 12
t (27 m3) carbon batch capacity.
 Screw feeder (44-FEDR-01).
 Regenerated carbon eductor tank (44-TANK-02)
 Regenerated carbon fines screen

Wet carbon is fed by gravity from the feed hopper into the hopper of the screw feeder, where it is fed
into the kiln retort tube. The dewatering screw mounts directly onto the kiln structure at the charge
end.

The feeder is equipped with a variable speed drive unit capable of feeding at the required throughput.
Coupled with the slow speed is an enlarged screw pitch, which assists in reducing the possibility of slugs
of water entering the retort tube.

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The feeder casing and screw auger are manufactured in stainless steel. The screw feeder has been
designed to remove as much free water as possible from the carbon, thus preventing excess water
entering the retort tube. The dewatering area consists of stainless steel wedge wire sections situated
down each side of the hopper collecting area, allowing water to drain leaving the carbon behind.

The base of the screw auger casing also comprises a wedge wire section, longitudinally positioned in the
same direction as the screw auger. Excess water is drained away, leaving the carbon to be fed into the
tube. The wedge wire sections are easily removed for maintenance or replacement purposes. The
outer casing of the screw feeder is ducted to a pipe for excess water removal.

The dewatering screw feeder is installed at an angle of 20 degrees to the horizontal axis of the rotary
kiln, thereby assisting the dewatering of the carbon.

Electrical interlocks are incorporated in the control design, to prevent the screw feeder transferring
carbon into the retort tube until a preset temperature is reached or if rotation of the tube stops.

 The screw feeder feed rate can be adjusted to control regeneration process retention time.
 Diesel fired regeneration kiln (44-REGN-01) designed to operate at between 700 to 800 o C with
thermostat control.
 The kiln is capable of handling a 12t batch in 20 hours at 600 kg/h

10.3.1 Retort Tube

The retort tube of the kiln is manufactured from stainless steel. Fitted inside the retort tube at the feed
end is a stainless steel end plate that allows the feeding portion of the screw feeder to project into the
tube and prevents carbon feedback into the charge section.

Slime and silica deposits have been found sintered onto the shell of the retort tube, usually when
inadequate washing of the carbon has taken place. Once these deposits sinter onto the tube, the heat
transfer efficiency falls, since the deposits act as an excellent insulating material and prevent heat
transfer to the carbon. The operating temperature is then increased to compensate for the poor
regeneration, which follows, resulting in early system component failure. It is recommended that
regular inspection takes place of the inner wall of the retort tube for the build-up of silica, slime and
other deposits, which could sinter onto the wall of the tube, thus reducing the heat transfer capabilities.

A removable inspection cover is provided in the rear wall of the discharge hopper, which allows for
inspection and deposit removal.

From previous experience, it has been found that the fitting of lifters in the retort tube leads to carbon
build up at the root of the lifter and eventual distortion of the tube. The peripheral speed of the tube is
calculated to give sufficient turn over of the carbon thus eliminating the need for lifters. The retort tube
has no removable lifters.

Drip feed lubricators filled with oil are fitted to the expanded metal cover, which guards the chain
drives. Oil is allowed to slowly lubricate the chains and support points mounted outside the guards.

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10.3.2 Discharge Hopper

Located at the discharge end of the kiln is a stainless steel hopper mounted on the main frame. Because
the retort tube is “fixed” at the charge end between the two thrust rollers, the expansion, which takes
place along the length of the tube, is accommodated in this hopper.

Mounted on top of the hopper is a discharge duct, for the release of steam/volatile gases, etc, from the
interior of the retort tube. The end of the duct is flanged, to which a stainless steel exhaust stack must
be connected by the client. It is at this point that filtering of the gases and other pollutants should be
added dependent upon the environmental requirements of the local authority.

A large access door is mounted in the rear wall of the discharge hopper, which allows access to the
retort tube for maintenance, and cleaning of the inside of the tube. A small inspection cover plate is
fitted to the access door, which permits the operator to visually monitor the progress of carbon along
the tube.

A stainless steel discharge pipe is fitted under the hopper, allowing carbon to be discharged directly into
the Quench Pan below. The pipe is immersed in water and the whole system is airtight. The steam
present inside the retort creates a partial positive pressure.

A stainless steel pipe located in the sidewall of the discharge hopper allows for steam injection into the
heating zone of the kiln should it be required. A stainless steel pocket is also provided to insert the
thermocouple for monitoring the carbon discharge temperature.

Battery powered backup drive (44-KEBC-01) to protect the kiln shell from geometry distortion during
cooling, in the event of a power failure.

10.3.3 Kiln Normal Drive

When operating under normal conditions, the retort tube is driven by a motor, close coupled to a triple
reduction gearbox with a keyed shaft arrangement. Mounted on the output shaft of the gearbox is a
free-wheel clutch fitted with chain sprocket. The driving of the tube is effected with a simplex chain
from the driving sprocket to a plate wheel mounted on the tube.

A frequency inverter is installed in the electrical control panel to provide the required rotational speed
of the retort tube.

10.3.4 Kiln DC Drive

Because of the extreme importance of the kiln in a gold reduction plant, an emergency drive system is
incorporated to protect the heated retort tube from distortion when the main power supply is
interrupted. Changeovers from mains supply to emergency supply and vice versa are automatic and
instantaneous. The speed is fixed. When one drive is rotating, the other drive will only rotate as far as
the freewheel clutch, thereby imposing no load on the gearbox or motor. The battery supply will drive
the tube for a minimum period of two hours to allow the tube to cool to a safe temperature.

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10.3.5 Quench pan (44-PAN-01)

Carbon discharging from the kiln is quenched in a bath of flowing water in the quench pan, completing
the regeneration process. Full activity is not regained without proper quenching. The quench pan
overflows carbon onto the quench screen, where the fine carbon is screened off before flowing into the
regenerated carbon transfer tank (44-TANK-02) from where it will be hydraulically transferred to the last
CIL Tank.

10.3.6 Carbon Sizing Screen (44-SCRN-01)

The regeneration process result in carbon degradation, producing some carbon fines due to the high
temperatures involved. Degradation of carbon is catalysed by and the presence of residual caustic on
the carbon particles. Fine carbon acts effectively as preg-robbers, adsorbing gold from leach solutions
and escaping through the inter-stage screens. It is therefore necessary to screen out the carbon fines
produced in the regeneration process before the carbon returns to the CIL process.

Regenerated and quenched carbon will be passed over a screen (44-SCRN-01) to remove fines, before
gravitating directly to the eductor tank (44-TANK-02).

Eluted carbon is transferred hydraulically from the elution column to the eluted carbon tank (44-TNK-01)
via a pipeline. When the regeneration kiln is unavailable eluted carbon can be transferred directly to the
CIL plant by repositioning two manually operated valves.

During the transfer operation to the storage tank excess water and fine carbon particles overflow the
tank through filters (44-STRN-01/2) and are discharged to the carbon fines thickener (44-THCK-01).
When the carbon transfer pump stops water in the storage tank (44-TANK-01) is drained through filters
at the bottom of the cone (44-STRN-03/4).

Carbon will be withdrawn from the eluted carbon tank (44-TANK-01) by screw feeder (44-FEDR-01),
which discharges the carbon to a diesel fired rotary kiln (44-REGN-01) for thermal regeneration.
Regenerated carbon will be quenched in the quench pan (44-PAN-01) and passed over a screen (44-
SCRN-01) to remove fines, before gravitating directly to the eductor tank (44-TANK-02).

Spillage from the regeneration section will be collected in a bulk bag with fines being pumped directly to
the tailings screen by spillage pump (44-PUMP-03). Excess water from eluted carbon vessel together
with the quench screen fines will gravitate to the carbon fines handling facility.

10.4 CONTROLS
Read in conjunction with REGENERATION P&ID (See Appendix ).

The regeneration section (See Figure below) will operate continuously, depending on the availability of
eluted carbon and the requirements for regenerated carbon to be added to the CIL circuit.

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The regeneration kiln has its own control panel and is operated in the field. Certain signals are repeated
to the PLC for information to the control room operator.

The transfer of carbon to CIL is initiated through PLC controlled air actuated valves. The quenched
carbon tank (44-TANK-02) is equipped with pressure (PID-25/50-V-10) and vacuum relief (PID-50-V-12)
valves to relieve excess pressure when transferring carbon and prevent vessel collapse if the column is
emptied with all other valves closed.

Regeneration is performed as a manually controlled operation. Operator intervention or

acknowledgement is required at various times during the sequences, i.e. starting the quench screen,
kiln, heater and screw feeder. Kiln heating is controlled by the vendor (Kemix) control package.

The eluted carbon batch can be transferred directly to CIL, by changing manual valves positions. The
regeneration section is bypassed if the equipment is not available and carbon is urgently required in the
CIL section.

The diesel fired carbon regeneration kiln (44-REGN-01) operates at temperatures between 700 and 800
o
C with thermostat control.

A battery powered backup drive will rotate the kiln in the event of a power failure in order to prevent
distortion of the shell geometry during cooling.

10.4.1 Vendor package

(See Kemix O & M manual and P&ID in Appendix).

The kiln and ancillaries are supplied with the vendor’s (Kemix) instrumentation and control system.

These controls will consist of the following:

 Thermocouples.
 Thermostat control.
 Screw feeder speed control switch.
 Diesel pump and controls.
 Diesel flow rate and temperature switches.
 Firing nozzle instrumentation and controls.
 Automatic start up and shut down button.
 Internal interlocks and alarms.

The system is designed to display and control the temperature and throughput of carbon at the desired
parameters. A floor mounted, front and rear access, mild steel control cubicle accommodates the
control equipment, batteries and charger unit. Instrumentation, indicators, pushbuttons and selector
switches are mounted on the front panel.

The main controllers for all zones are microprocessor based units with digital temperature indication,
set point control and alarm set point control. The alarm setting is utilised to control the temperature at

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which the screw feeder operates. Temperature measurement is obtained from duplex K type
thermocouples mounted in the roof of the heating cabinet.

The over-temperature controllers are mounted inside the control cubicle and are connected to the
thermocouples mentioned above. These controllers provide safety shutdown should the temperature
exceed the present value of the controller. The heating system is shut down and an alarm siren is
sounded.

The shutdown controller is connected to the thermocouple projecting into the rear end of the tube and
the heated carbon, giving a direct carbon temperature at the end of the heating cycle. The preset
temperature on this controller provides the shutdown temperature at which the kiln can safely switch
off and thus halt the retort tube rotation, which is normally in the region of 150-200° C.

There is an AUTO / SHUTDOWN / MANUAL switch. With AUTO selected, the kiln commences to rotate
and the heating system is started. At the preset shutdown temperature, the alarm circuits are activated
and at the preset alarm set point the screw feeder is switched on and feeds carbon into the tube.

With SHUTDOWN selected, the heating system and the screw feeder are switched off and at the preset
shutdown-temperature, the kiln ceases to rotate. With MANUAL selected, the kiln rotates but the
heating system will not operate until the tube is rotating and the screw feeder will not function until the
preset temperature is reached.

10.4.2 Interlocks
 Kiln Backup drive starts with power failure.
Carbon transfer pumps (44-PUMP-01/2) will stop on low level in the carbon transfer water tank (44-
TANK-03)

Regeneration spillage pump (44-PUMP-03) will stop:

 On low sump level (44-LSL-01)

 High Detox feed sump (34-TANK-01) level (34-LAHH-01)
 If Tails Linear Screen (34-LISC-01) stops

Kiln screw feeder (44-FEDR-01) will only start or run if:

 Regeneration carbon screen (44-SCRN-01) is running

 Eductor Tank Feed valve (44-VX-01) is open
 Eductor Tank overflow valve (44-XV-03) is open
 Eductor Tank discharge valve (44-XV-04) is closed
 Carbon Transfer water valve (44-XV-02) is closed
 kiln temperature is at set point.
 Regenerated carbon transfer tank level is high.

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Operator should make sure the spray water pump (44-PUMP-03/4) is running prior to starting the
regeneration kiln.

10.4.3 Alarms:
 Kiln temperature out of range.
 Kiln retort drive trips.
 Diesel flow rate low.
 Diesel temperature low.

10.5 PLANT OPERATING PROCEDURES:

10.5.1 Key operating parameters
Regeneration temperature 700oC

Maximum temperature 800oC

Typical kiln operating schedule 10hrs/batch

Carbon regeneration rate 600kg/hr

10.5.2 Normal operating procedures

10.5.2.1 Eluted carbon transfer

The filed operator performs the following checks and actions

 Checks the pipeline valves positions to discharge the eluted carbon batch to the storage tank or
directly to CIL.
 Checks that the storage tank discharge isolation gate valve is in the closed position.
 Ensures no coarse carbon particles are lost to the carbon fines handling facility during transfer
operations signifying perforated filters or strainers.
 Opens storage tank bottom drain valve to allow excess water to drain off the carbon batch
through the bottom strainers.

The carbon batch is now ready for the regeneration operation.

10.5.3 Kiln start-up procedures

10.5.3.1 Pre-checks
 Regenerated carbon transfer vessel (44-TANK-02) ready to receive regenerated carbon.
o Regenerated carbon transfer vessel feed valve (44-XV-01) open
o Regenerated carbon transfer vessel overflow valve (44-XV-03) open
o Regenerated carbon transfer valve (44-XV-04) closed.
o Carbon transfer water valve (44-XV-02) closed

 Fine carbon screen running with spray water turned on.

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 Water supply to quench pan turned on.

 Diesel supply healthy (Flow, Pressure, switches).
 Check for diesel or oil spillages.

Oils and grease cause serious fouling of carbon. Oil/diesel spillages into the CIL tanks must be
prevented at all cost. If it does occur accidentally the spill must be stopped immediately and the plant
manager must be notified.

10.5.3.2 Kiln start-up

 Set kiln operating temperature and screw feeder feed rate.
 Press the automatic START button on the control panel.
 Observe and check kiln automatic start up.
 Open storage tank discharge isolation valve (PID4410-150-V-04) fully.
 Check that water drains through the feeder screen panels.
 Observe screw feeder (44-FEDR-01) start-up when the kiln has reached the operating
temperature.
 Observe movement of the charge inside the retort through the observation port. The carbon
charge colour should be cherry red.
 Observe the carbon discharge and the quenching operation. Adjust quench water addition as
required using valve (PID4410-25-V-05)
 Observe carbon wet screening operation on (44-SCRN-01), correct operation of water sprays
(using valve PID4410-25-V-08), even spreads of carbon across the screen deck.
 Take a sample of screen discharge for size analysis.
No fines should adhere to the screen product. The screening efficiency of the regenerated carbon
screen must be maintained very high to prevent fine carbon from escaping into CIL tanks where it acts
effectively as a preg-robber.

10.5.3.3 Kiln operation

The eductor tank (44-TANK-02) has a capacity of 3 tons, as such each eluted batch will require two
transfers to the CIL circuit. As the regeneration operation is automated and extends over a 5 hr period in
between transfers from the eductor tank, no full time supervision is required. The CIL field operator
does however walk past the installation during his routine rounds for general check-up of the operation.
In particular, any hot spots on the kiln shell could indicate liner failure.

When the eductor tank is about 90% full (as indicated by 44-PT-01), the screw feeder will automatically
stop. This allows the carbon already in the kiln and fines screen to proceed into the eductor tank. After a
preset time when all the carbon in the kiln has passed into the eductor tank, operator selects
SHUTDOWN on the Kiln Control panel.

 Field operator closes water valves to the quench pan and carbon fines screen.
 Field Operator ensures carbon transfer water pump (44-PUMP-01/2) is running and opens
relevant manual valves on delivery line to eductor tank.
 Ensure CIL Tank (32-TANK-08/9) is ready to receive regenerated carbon
 CRO acknowledges Proceed with carbon Transfer and the PLC initiates the following

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 Close eductor tank carbon inlet valve

 Close eductor tank overflow valve (44-XV-03)
 Open carbon transfer water valve (44-XV-02) and carbon transport water valve (44-XV-05).
 At 2.5bar, opens carbon discharge valve (44-XV-04). Carbon transfer thus starts to CIL as
observed on the sight glass and on the discharge into CIL Tank 8.
 When no more carbon is discharging at the CIL tank (32-TANK-08/9), and as indicated by the
hydrostatic pressure transmitter, the transfer is complete.
 CRO acknowledges carbon Transfer Complete and the PLC executes the following:
 Close carbon transfer water valve (44-XV-02)
 Close carbon transport water valve (44-XV-05)
 Close carbon discharge valve (44-XV-04)
 Open eductor tank overflow valve
 Open eductor tank feed valve (44-XV-01)

At this stage, the eductor tank is ready to receive a new batch of regenerated carbon. After the
field Operator has confirmed there is still carbon to be regenerated in the eluted carbon tank
(32-TANK-01), the operator can press the Automatic Start button and the sequence starts all
over again.

10.5.3.4 Kiln planned shutdown procedures (When the eluted carbon hopper is empty)
 Ensure that the eluted carbon storage tank is empty. Hose down if necessary.
 Close tank discharge isolation valve.
 Press SHUT DOWN button on the control panel.
 Observe automatic shut down operations.
 It is important to make note that the kiln continues to turn until the temperature reaches a
preset final shut down temperature. This is normally set at 200 deg. C
 Close water supply to quench pan and fine carbon screen.
 Stop fine carbon screen and inspect screen panels for any damage.

10.5.4 Trouble shooting

No Symptoms Possible Cause Actions Required
1 No feed to kiln. Feed hopper outlet Hose tank with minimum
blockage water.
2 Coarse carbon escaping to Perforated screens. Identify source and repair.
tailings.
3 Carbon activity insufficient. Incomplete reactivation Check kiln operating
parameters.
4 Carbon burning at kiln Air ingress in kiln retort. Stop and inspect kiln.
outlet.
5 Hot spots on kiln shell. Liner failure. Stop and inspect kiln.
6 Fines in CIL feed. Screen panels blinded. Inspect screen deck and clean
Insufficient screening water. if required. Regulate spray
water.

10.6 APPENDICES
 Regeneration PFD.FD 4400
 Regeneration P&ID. PD4410, 4420

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 Kemix O & M Manual.

 Kemix Equipment P&ID.
 Kemix Certified Drawings.

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11. Carbon Fines Dewatering

The regeneration process results in carbon degradation, producing some carbon fines due to the high
temperatures involved. Degradation of carbon is catalysed by and the presence of residual caustic on
the carbon particles. Fine carbon acts effectively as preg-robbers, adsorbing gold from leach solutions
and escaping through the inter-stage screens. It is therefore necessary to screen out the carbon fines
produced in the regeneration process before the carbon returns to the CIL process.

11.1 PROCESS DESCRIPTION

Read in conjunction with Process Flow Diagram FD 4400 and P&ID 4420, 4430.

This circuit has been designed to recover and bag carbon fines from the carbon fines stream in the
regeneration section and avail the water for reuse in carbon movement purposes.

Regenerated and quenched carbon is passed over a screen (44-SCRN-01) to remove fines, before
gravitating directly to the eductor tank (44-TANK-02). The screen undersize streams from the eluted
carbon hopper strainers, screw feeder and regenerated carbon screen containing the fine carbon
gravitate into the carbon fines feed holding tank (44-TANK-06). The fine carbon slurry is then pumped by
the carbon fines feed pump (44-PUMP-03) into the filter (44-FILT-01) which then produces carbon fines
cake and a filtrate. The carbon fines cake is bagged and carried away to a storage area by folklift while
the filtrate is directed into a tank (44-TANK-05) from where it pumped (44-PUMP-05) to the carbon
transport water tank (44-TANK-03). The carbon transport water is then used in the movement of carbon
from the acid wash column, the elution column and the eductor tank.

11.1.1 Interlocks
Carbon fines filter feed pump (44-PUMP-03) will stop on low level in the carbon fines filter feed tank
(44-TANK-06)

Carbon fines filtrate pump (44-PUMP-05) will stop on low level in the filtrate tank (44-TANK-05)

For detailed operations and procedures on the carbon handling system, refer to the Vendor O & M
manual supplied.

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12. ACID WASH

12.1 SUMMARY DESCRIPTION
Carbon is re-used in numerous adsorption/elution cycles. As Gold adsorption efficiency depends on the
availability of active sites existing on the large specific surface area of carbon particles it is essential to
remove any scale and fouling as soon as it occurs in the CIL process. This is the motivation for the “Acid-
Wash” operation carried out prior to elution. A magnified picture of a typical carbon surface and a
schematic representation of its inner structure are shown in the Figure below. The yellow areas
represent fouling of the surface by precipitates e.g. carbonates.

Figure 12-1: Fouling of Carbon Particle’s Surface and Inner Structure

Scaling, especially Calcium Carbonates can normally be removed quite easily with a dilute acid
treatment at ambient temperatures. The extent of the scaling process does however depend on lime
addition rates and the quality of the local water i.e. composition (Presence of Magnesium) and varies
from one operation to the next. The acid strength and acid wash duration may be adjusted according to
the extent of the fouling. In some cases it is not necessary to perform an acid wash at each cycle but the
exact procedure must be optimised for the specific conditions prevailing at the mine. Failure to perform
an efficient acid wash will invariably result in poor Gold adsorption and a high solution gold loss to
tailings. Excessive acid washing results in unnecessary operating costs.

The loaded carbon batch is prepared for elution in the following manner:

 Elutriation or “Back Wash” for the removal of light tramp materials (e.g. adhering slimes plastic
and organic debris… trapped in the carbon bed) using clean water.
 Acid washing using a 3% strength solution of Hydrochloric acid pumped through the carbon bed,
in closed circuit with the dilute acid tank.
 Rinsing of the bed with clean water and removal of all traces of acid and dissolution products.
 Checking of effluent pH.
 Transfer of cleaned and acid-washed batch to the elution column.

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The acid batch becomes neutralised and contaminated as it is reused in closed circuit. A new batch must
normally be prepared after 3 to 4 cycles. The spent acid batch is treated as follows:

 Neutralisation with excess caustic soda solution.

 Checking of the pH>11.
 Pumping of the spent solution to the tailings linear screen for final disposal.
 Preparation of a fresh batch of acid.

12.1.1 Safety procedures

The acid wash operation uses a dilute solution of Hydrochloric acid which is pumped through the acid
wash cone via pressurised pipes. The solution is highly corrosive and potentially harmful if ingested or
sprayed over the exposed parts of the body, especially the eyes. The danger signs for this area are
shown below:

Figure 12-2: Danger Signs For Dilute Hydrochloric Acid

12.1.2 Principal hazards

 Contact with the eyes or skin can cause serious permanent damage.
 Inhalation of vapor is harmful.
 Ingestion may be fatal.

12.1.3 Emergency Procedures

 Eye contact: In the safety shower, flush the eye immediately with plenty of water. Continue for
at least ten minutes and call for immediate medical help.
 Skin contact: In the safety shower, wash off with plenty of water. Remove any contaminated
clothing. If the skin reddens or appears damaged, call for medical aid.
 If swallowed: Drink plenty of water and call for immediate medical help.
 Personnel shall take note of the location of the potable water safety shower and eye wash
station located in the area.
 Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in
the eye wash station. A picture of the safety shower is shown in the Figure below.
 The shower shall be used in all instances where any body part or clothing has been splashed or
exposed in any way to the acid solution.

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Figure 12-3: Safety Shower Features

EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

All personnel working or passing through the area shall therefore wear the required PPE, as listed
below:

 Hard Hat.
 Safety Glasses.
 Steel-Capped Boots.
 High-Visibility Clothing.
 Gloves (Neoprene, Butyl Rubber…)

In addition, Long Pants and Long-Sleeved shirts must be worn.

The relevant safety signs are shown in Figure below:

Figure 12-4: Acid Wash Section Safety Signs

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NOTE:

 Preparation of a fresh batch of dilute hydrochloric acid necessitates handling concentrated acid.
 Concentrated acid produces toxic fumes in addition of being extremely corrosive and is
therefore more dangerous to handle than the dilute solution.
 The procedures for the preparation of a new batch of dilute acid are part of the Reagent’s
handling procedures described in section

12.2 ACID WASH OPERATING PHILOSOPHY

The severity of fouling on the carbon particles depends on the water composition (Concentrations of
soluble salts of Calcium, Magnesium, pH etc.) These conditions dictate the required acid strength
(Normally from 1.5 to 3%) and acid wash duration (Normally 1 hr).

The acid wash duration can be reduced or the operation omitted altogether if it is required to complete
as many elutions as possible to meet gold production targets. In certain cases it may be necessary to
perform an acid wash operation only every second elution. Typical durations of the various operations
are summarised in below:

STEP DECRIPTION DURATION (Min.)

1 Water Wash 60
2 Acid Wash 60
3 Neutralisation 60
Manual samples can be taken during the acid wash and rinsing for pH measurement, solution analyses
checking for entrained solids.

12.3 DETAILED PROCESS AND PLANT DESCRIPTION

Read in conjunction with ACID WASH PFD 4100 (See Appendix).

Loaded carbon is discharged from the carbon screen (32-LISC-01) straight into the Acid Wash Column
(41-COLM-01).

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12.3.1 Water Wash

The carbon batch is back-washed with raw water to remove any light trash such as slimes, plastic and
organic trash captured in the bed. The flow rate is sufficient to expand the carbon bed and remove the
fines and light tramp materials without loosing the larger and heavier carbon particles. The trash is
flushed to the leach tailings linear screen (34-LISC-01) via a gravity pipeline by manipulation of the
relevant valves. This operation normally lasts for about 20 minutes.

12.3.2 Acid wash

The Acid Wash Column (41-COLM-01) is sized to accommodate a 6.0 tonne batch of loaded carbon. The
design requirement is to treat approximately 60 batches per month although this can be reduced
depending on plant operating requirements. Loaded carbon is received in the Acid Wash Column (41-
COLM-01). Once a 6.0 ton batch of carbon has been accumulated, it is acid washed with dilute
hydrochloric acid.

Dilute acid solution (~3% HCl) is pumped at the design flow rate of 2 BV/h through the carbon bed in the
Acid Wash Column (41-COLM-01), in closed circuit with the Acid Wash Tank (41-TANK-01) using the Acid
Wash Pump (41-PUMP-01/2). Note that sometimes it is necessary to increase the acid strength up to 5%
in the case where carbon fouling is very heavy. This normally happens where downstream processes in
the processing plant introduce some organic materials to the CIL circuit. This happens typically where
flotation is done prior to CIL to recover gold.

The bed will expand by 1% of the rest volume and this enables optimum contact between the carbon
particle’s surfaces and the slow flowing solution. The duration of the acid wash operation depends on
the severity of the scaling taking place at the mine and is determined by optimisation test work. The acid
wash column is emptied to the acid wash tank at the end of the operation.

12.3.3 Neutralisation and rinsing

The residual acid is neutralised and all traces of chlorides are removed by rinsing the carbon bed with
raw water. It is important to remove chlorides from the carbon prior to stripping because the chlorides
tend to form some auro-cyanide precipitates at high temperatures in during stripping reducing the strip
efficiency. The water rinse stage is therefore very important. The acid neutralisation effluent is routed to
tailings through the detox section.

The neutralisation of spent acid step is critical for safety reasons and should always be performed
diligently to avoid possible hydrogen cyanide gas emissions at the start of the elution cycle.

A bed volume of acid solution remains in the acid wash column (41-COLM-01) at the end of each acid
wash cycle before the rinsing. Immediate start of the rinsing cycle would send the acid solution to the
tailings linear screen which may result in formation of hydrocyanic gas at contact with cyanide
containing tailings. To reduce the chances of sending acid to the tailings screen, the bed volume of acid
remaining in the acid wash cone must be washed back into the tank before the rinse effluent is sent to
the tailings screen.

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Start the rinse process with valves 41-V-17 (acid return valve) open, while the acid wash rinse valve to
detox (41-V-18) is closed. Allow the carbon rinse process to take place with the two valves in this
position for the first 30min or until the acid wash tank is full. After 30minsor when the acid wash tank is
full, open the acid wash overflow valve (41-V-18), and close the acid return valve (41-V-17). This process
will retain residual acid in the acid wash cone to be retained in the acid wash tank, reducing the chances
of producing the dangerous hydrocyanic gas at the tailings screen.

The field operator must check the effluent pH before ending the acid wash rinsing operation.

Due to the use of hydrochloric acid, two safety showers (41-SASH-01/2) are provided in this area. Each
safety shower is activated by a foot pedal and is equipped with an eye bath.

Acid solution escaping the acid wash column (41-COLM-01) through the bursting disc 41-PSE-03) is
directed into the Acid Overflow Pot (41-POT-01).

Acid Wash Spillage Pump (41-PUMP-03) is installed in the acid wash area. Acidic spillage is pumped to
the detox linear screen (32-LISC-01) feed box.

12.3.4 Carbon transfer to elution

Once the process of acid wash and rinsing has been complete (rinse solution pH equal to the wash
water), the pre-treated carbon batch is hydraulically transferred into the Elution Column (41-COLM-02).
The Transfer Water Pump (41-PUMP-01/2) draws water from the Transfer Water Tank (44-TANK-03) and
delivers pressurising water to the top of the column and transport water to the outlet bend at the base
of the column. A slurry of carbon in water is delivered to the Elution Column (41-COLM-02). .

The neutral rinse water that remains in the column after the rinsing process assists in the transfer
process into the elution column by fluidising the carbon. The elution column drain valve must always be
open during carbon transfer to elution column to get rid of the transfer water. The field operator will
inspect the tank and flush any remaining carbon with hosing water.

12.3.5 Preparation of fresh acid solution

The acid batch is used to do a number of acid washes (typically a batch every 3 to 4 acid washes) before
it is discarded. After the required number of acid washes, the acid batch becomes too contaminated for
further use and is neutralised with excess caustic soda and discarded to tailings. Caustic soda is pumped
into the acid wash (41-TANK-01) tank through a level valve (41-LV-01B). Enough caustic is dumped to
achieve a pH >11. Once the neutralisation is achieved the contents of the acid wash tank is then be
pumped to the detox linear screen (32-LISC-01) for disposal to the tailings.

The procedures for disposal of the spent solution batch as well as the preparation of a new batch of
diluted acid are given in the Safe Working Procedures (SWP) for reagents.

12.4 ACID WASH PLANT MAJOR EQUIPMENT:

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Equipment code Equipment name kW Description Supplier

41-COLM-01 Acid wash column 14 m3, FRP ,closed
column tank,
41-STRN-01/2 Acid column exit strainer 1/2
41-TANK-01 Acid wash tank 14 m3,closed flat
bottom tank, FRP.
41-POT-01 Acid overflow pot
41-PUMP-01/2 Acid wash pump 1/2 11
41-PUMP-03 Acid spillage pump 2.2
41-PUMP-04 Acid drum pump 0.6
41-SASH-01 Acid safety shower U-type, double Delta health &
column, platform Safety
activated cw hand
operated side
mounted eyewash

12.5 ACID WASH CONTROL PHILOSOPHY

The acid wash tank (41-TANK-01) will be equipped with an ultrasonic level transmitter to give levels of
fluid in the tank. The level transmitter will also be used to stop the acid wash pumps on low tank levels
and will shutdown the dilution water air actuated valve during acid make up.

A pH probe (41-AE-01) will be installed in the acid wash tank so that right amounts of caustic are added
during acid neutralisation stage. The same probe will be useful in determining when a fresh acid batch
has to be made up.

The acid wash column (41-COLM-01) will be equipped with the following devices for safety and easy of
operability:

 High-level switch (41-LSH-04), which will stop the loaded carbon transfer pump (32-PUMP-01/2)
to avoid overfilling the column.
 Pressure Gauge (42-PI-02) & Pressure transmitter (41-PT-01). The pressure transmitter will trip
the acid wash pumps (41-PUMP-01/2) and or hydraulic carbon transfer pumps (44-PUMP-01/2)
in the event of pressures in the column exceeding maximum set value.
 Pressure relief valve (41-PSV-01) will open and discharge acid solution into the wash Tank (41-
TANK-01) if the event of column of excess column pressure and the carbon transfer water
pump(44-PUMP-01/2) not stopping.
 Bursting disc (41-PSE-03) as an extra back up to the pressure relief valve The rupture disc will
protect the column in the event of excess pressure if the pump did not stop on high pressure
and the pressure relief valve failed.
 Vacuum relief valve (41-V-08) will protect the column from collapsing in the event of the vent
valve (61-XSV-01B) not opening when draining the column (valve 41-XV-06A open).

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A combination of air actuated valves, magnetic flow meter and instruments mentioned above will be
used to effect the PLC controlled acid wash; carbon neutralization and emptying of the column.

Each safety shower (41-SASH-01/2) is equipped with a flow switch. An alarm on SCADA, siren and a
rotating light are triggered when flow to the safety shower is detected.

12.5.1 Acid Wash VDU Page Features

The Acid Wash VDU page features include the following:

 Status (stopped/running) of all drives.

 Acid Wash Tank (41-COLM-01) high level alarm
 Acid Wash Tank (41-TANK-01) low level alarm
 Acid Wash Column (41-COLM-01) pressure
 Acid Wash Tank (41-TANK-01) level %
 Position (Open/Close) of all actuated valves

12.5.2 Alarms
 Acid wash tank low level alarm (41-LAL-01)
 Acid wash Safety shower flow alarm (41-FAH-02)
 Acid wash area safety shower flow alarm (41-FAH-03)
 Acid wash column high level alarm (41-LAH-04)
 Acid wash column high pressure alarm (41-PAH-01)

12.5.3 Interlocks
Acid spillage pump (41-PUMP-03) will stop on low level (41-LSL-02). Pump is started manually when
sump level is high.

Acid spillage pump will not start or run if:

 Tails linear screen (34-LISC-01) is not running

 Detox feed sump (34-TANK-01) level is high (34-LAHH-01)

Acid wash pump (41-PUMP-01/2) will be stopped on acid wash tank (41-TANK-01) level low alarm (41-
LALL-01)

Acid wash pump (41-PUMP-01/2) will only start or run if:

 Rinse valve (41-XV-01) is closed

 Either valve (41-XV-02) or (41-XV-01) 0r (41-XV-04) is open

Sequence valve (41-XV-04) only opens if:

 Column drain valve is closed

 Column vent valve (41-XV-06B) is closed.
 Carbon transfer valve (41-XV-10) is closed

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 Column feed valve (41-xv-13) is closed

 Column discharge valve (41-XV-07) is open
 Sequence valve (41-XV-09) is closed.
 Sequence valve (41-XV-08) is open

Sequence valve (41-XV-04) will close on high column pressure (41-PAHH-01)

Sequence valve (41-XV-020 will not open if :

 Tails screen (34-LISC-01) is not running

 Detox feed sump(34-TANk-010 level is high (34-LAHH-01)

12.6 DESCRIPTION OF ACID WASH PROCEDURE

Once a complete batch of carbon is ready in the Acid Wash Column (41-COLM-01), the operator can
perform the acid wash procedure. The acid wash procedure is PLC controlled. Operator intervention is
required at times .The various steps are described below.

12.6.1 Water Wash (before Acid wash)

The water wash is PLC controlled with operator intervention required at times.

Operator prompted to:

 Close acid pump discharge manual valve (41-XV-07/13)

 Start raw water pump (62-PUMP-07/8) if not running
CRO acknowledges Start Water Wash and PLC initiates the following:

 Closes column feed valve (41-XV-13)

 Closes mixing valve (41-XV-01)
 Closes column drain valve (41-XV-06A) and vent valve (41-XV-06B)
 Opening column discharge valve (41-XV-07)
 Recircuilation valve (41-XV-08) closes
 Opening sequence valve (41-XV-09)
 Opens sequence valve (41-XV-04)
 Opens rinse valve (41-XV-03)

Rinse water (1BV) flows through the acid wash column (41-COLM-01) and out to leach tails linear screen
(34-LISC-01). The process continues until 1 BV has passed through the column after which the initial
water wash stage is complete. PLC then initiates the following:

 Rinse valve closes (41-XV-03)

 Sequence valve (41-XV-04) closes
 Column vent valve (41-XV-06B) opens
 Column drain valve (41-XV-06A) opens

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12.6.2 Acid Wash Procedure

Check level & acid strength in Acid Wash Tank (41-TANK-01).
 If required, add calculated fresh acid using the Acid Pump (41-PUMP-04)
 If required add water by opening valve (41-LV-01A).
 Recheck levels & acid strength in Acid Wash Tank (41-TANK-01). Detailed acid preparation
procedure is covered under reagents preparation.
 Ensure selected duty Acid Wash Pump suction valve (41-V-02/8) is open.
 Ensure selected duty Acid Wash Pump delivery valve to Acid Wash Column (41-XV-07/13) is
open.
 Ensure selected strainer feed valve (4120-V-13/14) and discharge manual valve (4120-V-15/16)
are open

Status of the following valves should be as follows and the operator should confirm that.

 Rinse valve (41-XV-03) must be closed

 Sequence valve (41-XV-09) must be open
 Carbon transfer water valve (41-XV-10) must be closed
 Carbon transfer valve (41-XV-12) must be closed

Operator acknowledges Start Acid Wash and the PLC initiates the acid wash sequence by:

 Closing column drain valve (41-XV-06A)

 Closing column vent valve (41-XV-06B)
 Closing Column feed valve (41-XV-13)
 Opening column discharge valve (41-XV-07)
 Opening sequence valve (41-XV-08)
 Opening sequence valve (41-XV-04)
 Close sequence valve (41-XV-01)
 Closing mixing valve (41-XV-01)
 Starting acid wash pump (41-PUMP-01/2)

After 27m3 of dilute acid has been circuilated through the column:

 Acid wash pump (41-PUMP-01/2) stops

 Sequence valve (41-XV-04) closes

12.6.3 Rinse stage

Operator prompted to:

 Close acid pump discharge manual valve (41-XV-07/13)

 Start raw water pump (62-PUMP-07/8) if not running

CRO acknowledges Start Rinse Stage and PLC initiates the following:

 Reopen sequence valve (41-XV-04)

 Open rinse valve (41-XV-03)

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 Rinse water (1BV) flows through the acid wash column (41-COLM-01) and back into the acid
wash tank (41-TANK-01) after which:
 Valve (41-XV-09) opens
 Recircuilation valve (41-XV-08) closes

Rinse effluent is now directed to the leach tails screen (34-LISC-01). The process continues until another
BV has passed through the flowmeter after which the rinse stage is complete.

 Rinse valve closes (41-XV-01) closes

 Sequence valve (41-XV-04) closes
 Column discharge valve (41-XV-07) closes
 Column vent valve (41-XV-06B) open
 Column drain valve (41-XV-06A) opens to drain the column

12.6.4 Transfer to Elution Column Procedure

Carbon transfer to Elution Column is PLC controlled. Operator intervention is required at times

PLC prompts operator to make sure that draining is completed & drain valve (41-XV-06A) is closed.
Operator must acknowledge. PLC also prompts Operator to acknowledge that the Elution Column (42-
COLM-02) is empty of previous batch of carbon and that the vent valve (42-HV-05B)) and Drain valve
(42-HV-05A) are open.

Operator acknowledges Start Transfer to Elution Column & PLC initiates the transfer sequence by:-

 Closes if required, Elution Column (42-COLM-01) carbon outlet valve (42-XV-02)

 Checks & closes, if required Elution Column Eluant inlet valve (42-TV-01A)
 Checks & closes , if required Elution Column Eluate outlet valve (42-XV-06)
 Checks & closes if required Acid Wash Column carbon inlet valve (41-XV-13)
 Checks and opens if required Elution column carbon inlet valve (42-XV-05)
 PLC prompts operator to open Transfer Water Pump (44-PUMP-01/2) suction (44-V-03/6) &
delivery valves (44-V-05/8) and common line valve (44-V-10). Operator must confirm valves are
open.
 Opens Transfer water to Acid Wash Column pressure water valve ( 41-XV-10)
 Opens Transfer Water to Elution Column valve (41-XV-11).
 Starts Transfer Water Pump (44-PUMP-01/2).
 At pressure 2.5 bar on the Acid Wash Column (41-PT-01), opens Acid Wash Column carbon
outlet valve (41-XV-12)
 Waits preset period (normally 1 hour) for transfer of carbon to Elution Column.
 Stops Transfer Water Pump ( 44-PUMP-01/2)
 Closes Transfer water to Acid Wash Column pressure water valve (41-XV-10)
 Closes Transfer water to Elution Column valve (41-XV-11)
 Closes Acid Wash Column carbon outlet valve (41-XV-12)
 Displays ACID WASH COLUMN READY.

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12.6.5 Acid Neutralisation

After 3- 4 elutions, the spent hydrochloric acid is neutralized first and the discarded to the leach tailings
linear screen.

Check the level of the Acid Wash Tank (41-TANK-01) and calculate the caustic soda volume required to
neutralise the acid.

Set the volume of caustic to be transferred to the acid wash tank through flow Controller (51-FIC-03).

Field operator to open the manual valves on the caustic line feeding the acid wash tank.

CRO acknowledges Start Neutralisation and the PLC initiates the following:

 Opens mixing valve (41-XV-01)

 Starts acid wash pump (41-PUMP-01/2)
 Opens caustic valve (41-LV-01B)
 Starts the caustic dosing pump (if not running)

At the end of the transfer, operator to allow 5 minutes of mixing, then check the pH on Scada. If pH >7,
then the batch is neutralised and can be discarded to tailings. CRO acknowledges Discharge to Tailings
and the PLC initiates the following:

 Opens valve (41-XV-02)

 Closes mixing valve (41-XV-01)
 Acid wash pump continues to run until it stops on low level in the acid wash tank (41-TANK-01)

Field Operator then opens acid wash tank drain valve (41-V-01) and empty the remainder into the acid
area bund. The spillage is then pumped to the detox linear screen (34-LISC-01) using the acid spillage
pump (41-PUMP-03)

The acid wash tank is now ready for preparation of a new batch of acid.

12.7 APPENDICES
 ACID WASH PFD FD 4100
 ACID WASH 1 P&ID PD 4110
 ACID WASH 2 P&ID PD 4120
 ACID WASH COLUMN VENDOR CERTIFIED DRAWING.
 ACID WASH TANK VENDOR CERTIFIED DRAWING.
 ACID WASH PUMP VENDOR CERTIFIED DRAWING.
 ACID WASH SPILLAGE PUMP VENDOR CERTIFIED DRAWING.

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13. ELUTION
13.1 SAFETY
The elution operation uses concentrated caustic soda and sodium cyanide solutions at high
temperatures and pressures. The cyanide solution is highly toxic and may form hydrogen cyanide gas
(HCN) if mixed with acid or to a lesser extent with water. The hot solutions have temperatures up to 120
o
C which will flash to vapour if leaked out of the pressurised system. The elution column, pipes and
tanks surfaces are also likely to be sufficiently hot to burn exposed skin on contact. The work place is
safe if all plant operating and safety procedures are strictly adhered to.

Refer to the information contained in the material safety data sheets for the handling of cyanide and
caustic soda.

13.2 THE MAIN HAZARDS ARE DISCUSSED BELOW

13.2.1 Sodium Cyanide (NaCN)
Cyanide is potentially the most hazardous chemical on site. It is highly toxic (poisonous) and potentially
fatal. However, if the required safety procedures are implemented it can be used with complete safety.
Material safety data sheet (MSDS) for sodium cyanide is available with this manual for complete
reference to safe use of sodium cyanide.

WARNING!
ALL FORMS OF CYANIDE ARE POISONOUS WHETHER IT IS IN THE SOLID FORM, DISSOLVED AS A LIQUID
OR GIVEN OFF AS HYDROGEN CYANIDE (HCN) GAS.

Figure 13-1: Danger Signs for Sodium Cyanide Solutions

13.2.1.1 Principal hazards

Cyanide poisoning can occur as a result of

 Inhalation of gas, dust or fine spray into the lungs.

 Ingestion (swallowing) of cyanide dust or solution.

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 Absorption through the skin via contact with solution or dust.

Small doses can incapacitate quickly and even cause death by blocking the body’s ability to use oxygen.

13.2.1.2 Emergency Procedures

Eye contact: In the safety shower, flush the eye immediately with plenty of water. Continue to do so
while medical help is obtained.

Skin contact: In the safety shower, wash off with soap and plenty of water. Remove any contaminated
clothing. Call for medical help.

If swallowed: Induce vomiting and call for immediate medical help. Dispense first aid immediately.

In the event of HCN gas emissions

 > 10 ppm: Wear Gas Mask with correct cartridge.

 > 60 ppm: Wear full face cover respiration apparatus.

13.2.2 Caustic Soda (NaOH)

13.2.2.1 Principal hazards

 Contact with the eyes can cause serious long-term damage.
 The solid and its solutions are corrosive.
 Significant heat is released when sodium hydroxide dissolves in water.

Figure 13-2: Danger Signs for Caustic Soda

13.2.2.2 Emergency Procedures

Eye contact: In the emergency shower, flush the eyes immediately with plenty of water. Continue
for at least ten minutes and call for immediate medical help.

Skin contact: Wash off with plenty of water. Remove any contaminated clothing. If the skin reddens or
appears damaged, call for medical aid.

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If swallowed: If the patient is conscious, wash out the mouth well with water. Do not try to induce
vomiting. Call for immediate medical help

Personnel shall take note of the location of the potable water safety shower and eye wash station
located in the area.

Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in the figure below.

The shower shall be used in all instances where any body part or clothing has been splashed or exposed
in any way to the acid solution.

Figure 13-3: Safety Shower Features

EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

All personnel working or passing through the area shall therefore wear the required PPE, as listed
below:

 Hard Hat.
 Safety Goggles or safety glasses.
 Steel-Capped Boots.
 High-Visibility Clothing.
 Gloves (Neoprene, Butyl Rubber…).
 Full face cover respiration apparatus shall be worn in the event of Hydro cyanide Gas (HCN)
emissions.

In addition, Long Pants and Long-Sleeved shirts must be worn.

The relevant safety signs are shown in the figure below:

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Figure 13-4: Elution Section Safety Signs

NOTE:

Preparation of a fresh batch of caustic cyanide necessitates handling of highly toxic substances.

The procedures for the preparation of a new batch are part of the Reagent’s handling procedures
described in section

13.3 SUMMARY OF ELUTION PRINCIPLES

Loaded carbon batch is hydraulically transferred to the elution column after completion of the acid-
wash. Elution is the process that is used to extract the gold from loaded carbon into solution which can
then be further treated (electrowinning). Elution can be sectionalised into two very important stages,
stripping and electro-winning.

In CIL there is a high concentration of calcium ions from the lime added to modify pH. The calcium Ca 2+
ions, forms a very stable complex with auro-cyanide complex under normal CIL conditions. The calcium
auro-cyanide complex forms a strong bond with active surfaces on the carbon surface. Therefore in a
typical CIL circuit gold adsorbs onto carbon in the form of the calcium-auro-cyanide complex. Stripping is
achieved by running hot (120deg.C) 1% cyanide, 3% caustic solution (called the eluate) through loaded
carbon in the elution column at a high pressure.

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At high temperature and pressure, in a high Na+ ion concentration environment, Na+ ions replace Ca2+
ions from the auro-cyanide complex to form the Na+ Au CN 2 ) which is more stable under such


conditions. Because of its smaller size, the sodium-auro-cyanide complex forms a stronger bond with
water than it does with the active centres on the carbon surface. The exchange of cations from the
larger calcium to the smaller sodium ion will therefore result in gold auro-cyanide complex moving from
active surfaces on carbon into solution (the pregnant solution). Pregnant solution is pumped to electro-
winning cells where the gold is recovered by electroplating onto mild steel wool.

The elution and electro-winning processes operate independently when using the AARL method. A gold
recovery in excess of 97% can normally be achieved in the elution operation after a continuous 9 hours
operation.

13.3.1 Elution Process Fundamentals

The mechanism for the adsorption of gold onto activated carbon has been investigated for many years.
A widely accepted mechanism for gold adsorption, under conditions of high ionic strengths, is via ion
pair formation.

Mn+ + Au(CN)2-  Mn[Au (CN)2]n

Where M is a cation of Alkali or Alkali earth series;

e.g. Na+, K+, Ca2+, Mg2+ etc.

A number of factors that affect the extent of gold adsorption; the pH of the adsorption medium,
temperature (since the adsorption process is exothermic, adsorption decreases with increasing
temperature), ionic strength, competitive adsorption of organic and inorganic species, and the nature of
activated carbon.

The effect of ionic strength on the adsorption of gold onto activated carbon is important as cations are
necessary for the ion-pair formation. Different cations have different effects. Research into this
phenomenon shows that the extent of the adsorption is dependent on the type of cation present, which
is related to the strength of the ion pair formed between dicyanoaurate anion and the cation.

The stronger complexes, i.e. more neutral species are more effectively adsorbed by activated carbon.
The strongest ion-pairs are formed between the dicyanoaurate anion and calcium (Ca2+), lithium (Li+)
and hydrogen (H+) ions, as the surrounding water is polarised around these cations which diffuses the
charge of these cations, effectively increasing the size of the cations to a size that matches that of gold
cyanide. The cations sodium (Na+) potassium (K+) and rubidium (Rb+) are less well hydrated, thus the ion
pairs formed are weaker as these cations are smaller than the dicyanoaurate anion

Thus, from an application in CIL & CIP gold recovery plants, enhanced gold adsorption occurs because of
the presence of calcium ions in the pulp, which is usually added to the pulp as lime.

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This means that the most likely ion pair formed in commercial gold plants is between the dicyanoaurate
anion calcium.

Ca2+ + 2Au(CN)2-  Ca[Au (CN)2]2

The elution of gold via the methods using sodium hydroxide with or without sodium cyanide (Zadra and
AARL) follows the following mechanism:

Step 1 The calcium dicyanoaurate ion pair is converted to the weaker sodium ion pair due to the effect
of the high concentration of sodium in the eluate (concentration differential drives the reaction).

Ca[Au(CN)2]2 + 2Na+  Ca2+ + 2NaAu(CN)2

Step 2 In the presence of heat and in the absence of calcium, the ion dissociates into the ions.

NaAu(CN)2  Na+ + Au(CN)2

The above reaction is reversible (depending on the concentration of gold complex). Because of this
equilibrium, the fresh eluate must be gold free, otherwise the gold will not be eluted to low-levels of
gold on activated carbon.

The above two steps show that cyanide does not play an active role in the elution of gold from activated
carbon. A number of plants utilise a hot acid washing step prior to elution. This hot acid washing step
results in the degradation of the dicyanoaurate anion:

H+ + Au(CN)2  AuCN + HCN

Gold cyanide (AuCN) is insoluble in water and thus cannot be removed by a water wash. In a
subsequent caustic wash, gold cyanide has been shown to decompose:

2AuCN + e-  Au + Au(CN)2- (alkaline solution)

This is the reason why gold has been detected in the spent solution from an acid neutralising step after a
hot acid wash step.

In the presence of cyanide the gold and gold cyanide reverts rapidly to the soluble sodium
dicyanoaurate ion pair in the presence of sodium cyanide:

AuCN + NaCN  NaAu (CN)2

Au + 2NaCN  NaAu (CN)2 + Na+

If a cold acid wash step and subsequent water wash step are carried out prior to elution, and since the
cold acid wash step does not necessarily interfere with the ion pair, the elution of gold from activated
carbon using sodium hydroxide only (i.e. cyanide free), may be successfully achieved. Since hot acid

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washing of gold laden activated carbon degrades the ion pair, elution without cyanide is probably not
possible after a hot (60°C to 90°C) acid washing step.

The plant major equipment is described in detail in the following paragraphs.

13.3.2 Elution Plant Major Equipment.

Equipment Kw
Description Size/Type Supplier
No
42-TANK-01 Eluant Tank 14 m3 Mild Steel Senet
42-SASH-01/2 Safety Shower U type double column, platform Delta Health &
activated c/w hand operated side Safety
mounted eyewash
42-COLM-01 Elution Column 14 m3, 304 SS.
42-MIXR-01 Eluant mixer 1.5 AMX 75, 1 blade, 2.61mDx3.0mH tank Kemix
42-PUMP-01 Elution Pump No 1 11
42-PUMP-02 Elution Pump No 2 11
42STRN-01 Elution Strainer 1
42-STRN-02 Elution Strainer 2
Thermostat 1750-LO diesel fired, Applied heat
42-PUMP-01 Elution Heater 1
1750KW
Thermostat 1750-LO diesel fired, Applied heat
42-PUMP-02 Elution Heater 2
1750KW
42-HEXR-01 Primary Heat Exchanger Shell & Tube, G304L welded tubes Applied heat
Secondary Heat Exchanger Applied heat
42-HEXR-02/3 Plate & Frame, G316L plates
(Recuperative)
42-PUMP-03 Elution Spillage Pump 5.5
42-HCND-01 HCN gas detector
Elution Heating auxillary
Equipment
42-TANK-02 Deaerator tank
42-TANK-03 Expansion tank
42-PUMP-04 Elution Heater pump 1 15
42-PUMP-05 Elution Heater Pump 2 15
42-FAN-01 Elution Burner Fan 1 7.5
42-FAN-02 Elution Burner Fan 2 7.5

13.4 ELUTION PROCESS DESCRIPTION

13.4.1 Selective Copper Stripping
The Bisha elution circuit is designed to do Selective copper stripping from the loaded carbon before gold
elution. The selective copper stripping is carried out at ambient temperature and atmospheric pressure
using 1 BV of 2% cyanide solution that is pumped (from 42-TANK-01) by elution pumps (42-PUMP-01/2)
through the carbon bed with the resultant high copper solution being directed to the detoxification
section linear screen (34-LISC-01). The copper in solution complements the copper requirements in the

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detox section as a catalyst in the cyanide destruction process. At the end of the water wash, the
remaining water in the elution column is drained into the elution bund and subsequently pumped to the
tailings linear screen. The carbon is now ready for gold elution. While the water wash is in progress, a
fresh batch of caustic cyanide solution is then prepared as discussed below after which the elution of
gold can start.

13.4.2 Gold Elution

Gold elution from loaded carbon is done using the AARL method. The elution liquor, a dilute (3%
strength) caustic cyanide solution is pumped from the Eluant Tank (42-TANK-01) via the Secondary
(recuperative) Heat Exchanger (42-HEXR-02/3) and then through the Primary Elution Heat Exchangers
(42-HEXR-01), into the Elution Column (42-COLM-01) under elevated temperature and pressure. This
promotes a chemical reaction where the gold adsorbed onto the carbon can be removed by washing
with a number of bed volumes of hot water. Thus, the gold is stripped from the carbon into the eluate
solution.

The Elution Column is pressurised. Heat for the elution circuit is provided by Diesel fired Elution Heaters
(42-HETR-01/2). The heater burners heat a thermic oil, which is used to transfer heat to the eluant
solution entering the column via the Primary Elution Heat Exchanger (42-HEXR-01). Hot eluant solution
exiting the column is cooled by contacting with fresh eluant solution in the Secondary (recuperative)
Heat Exchanger being pumped into the Elution column. The secondary heat exchanger therefore
recovers some of the heat from eluant solution fed to the column. The Primary Elution heat exchangers
(42-HEXR-01) is a shell and tube type fabricated in stainless steel while the recovery heat exchanger (42-
HEXR-02/3) is of the plate & frame type.

The pregnant electrolyte flows out of the Elution Column to one of two Pregnant Tanks (41-TANK-01/2).
From either tank, the electrolyte is pumped in a recycle circuit to the Electrowinning Cell Feed Tanks
(43-TANK-04/7) - a steady head tank feeding the CIL electrowinning cells in the Gold Room. In the
electrowinning cells, gold is deposited on the stainless steel woven wire mesh cathodes. Once
electrowinning is complete, the barren liquor is pumped from the active Pregnant Tank (43-TANK-01/2)
to the Barren Tank (43-TANK-03). The barren electrolyte pump (43-PUMP-05/6) recycles the barren
electrolyte to the eluant Tank (42-TANK-01) for use as wash solution in the next elution or alternatively
to CIL tanks (32-BOX-01), thus allowing the recovery of any residual gold in the electrolyte.

Two Pregnant Tanks are provided in order that completion of electrowinning of a batch of electrolyte
and transfer of spent electrolyte to the barren tank does not hold up the start of the next elution.

Once the gold has been stripped from a batch of loaded carbon, i.e. after a preset volume (denoted in
Bed Volumes equivalent to volumes of the elution column) of rinse solution has passed through the
column the elution is complete. The eluted carbon is transferred hydraulically (in a similar manner to
the transfer from the Acid Wash Column to the Elution column) from the Elution Column to the Eluted
Carbon Tank , (44-TANK-01) in the Regeneration section or to CIL tank 9 or 8 (32-TANK-08/9).

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13.5 Elution Control Philosophy

Elutions are performed via operator initiated PLC sequences. Operator intervention or
acknowledgement is required at various times during the sequences.

13.5.1 Eluant Tank

The eluant tank (42-TANK-01) will be equipped with an ultrasonic level transmitter (42-LT-01) to give
levels of fluid in the tank. The level transmitter will also be used to stop the elution wash pumps (42-
PUMP-01/2) on low tank levels and addition of wash water during elution.

Addition of required amounts of caustic and cyanide to the eluant tank (42-TANK-01) will be through a
combination of magnetic flow meters and and actuated valves : (42-FE-01) and (42-42-LV-01B) for
Cyanide and : 42-LY-01A and 51-FE-03 for Caustic addition.

13.5.2 Elution Column

The elution column (42-COLM-01) will be equipped with the following devices for safety and easy of
operability:

 Temperature gauge (42-TE-02) and temp transmitter (42-TT-02) for measurement of column exit
temperature
 Pressure Gauge (42-PI-05) & Pressure transmitter (42-PT-01). The pressure transmitter will trip
the elution pumps (42-PUMP-01/2) and or hydraulic carbon transfer pumps (44-PUMP-01/2) in
the event of pressures in the column exceeding maximum set value. The pressure transmitter
will also be used to regulate the operation of the pressure control valve (42-PCV-01), opening
more or closing to maintain column pressure on the set point.
 Pressure relief valve (42-V-27) will open and discharge eluant into the Elution Tank (42-TANK-01)
if the event of column of excess column pressure and elution pump (42-PUMP-01/2) or the
carbon transfer water pump(44-PUMP-01/2) not stopping.
 Bursting disc (41-PSE-03) as an extra back up to the pressure relief valve .The rupture disc will
protect the column in the event of excess pressure if the pump did not stop on high pressure
and the pressure relief valve failed.
 Vacuum relief valve (42-V-24) will protect the column from collapsing in the event of the vent
valve (42-HV-05B) not opening when draining the column (valve 42-HV-05A open).

13.5.3 Elution Step

A combination of air actuated valves, magnetic flowmeter, eluant inlet temperature transmitter and
instruments mentioned above will be used to effect the PLC controlled elution wash and emptying of
the column. Temperature and pressure gauges will be installed on the inlet and outlets of the heat
exchangers.

13.5.4 Elution Heaters

This will be a vendor package (heaters and heat exchangers; skid mounted) complete with its own
control philosophy.

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The hot oil burner system is partially automated. Each Thermic Oil Heater unit has a local control panel.
The operator must select which of the two thermic oil pumps is the duty pump, on the local panel for
each Thermomat unit.

Each safety shower (42-SASH-01/2) is equipped with a flow switch. An alarm on SCADA, siren and a
rotating light are triggered when flow to the safety shower is detected.

A hydrogen cyanide gas detector (42-HCND-01) is installed in the elution area with SCADA indication.
High levels of hydrogen cyanide gas will alarm (42-AAH-01) on SCADA and a siren sounds in the elution
area.

13.5.4.1 Elution and Elution Heating VDU Pages

The Elution VDU page features include the following:

 Status (stopped/running) of all drives.

 Elution Tank level (%).
 Elution Column eluate exit temperature (ºC).

The Elution VDU page controls include the following:

 Elution start sequence

 Elution stop sequence
 Elution Tank low level alarm set point.
 Elution Column temperature controller.
 Elution pressure control valve position
 Eluant pump output %
 Eluant Tank level controller.

13.6 SCADA DISPLAY

13.6.1 Description of Elution PROCEDURE

13.6.1.1 Copper Stripping

Prior to the copper stripping stage, a solution of 2.0% NaCN is automatically prepared by diluting the 25
% cyanide solution from the cyanide mixing and dosing plant with raw water in the Eluant Tank (42-
TANK-01). The raw water to Eluant Tank valve (42-LV-01C) is opened until the level in the tank has risen
to 70%. The cyanide to Eluant Tank valve (42-LV-01B) is opened until 900 litres has gone into the tank as
recorded by flowmeter (42-FT-01) after which the valve closes. Water is then added to the tank until
100% (as read from (42-LT-01).

With the heaters not running, the eluant pump (42-PUMP-01/2) starts, pumping the cyanide solution
through the reclaim (42-HEXR-02/3) and primary heat exchangers (42-HEXR-01), elution column (42-
COLM-01). The copper rich solution exiting the elution column is directed to the detox section (34-LISC-
01) by having the detox line valve (42-XV-04) open while valves to the elution tank (42-TV-02B) and the

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pregnant tanks (42-TV-02A) are closed. The eluant pump will stop on low level in the elution tank. This
signal the end of the copper strip. The copper strip is subsequently followed by a water wash with the
resultant solution directed to the leach tailings screen. The raw water valve opens until about 1.5BV of
raw water has been transferred to the eluant tank (42-TANK-01) with the raw water being pumped
through the column by 42-PUMP-01/2. At the end of the water wash, the remaining water in the elution
column is drained into the elution bund and subsequently pumped to the tailings linear screen. The
carbon is now ready for gold elution. While the water wash is in progress, a fresh batch of caustic
cyanide solution is then prepared as discussed below after which the elution of gold can start.

13.6.1.2 Gold Elution

Prior to the elution cycle, the Eluant solution of about 3% NaOH and 1.0% NaCN is automatically
prepared by mixing caustic and cyanide solutions together in the Eluant Tank (42-TANK-01). The raw
water to Eluant Tank valve (42-LV-01C) is opened until the level in the tank has risen to 70%. The Caustic
to Eluant Tank valve (42-LV-01A) is opened until 2100 litres (as read from (51-FT-03) have gone into the
Tank after which the valve closes. The cyanide to Eluant Tank valve (42-LV-01B) is opened until 450
litres has gone into the tank as recorded by flowmeter (42-FT-01) after which the valve closes. Water is
then added to the tank until 100% (as read from (42-LT-01).

Eluant Tank Recycle valve (42-TV-01B) & the Eluant pump (42-PUMP-01/02) starts. Eluant solution in the
Eluant tank is then pumped in circulation back to the Eluant tank, being heated by the Primary Heat
Exchangers (42-HEXR-01) during the recirculation until a temperature of 800C as recorded on (42-TT-
01).The Primary heat exchangers have Thermic oil heat transfer fluid being circulated through it. The
heat transfer oil is heated up by any of or all the two diesel fired Elution Heaters (42-HETR-01/2).

At 800C (42-TT-01), Eluate return to Eluant Tank valve (42-TV-02B), Eluate column outlet valve (42-XV-
06), column inlet valve (42-TV-01A) open & Eluant Recycle Valve (42-TV-01B) closes.

When a temperature of 1200C has been attained on the column outlet, (42-TT-02), the Eluant pump (
42-PUMP-01/02) is stopped, the heaters are stopped, all the valves closed and the eluant is allowed to
soak for a period of 40 minutes after which the selected electrolyte tank (43-TANK-01/2) feed valve (43-
LV-01A/2A) & the eluate outlet valve to pregnant tanks ( 42-TV-02A) open. The Column inlet valve (42-
TV-01A), Column outlet (42-XV-06) and the Recycle tank to Eluant tank valve (42-TV-02B) open, the
Eluant Pump (42-PUMP-01/02) is started & the eluant heaters (42-HETR-01/02) switched on. The Barren
Pump outlet valve to eluant tank (43-V-15) opens automatically and the outlet valve to CIL (43-V-08)
closes. The barren pump (43-PUMP-05/6) is also started. Hot water (barren solution) is passed through
the column at 1200C.

On leaving the column, the hot eluate solution (now the pregnant solution) passes through the Reclaim
Heat Exchanger (42-HTEX-02/3) where it is cooled by contacting with more barren solution from the
elution tank. This pregnant solution is directed and stored in the selected pregnant electrolyte tank (43-
TANK-02/03).

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The elution pumps continue to run until 9BV (126M3) of solution have passed through the column (as
indicated by the level drop in the barren tank) after which the elution heaters switch off, leaving the
Barren pump (43-PUMP-05/06) & Eluant pump (42-PUMP-01/02) running until another bed volume
(1BV) has gone through the column. Running with the heaters off constitutes the cooling stage. At the
end of the cooling stage, the barren pump and elution pumps stop.

The Column inlet valve (42-TV-01A), Column outlet valve (42-XV-06), Feed to Pregnant tank valve (42-
TV-02A), Selected Pregnant tank valve (43-LV-01A/02A) and Barren Tank discharge valve (43-V-15) close.

The eluted carbon can now be transferred to regeneration or returned to the last CIL tank.

13.6.1.3 Alarms
Elution column pressure

 PAH @ 360 kPa Field operator to check strainers for blockages.

 PAHH @ 400 kPa See interlock.

Elution Tank level:

 LAH
 LAL
 LALL

Safety shower in use.

 42-FAH-02
 42-FAH-03

Cyanide detector

 42-AAH-01

Limit switch positions un-healthy.

Problems with heaters (See vendor operating manual).

13.6.1.4 Elution Interlocks

If any of the nominated valves are not in their prescribed position (fully open or fully closed i.e limit
switch indication on SCADA) for the elution step currently active, the sequence will not proceed to the
next stage.

Elution spillage pump (42-PUMP-03) will be started manually and will stop on low sump level (42-LSL-02)

Column outlet pressure of above 3.5 will stop the duty Eluant pump & or Recycle pump if running.

Duty elution pump (42-PUMP-01) will stop on low level (42-LALL-01) in the eluant tank (42-TANK-01)

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Barren electrolyte pumps (43-PUMP-05/6) will trip on LALL in the Recycle Electrolyte Tank (43-TANK-03).

Barren Tank valve to Eluant Tank is interlocked to level in Eluant Tank (42-LT-01)

Eluate to Pregnant Tanks valves (43-LV-01A/02A) interlocked to Level in Pregnant Tanks (43-TANK-
01/02)

All Pressure Transmitters & Temperature Transmitters have SCADA indication.

Elution pump (42-PUMP-01/2) will not start or run unless:

 Duty pump Suction valve (42-HV-01/2) and delivery valve (42-HV-03/4) are open
 Either temperature valve (42-TV-01A) or (42-TV-01B) is open
 Eluant tank level is high. A low level (42-LALL-01) will stop the duty pump.

Temperature valve (42-TV-01A) only opens if:

 Column drain, Column vent, carbon transfer valve, column feed valve are closed.
 Column discharge and either Temperature valve (42-TV-02A/B) or Copper rinse valve are open

Common feed valve to electrowinning tanks (Temperature valve 42-TV-02A) will only open if one of the
electrolyte tanks (43-TANK-01/2) is not full and the feed valve (43-LV-01A/B) to that tank is open.

Copper rinse valve will close when the tails screen (34-LISC-01) stops and detox feed sump (34-TANK-01)
level is high (34-LAHH-01)

13.6.2 Program – Elution

13.6.2.1 Copper Stripping

This stage is optional and can be skipped. Operator is prompted to select whether to PROCEED with
copper strip stage or to SKIP Copper strip. If CRO selects PROCEED, then the procedure given below
follows. If CRO selects SKIP, then the process moves straight to Gold Elution according to the steps given
under Gold Elution stage.

This is a fully automatic three stage sequence:

 Solution makeup
 Copper rinse
 Water wash

Prerequisites for a start of the Copper rinse stage are:

 transfer to or from column not active

 column not draining
 Detoxification section is operational

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 Copper stripping ENABLED, by completion of the elution column filling sequence.(see acid wash
transfer to elution column).
 elution cycle not already active
 all nominated drives and valves selected REMOTE and healthy.
 all valves on the elution column closed.

The sequence is initiated from the Scada. The START Copper Rinse command on SCADA initiates the
Stripping sequence.

The Raw water to elution tank valve (42-LV-01C) opens and at 70% level in the Eluant Tank (42-TANK-
01), the valve closes. The Cyanide Addition to Elution valve (42-LV-01B) then opens & closes after
delivery of 900 litres (42-FT-01). The raw water to elution valve (42-LV-01C) opens until the tank is 100%
full after which it closes. This marks the end of Solution make up step

PLC prompts the operator to check correct valves are open for the selected duty unit and closed for the
selected standby unit:

 Eluant Pump 1 & 2, 42-PUMP-01/2 suction valves

 Eluant Pump 1 & 2, 42-PUMP-01/2 delivery valves
 Reclaim Heat Exchanger, 42-HEXR-02/3 eluant side inlet valves
 Reclaim Heat Exchanger, 42-HEXR-02/3 eluant side outlet valves
 Reclaim Heat Exchanger, 42-HEXR-02/3 eluate side inlet valves
 Reclaim Heat Exchanger, 42-HEXR-02/3 eluate outlet valves
 Primary Heat Exchanger, 42-HEXR-01 tube side inlet valves
 Primary Heat Exchanger 42-HEXR-01 tube side outlet valves
 Primary Heat Exchanger 42-HEXR-01 shell side inlet valves
 Primary Heat Exchanger 42-HEXR-01 shell side outlet valves
 Operator must acknowledge all of the above.

The Proceed command on SCADA initiates the following:

 Opening valve (42-XV-04)

 Opening valve (42-xv-06)
 Opening valve (42-TV-01A)
 Opening valve (42-HV-03/4)
 Opening valve (42-HV-01/2)
 Starting Eluant pump (42-PUMP-01/2)

The high copper solution from the copper rinse is directed to the tailings linear screen (34-LISC-01). This
stage runs until 1BV has passed through the elution column (as indicated by the level drop (42-LT-01) in
the eluant Tank 42-TANK-01). When the eluant tank level gets to 20% (as read by 42-LT-01), the raw
water valve (42-LV-01C) opens.

Duty eluant pump (42-PUMP-01/2) continues to run until 1.5BV of raw water has been pumped through
the elution column washing off the copper rich solution to tails (34-LISC-01).

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After the water wash, the duty eluant pump stops

Temperature valve (52-TV-01A) closes

Valve to tailings linear screen (42-XV-04) closes

Vent valve (42-HV-05B) and Drain valve (42-HV-05A) open to drain the column

When draining is complete, the operator closes the vent and drain valves, readying the column for the
next stage.

13.6.2.2 Gold Elution

This is a fully automatic cycle comprising a Five-stage sequence:

 Solution make-up
 Pre-heat
 soak
 elution
 cooling.

In this AARL elution system, in order to minimise the use of raw water, barren solution after
electrowinning is stored in the barren tank for re-use in the following elution cycle.

Any one of the five stages (or "steps") may be cancelled at the operator's discretion, to allow, for
example, a repeat elution without the need to repeat the previous step e g, a cancellation of Step 2 will
allow restart of the sequence at the same Step 2.

The PLC will prompt the operator at the end of each step to which the operator must
acknowledge for the sequence to proceed.

Prerequisites for a start of the elution cycle are:

 transfer to or from column not active

 column not draining
 Eluant tank below 70% & recycle tank full.
 One of the pregnant electrolyte tanks empty (less than 3%)
 elution ENABLED, by completion of the elution column filling sequence (see acid wash transfer
to elution column).
 elution cycle not already active
 All nominated drives and valves selected REMOTE and healthy.
 all valves on the elution column closed.

The sequence is initiated from the Scada. The START ELUTION command on SCADA initiates the Elution
sequence.

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Step 1: Solution makeup (3% caustic & 2% cyanide)

The raw water to Eluant Tank valve (42-LV-01C) is opened until the level in the tank has risen to 70%.
The eluant tank mixer starts at 40% level in the eluant tank. The Caustic to Eluant Tank valve (42-LV-01A)
is opened until 2100 litres (as read from (51-FT-03) have gone into the Tank after which the valve closes.
The cyanide to Eluant Tank valve (42-LV-01B) is opened until 900 litres has gone into the tank as
recorded by flowmeter (42-FT-01) after which the valve closes. Water is then added to the tank until
100% (as read from (42-LT-01). The contents of the tank are allowed to mix for 5minutes before the next
step.

Step 2: Preheating

PLC prompts the operator to check correct valves are open for the selected duty unit and closed for the
selected standby unit.

The heaters and heater circulation pumps should be started in the field. PLC prompts the operator to
switch on Thermic Oil Systems, 42-HETR-01/2. Operator must acknowledge and ensure the fuel delivery
system is open and sufficient diesel is available. The Proceed Command on Scada intiates the following:

The Eluant Tank Recycle valve (42-TV-01B) opens and the Eluant pump starts.

Normally all the two heaters are active at start of elution. A temperature set-point of 80°C is
automatically selected for recirculation to Eluant tank. Given a successful pre- heating cycle, that is at
attainment of a temperature of 800C on the primary heat exchanger outlet (42-TT-01), Step 2 is
registered as complete, after which the column inlet valve (42-TV-01A), column outlet valve (42-XV-06),
column return to Eluant tank valve (42-TV-02B) open and the recycle valve (42-TV-01B) closes.

Step 3: Presoak

A temperature set point of 1200C is automatically selected for column return to eluant tank. A successful
heating cycle, that is at attainment of a temperature of 1200C on the column outlet (42-TT-02), the
eluant pump stops and all valves close. After a soak period of 45 minutes, the selected pregnant
electrolyte tank, 1 or 2 electrolyte valve, the column outlet valve, the common line to pregnant tanks
valve (42-XV-02A), and the column inlet (42-TV-01A) valve all open, and the Eluant pump starts. At this
stage Step 2 is registered as complete.

Step 4: Wash

The barren valve to eluant tank opens and the Barren pump (43-PUMP-05/6) starts. An elution
temperature set-point of 120°C is maintained on the column outlet. A volume of 126M3 recorded by the
level transmitter (43-LT-01/2) on the selected pregnant tank (43-TANK-01/2) signals the completion of
Step 3: the heaters switch off.

If the barren tank level is low or becomes low during the wash stage, then the raw water valve opens to
complete the wash stage.

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Step 5: Cooling

The Eluant pump and the recycle pump continue to run until 14M3 have passed through the column as
recorded by the level transmitter (43-LT-01/2) on the selected pregnant tank (43-TANK-01/2). This
signals the end of Step 4: the selected electrolyte tank feed valve and the recycle tank discharge valve
closes and the recycle pump & eluant pump stop.

An ELUTION COMPLETE signal is registered.

This completes the eluate transfer cycle.

13.6.3 Eluted Carbon Transfer to Regeneration Kiln Procedure

 Once an elution is complete the operator must check & confirm
o The Eluted Carbon Tank, 44-TANK-01 is empty
o Regeneration feed valve (44-V-01), directing carbon to the Eluted Carbon Tank (44-
TANK-01) is open and Regeneration bypass valve (44-V-02) directing carbon to CIL (32-
TANK-08/9) is closed.
o That both top and bottom strainers in the Eluted Carbon Tank are clean.
o The Eluted Carbon Tank bottom strainers drain valve (44-V-03) is open.
o The Eluted Carbon Tank outlet valve (44-V-04) is closed
 Open Transfer Water Pump, 44-PUMP-01/2 suction and delivery valves. Operator must confirm
the valves are open.
o Check & close, if required Elution Column Eluant inlet valve
o Check & close , if required Elution Column Eluate outlet valve
o Check & close if required Elution Column carbon inlet valve
 A Start Carbon Transfer command on Scada initiates the following:
o Opens Transfer water to Elution Column pressure water valve (42-XV-03)
o Open Transport Water valve (42-XV-01)
o Start Transfer Water Pump (44-PUMP-01/2).
o At pressure 2.5 bar on the Elution Column (42-PT-01), Opens Elution Column carbon
outlet valve (42-XV-02)
o Waits preset period (normally 1 hour) for transfer of carbon to Regeneration Kiln.
o Check for transfer of carbon to Eluted Carbon Tank (44-TANK-01) through the sight
glass.(44-V-99). When carbon transfer is complete:
o Stop Transfer Water Pump ( 61-PUMP-01)
o Close Transfer water to Elution Column pressure water valve
o Close Transfer water to Elution Column valve
o Close Elution Column carbon outlet valve

If the Regeneration section is to be bypassed the operator would close the Regeneration feed valve
directing carbon to the Eluted Carbon Tank (42-V-01) and open Regeneration bypass valve directing
carbon to the CIL (44-V-02)

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13.7 ELUTION Equipment

13.7.1 Elution Column (42-COLM-01):
(See Vendor certified drawing in Appendix).

The elution column (14 m3) is made of 304 Stainless Steel and can handle a 6t batch of loaded carbon
with a bed expansion of 1% of the packed volume. The eluant solution is pumped at constant flow rate
of 2 BV/h via positive displacement pumps (42-PUMP-01/02), one duty and one standby. This allows for
bed expansion during the elution process and optimum contact with the eluant solution for efficient
Gold extraction. The up flow velocity through the carbon bed will cause bed expansion without carry
over except for a few small fractions created by abrasion or breakage of the larger particles.

These will be collected in strainers (42-STRN-01/02) fitted with 700 µm wedge-wire screens.

The strainers are operated on an alternative basis which allows clean up, when required, without
stopping the elution process. Filter blockages will be identified by increased column inner pressures
which are monitored via a pressure transducer.

The column is equipped with a number of nozzles (See Appendix) for carbon and solution movement
and for mounting of safety and process control instrumentation.

13.7.2 Elution Pumps (42-PUMP-01/02)

The pumps, one duty and one standby are positive displacement pumps delivering constant flow rate of
28 m3/h, equivalent to 2 BV/h. Pump deliveries are fitted with pressure relief valves for protection
against over pressure in the event of a closed or blocked delivery line.

The pumps arrangement and the “Helical Rotor” type mechanism are shown in the figure below.

Figure 13-5: Elution Pumps arrangement and construction

Eluant pump arrangement

picture

Gearbox &
Pulley Drive

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13.7.3 Thermic Oil Heaters (42-HETR-01/2)

The thermal oil circuit comprises circulation of thermal oil through Thermic Oil Heaters to the Primary
Heat Exchanger, where heat transfer occurs and back to the de-aeration/expansion system and back to
the Thermic Oil Heaters. The circuit is suited for oil temperature up to 300ºC.

Each Thermic Oil Heater has its own panel which controls the burner in 2-stage firing sequence: high
fire, low fire or off. Each heater controls oil temperature via thermocouples on the inlet and outlet
manifolds measuring: INLET, OUTLET, LIMIT and MODULATION temperatures, set manually on digital
controllers situated on the front of each heater control panel. Typically, the unit switches to high or low
fire, in accordance to the MODULATION controller, placed either on the inlet or outlet, to regulate the
firing rate. INLET and OUTLET controllers switch the unit off on activation. The LIMIT is a maximum oil
temperature limit, which is lockable and situated inside the panel to avoid external tampering.

Main control of elution temperature is the very important 3-way actuated valve. This valve diverts hot
oil flow to OR away from the Primary Heat Exchangers (42-HEXR-01). The actuator is pneumatic to allow
for a speedy actuation of the valve in accordance with the temperature controller on the Elution
Column. The valve is fitted with a single-stage pneumatic positioner. The valve modulates flow to OR
bypassing the Primary Heat Exchangers, rather than being either open or closed.

Hence, there is a primary oil temperature control loop, where the oil is heated up and either recirculates
or feeds, via the 3-way valve, to control the secondary eluate temperature control loop.

Control of the burner is via photoelectric cell, which monitors flame. Should any particular problem
occur related to combustion, the burner will trip to SAFETY lockout and a manual reset is required inside
the panel as well as on the panel front door. This is to ensure a physical inspection of the burner and its
various components to remedy the reason for flame failure.

13.7.3.1 De-scaling Heat Exchangers

The heat exchangers may experience scaling that will reduce their effectiveness over a period. A de-
scaling facility is provided. A regular check of the temperature and pressure indications at the heat
exchanger inlets and outlets and calculation of the temperature and pressure differentials over the heat
exchanger will indicate if it is scaled up and requires cleaning. A regular de-scaling program maybe
necessary to ensure optimal elution performance.

The Secondary Heat Exchanger (sides A and B) and Primary Heat Exchangers (side A only) are fitted with
a hose connection points at the inlet and outlet. One hose connection point is located at a high point,
and the other at a low point. The Primary Heat Exchanger side B carries thermic oil, not eluant solution,
therefore will not require de-scaling.

To de-scale a heat exchanger it is isolated from the process flow by manual operation of the heat
exchanger isolation valves. This must be done between elutions. The unit to be cleaned should be left
to cool. The heat exchanger is drained by connecting a hose, directed to the Elution area floor, to the

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lower hose connection point and opening the isolation valve at both the lower and top hose connection
points. The heat exchanger is then rinsed with water from the top hose connection point and drained.

Descalant solution, a dilute solution of sulphamic acid is pumped into the heat exchanger from the
lower hose connection point valve, allowing air to vent from the top hose connection points. Once the
heat exchanger is full the lower hose connector point valve should be closed and the delivery hosepipe
from the descalant pump removed. The heat exchanger should be left for 1-2 hours to soak. The drain
hose is reconnected to the lower hose connector point valve and the spent descalant solution drained
from the heat exchanger.

The heat exchanger is rinsed with water from the top hose connection point. After checking the heat
exchanger for any other maintenance requirements and closing all the hose connector points the heat
exchanger is ready to be put back on line.

13.7.4 Elution Troubleshooting

Observation Possible Problem Action Required
Temperature too low Check heat exchangers

Poor acid wash Observe/sample acid wash on next batch

Cycle time insufficient Re-run if incomplete

Low elution flowrate Check strainers

Eluant reagent concentration incorrect Check by titration

13.8 ELUTION TEMPERATURE MEASUREMENT LISTING

A number of temperature probes are installed around the elution circuit. They are either indicating at
the SCADA or local (field) indication only. The local temperature indicators are local at the entrance and
exits of the heat exchanger to check the heat exchanger performance.

SCADA Temperature indications

 Primary Heat Exchanger eluant outlet

 Elution Column (42-COLM-01)

Field Temperature indications:

 Elution Column (42-COLM-01)

 Reclaim Heat Exchanger (42-HEXR-02/3) A Side Inlet
 Reclaim Heat Exchanger (42-HEXR-02/3) A Side Outlet
 Reclaim Heat Exchanger (42-HEXR-02/3) B Side Inlet
 Reclaim Heat Exchanger (42-HEXR-02/3) B Side Outlet

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 Primary Heat Exchanger 2(42-HEXR-01) A Side Inlet

 Primary Heat Exchanger (42-HEXR-01) A Side Outlet
 Primary Heat Exchanger (42-HEXR-01) A Side Inlet
 Primary Heat Exchanger (42-HEXR-01) A Side Outlet

13.9 ELUTION PRESSURE MEASUREMENT LISTING

A number of pressure gauges are installed around the elution circuit, located at the inlets and outlets of
the heat exchangers to check the heat exchanger performance and on the Elution Column.

 Elution Column (42-COLM-01)

 Reclaim Heat Exchanger (42-HEXR-02/3) A Side Inlet
 Reclaim Heat Exchanger (42-HEXR-02/3) A Side Outlet
 Reclaim Heat Exchanger (42-HEXR-02/3) B Side Inlet
 Reclaim Heat Exchanger (42-HEXR-02/3) B Side Outlet
 Primary Heat Exchanger 2(42-HEXR-01) A Side Inlet
 Primary Heat Exchanger (42-HEXR-01) A Side Outlet
 Primary Heat Exchanger (42-HEXR-01) A Side Inlet
 Primary Heat Exchanger (42-HEXR-01) A Side Outlet

13.10 APPENDICES
 ELUTION PFD FD 4200 Rev. 5
 ELUTION P&ID PD 4210 and PD4220 Rev. 3
 ELUTION COLUMN VENDOR CERTIFIED DRAWING.
 ELUTION TANK VENDOR CERTIFIED DRAWING.
 ELUTION PUMP VENDOR O & M MANUAL.
 ELUTION SPILLAGE PUMP VENDOR CERTIFIED DRAWING.
 DIESEL HEATER VENDOR O & M MANUAL.
 HEAT EXCHANGER VENDOR O & M MANUAL.

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14. ELECTROWINNING AND CATHODE WASH

14.1 SUMMARY
The purpose of the electro winning plant is to convert the Auro-Cyanide complex from the soluble to the
solid state using the electrolysis process. The pregnant solution, produced in the elution process,
circulates through the electrolytic cells and going back to the source electrolyte tank, for a period of up
to 12 hours. Gold extracted from the loaded carbon is deposited as “Gold sludge” consisting of fine
grains of metallic Gold loosely attached to the cathodes. Under normal conditions up to 97 % of Gold is
extracted at the end of the cycle. The Gold sludge is then washed off the cathodes with high pressure
water and filtered. The filter cake, of smeltable grade, is treated further in the Gold room to produce the
final Gold bar product. This process will be described in the gold room section. The processes use highly
toxic and hot solutions as well as high amperage electric currents and safety procedures must be strictly
adhered to ensure a safe work place. Bullion grade products are handled in the electro-winning cells and
this is the reason for installing the plant in the Gold house.

14.2 SAFETY
Electro-winning is done in a close circuit with stripping, and the complete process is called elution.
Therefore reagents met and mentioned in Elution circuit description are the reagents encountered in
electro-winning. However there is a further safety concern which is brought by the use of high electric
current in the electro-winning process. Currents up to 700A and voltages up to 10V are used in the
electro-winning process and these can pose a serious hazard if proper safety standards are not followed.

14.3 ELECTRO-WINNING SAFETY PROCEDURES

The electro-winning operation uses concentrated caustic soda (NaOH) and cyanide solutions at high
temperatures. The cyanide solution is highly toxic and may form Hydro cyanide gas (HCN) if mixed with
acid or to a lesser extent with water. Ammonia gas is also produced in gold electro-winning process. The
hot solutions have temperatures up to 90 o C which may form vapour or fumes. The cell tanks and pipe
surfaces are also likely to be sufficiently hot to burn exposed skin on contact.

 Operators must read and understand the hazards and safe working procedures for the section
before they are left to operate the section alone.
 Isolation of electro-winning cells: proper isolation by a qualified person is required prior to
working on the cells. An isolation tag must be put on the isolation point with the following
information; date, time of isolation, name and signature of the competent person
 Tagging: all personnel working on electro-winning cells must have completed the proper
personal danger tags be hanging on the isolation point together with the isolation tag
 Ammonia gas in produced in gold electro-winning process and proper ventilation of the cell
enclosure must be ensured to keep the gases out. It is important to take an ammonia gas
detector when going into the electro-winning cells enclosure
 A chemical dust mask is needed when washing off sludge from the cathodes. Washing process
produces mists and fumes that contain some amounts of cyanide, ammonia and caustic.

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14.3.1 Sodium Cyanide (NaCN)

Cyanide is potentially the most hazardous chemical on site. It is highly toxic (poisonous) and potentially
fatal. However, if the required safety procedures are implemented it can be used with complete safety.

WARNING!

ALL FORMS OF CYANIDE ARE POISONOUS WHETHER IT IS IN THE SOLID FORM, DISSOLVED AS A LIQUID
OR GIVEN OFF AS HYDROGEN CYANIDE (HCN) GAS.

Figure 14-1: Danger Signs for Sodium Cyanide Solutions

14.3.1.1 Principal hazards

Cyanide poisoning can occur as a result of:

 Inhalation of gas, dust or fine spray into the lungs.

 Ingestion (swallowing) of cyanide dust or solution.
 Absorption through the skin via contact with solution or dust.
Small doses can incapacitate quickly and even cause death by blocking the body’s ability to use oxygen.

14.3.1.2 Emergency Procedures

Eye contact: In the safety shower, flush the eye immediately with plenty of water Continue to do so
while medical help is being obtained.

Skin contact: In the safety shower, wash off with soap and plenty of water. Remove any contaminated
clothing. Call for medical help.

If swallowed: Induce vomiting and call for immediate medical help. Dispense first aid immediately.

14.3.1.3 In the event of HCN gas emissions

 > 10 ppm: Wear Gas Mask with correct cartridge.
 > 60 ppm: Wear full face cover respiration apparatus.

14.3.2 Caustic Soda (NaOH):

14.3.2.1 Principal hazards

 Contact with the eyes can cause serious long-term damage.
 The solid and its solutions are corrosive.
 Significant heat is released when sodium hydroxide dissolves in water.

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Figure 14-2: Danger Signs for Caustic Soda

14.3.2.2 Emergency Procedures:

Eye contact: In the emergency shower, flush the eyes immediately with plenty of water. Continue for
at least ten minutes and call for immediate medical help.

Skin contact: Wash off with plenty of water. Remove any contaminated clothing. If the skin reddens or
appears damaged, call for medical aid.

If swallowed: If the patient is conscious, wash out the mouth well with water. Do not try to induce
vomiting. Call for immediate medical help

Personnel shall take note of the location of the potable water safety shower and eye wash station
located in the area.

Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in Figure 10.1 below.

The shower shall be used in all instances where any body part or clothing has been splashed or exposed
in any way to the acid solution.

Figure 14-3: Safety Shower Features

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EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

All personnel working or passing through the area shall therefore wear the required PPE, as listed
below:

 Hard Hat.
 Safety Goggles or safety glasses.
 Steel-Capped Rubber Boots.
 High-Visibility Clothing.
 Gloves (Neoprene, Butyl Rubber…).
 Full face cover respiration apparatus shall be worn in the event of Hydro cyanide (HCN) or other
toxic gas emissions.

In addition, Long Pants, apron and Long-Sleeved shirts must be worn.

The relevant safety signs are shown in the figure below

Figure 14-4: Elution Section Safety Signs

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14.4 ELECTRO WINNING PROCESS PRINCIPLES OF OPERATION

14.4.1 Theoretical background
Each electrolytic cell consists of four components making up the electro winning circuit:

14.4.1.1 Rectifier
This produces the electro-chemical energy driving the anodic and cathodic reactions taking place in the
cell. The direct current amperage depends on the number and size of electrodes to produce the
required constant current density of ± 750 A/m2 at constant voltage of 4 to 6 V.

14.4.1.2 Anode
The anode is connected to the positive terminal. Oxidation reactions occur at the anode. The
predominant anodic reaction in the current application produces oxygen gas, as shown below

2H2O 4 H+ + O2 + 4e

14.4.1.3 Cathode
The cathode is connected to the negative terminal. A number of reduction reactions occur at the anode
depending of the composition of the electrolyte. In this instance Gold in solution is reduced to metal.
Other metals such as Lead, Silver, copper always present in the types of Gold ores in the region will also
deposit in the following order of priority:

Pb>Ag>Au>Cu>Fe

The presence of Lead traces can sometimes be beneficial to the process as it forms a thin pre-coat
preventing strong attachment of Gold to the cathode. Copper may deposit with Gold depending on the

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pregnant solution concentrations. Hydrogen and ammonia gasses are also emitted at the cathode and
this creates a potential hazard. The hydrogen producing reaction is shown below:

2H2O + 2e H 2 + 2 OH-
14.4.1.4 Electrolyte
The electrolyte flowing between the electrodes contains high concentrations of caustic soda. This
increases the conductivity and lowers the resistance to the passage of electric current carried by the
ions migrating to the electrodes. The high temperature also increases the conductivity and reduces the
soluble oxygen content which increases energy consumption.

The operation of the electro winning cell is illustrated in the figure below

Figure 14-5: Gold Electro-winning Process Mechanism

14.4.2 Electrowinning Equipment

Equipment code Equipment ID kW Description Supplier

43-TANK-01/2 Pregnant tank 01/2
43-TANK-03 Barren tank
43-PUMP- Pregnant pump 01/2/3/4 7.5
01/2/3/4
43-SASH-03 Preg. Soln safety shower
43-PUMP-07 Pregnant soln spillage pump 0.75
43-PUMP-01/2 Barren pump 01/2 2.2
43-PUMP-11 Barren spillage pump
43-TANK-04/7 Cell feed tank 01/2
43-EWCL-01-6 EW Cell 1-6 Double sludge cell, 16 Kemix
cathode 18 anode,
0.7x0.7m ss mesh cathodes
43-RECT-01-6 Rectifier 1-6 12 0 – 10V, 0 – 1200Amp, DC Kemix
rectifier
43-FAN-01 Cell extraction fan 7.5

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43-HYST-01/2 Cathode hoist 01/2 2 1.75

43-SASH-01 EW safety shower U type double column, Delta health &
platform activated c/w Safety
hand operated side
mounted eyewash.
43-TANK-05 Cathode wash tank
43-TANK-06 Gold sludge tank
43-TANK-07 Flash/Cell feed tank 2
43-PUMP-08 Cathode HP wash pump 3.0
43-PUMP-09 Filter feed pump 1.1
43-FILT-01 Gold sludge filter press SB500/30/25/M , manual Lantham Filtration
sidebar, 30 chambers Technology
25mm deep
43-PUMP-10 EW spillage pump 1.1
43-SASH-02 Gold sludge safety shower U type double column, Delta health &
platform activated c/w Safety
hand operated side
mounted eyewash.
43-HCND-01 HCN Gas Detector
43-SASH-03 Pregnant solution safety shower U type double column, Delta health &
platform activated c/w Safety
hand operated side
mounted eyewash.

14.4.3 Electrowinning Cell

The plant uses 6 Kemix double sludge electro-winning cells. The electro-winning cell consists of a
sandwich arrangement of anode assemblies on either side of cathode compartments, all contained in a
stainless steel tank. The eluate is pumped into each cell at one end and flows through all the electrodes
prior to exiting the cell via the overflow weir at the opposite end into a common discharge for the
double cell. Solution bypassing is minimised resulting in the optimisation of pass efficiency.

Generation of toxic and potentially explosive gasses necessitates proper ventilation which is done via
the goldroom ventilation fans mounted on the roof.

14.5 ELECTRO-WINNING PROCESS DESCRIPTION

The eluate from the Elution Column is directed to fill either of the Pregnant Tanks 1 or 2, (43-TANK-
01/02). Once the tank is sufficiently full of eluate and the electrowinning circuit is available, the selected
Pregnant Eluate Pump, (43-PUMP-01/2) at Pregnant Tank 1, or (43-PUMP-03/4) at Pregnant Tank 2 can
be started.

Pregnant solution is pumped from the Pregnant Tank, by the Pregnant Eluate Pump to the
Electrowinning Cell Feed (steady head) Tank, (63-TANK-04/7). From the steady head, electrolyte is
distributed to the EW Cells (43-EWCL-01/2/3/4/5/6). Any cell is isolatable by closing the feed valve from
the EW Cell Feed Tank. Excess solution in the Cell Feed Tank overflows, bypassing the EW cells, joining
the cell outlet solution to the return pipe which directs it back to the selected Pregnant Tank. The
design flow rate to the EW cells is 70m3/.

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Gold is electro-won from the eluate solution using sludging type stainless steel mesh cathodes. Gold is
plated as loosely adhering finely divided sludge onto the pad of stainless steel knit mesh contained in
the cathode basket. Circulation of the projected 133m3 of pregnant solution continues for about 11hrs,
taking the pregnant solution grade from a target of 180ppm to a barren solution grade of 5ppm marking
the end of electrowinning.

Once an electrowinning batch is complete i.e. the gold grade of the solution has reduced to a stipulated
level, the valves on the operating Pregnant Eluate Pump delivery are set to direct the electrolyte to the
Barren Tank, (43-TANK-03). From this tank the barren Eluate Pump (43-PUMP-05/6) delivers to the
Elution section (eluant tank 42-TANK-01) or to the CIL feed Splitter Box. (32-BOX-01).

Two Electrowinning Cathode Hoists (43-HYST-01/2) are provided to remove loaded cathodes periodically
and lower these into the Cathode Wash Tank, (43-TANK-05). The Cathode Wash Pump, (43-PUMP-08)
provides a high-pressure water spray to remove sludge adhering to the cathode mesh. The washings
and cell sludge are collected in the Cathode Sludge Tank (43-TANK-06) from where it is pumped by the
filter feed pump (43-PUMP-09) to the Cathode Sludge Manually Operated Plate Shifting (MOPS) Filter
Press (43-FILT-01) to dewater the sludge. Compressed air may be applied to the press to assist in drying.
The dewatered sludge is packed into trays and taken to the Calcining Oven (45-CALO-01) in the Gold
Room for drying.

A fume extraction system (Cell Fume Extraction (43-FAN-01)) is installed to collect potential poisonous
and explosive gases evolved during electrowinning from the cells. The fume extraction fan discharges
through the gold room roof.

Pregnant solution spillage is directed to a sump from where it is pumped (by 43-PUMP-07) into either of
the pregnant solution tanks or into the barren solution tank. Spillage generated in the EW section is
either pumped back into the gold sludge tank (43-TANK-06) or into the barren tank (43-TANK-03).
Spillage in the barren tank area is pumped into the barren tank using pump (43-PUMP-11).

Three safety showers (43-SASH-01/2/3), one in each of EW, pregnant solution and gold sludge areas, are
provided with a siren and rotating light being triggered when flow to the safety shower is detected.

A hydrogen cyanide gas detector (43-HCND-01) is installed in the EW circuit with SCADA indication. High
levels of hydrogen cyanide gas will alarm (43-AAH-01) on SCADA and a siren sounds in the EW area.

14.5.1 Electrowinning Controls

The operations are essentially done manually but incorporate a few alarms and interlocks.

Pregnant and barren tanks will be equipped with ultrasonic level transmitters

Air actuated valves will enable solution from elution to be directed to one of the pregnant tanks;
addition of caustic solution to the pregnant tanks; barren solution management and routing of pregnant
solution.

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The operator is supposed to regularly monitor these readings and adjust the potentiometer so that
these fall in line with the requirement of 4-6V and above 700 A.

The electrowinning cell’s current and voltage will be indicated at the rectifier, located in the rectifier
room outside the gold room and at the SCADA. The controller potentiometer is located at the rectifier.

All pregnant electrolyte pipes in the electrowinning circuit are insulated for conservation of heat.

Steady feed to the EW cell header tanks will be done using Flow transmitters (43-FT-04/5) and flow
control valves (43-FCV-04/5).

14.5.2 Alarms
 Safety shower in use (43-FAH-01, 43-FAH-02, 43-FAH-03)
 Low level in Pregnant Tank (43-LALL-01, 43-LALL-02)
 Low level in Barren tank (43-LALL-03)
 High HCN gas levels (43-AAH-01)
 Filter press high pressure alarm (43-PAH-01)
 Electro-winning Cell:
o Low Voltage.
o Amperage out of range.
 Fumes extraction fan stops.

14.5.3 Interlocks
 Rectifiers stop if fumes extraction fan (43-FAN-01) stops.
 Barren solution Spillage pump (43-PUMP-11) will stop on low level in the sump (43-LSL-04).
 Pregnant solution spillage pump (43-PUMP-07) will stop on low level in the sump (43-LSL-06).
 Barren electrolyte pumps (43-PUMP-05/6) will stop on low level (43-LALL-03) in the barren tank
(43-TANK-03).
 Pregnant pump (43-PUMP-01/2) will stop on low level (43-LALL-01) in the pregnant tank (43-
TANK-01).
 Pregnant pump (43-PUMP-01/2/3/4) will stop on high level (43-LAHH-03) in the barren tank (43-
TANK-03)
 Pregnant pump (43-PUMP-01/2) will only start or run if:
o The level in the pregnant tank (43-TANK-01) is healthy and
o Either sequence valve (43-XV-02) to barren tank or sequence valve (43-XV-01) to EW
cells is open. The later only opens if the electrolyte return to tank 1 valve (43-LV-01B) is
open while electrolyte return valve to tank 2 (43-LV-02B) is closed together with
pregnant to EW from tank 2 valve (43-XV-03).
 Pregnant pump (43-PUMP-03/4) will only start or run if:
o The level in the pregnant tank (43-TANK-02) is healthy and
o Either sequence valve (43-XV-04) to barren tank or sequence valve (43-XV-03) to EW
cells is open. The later only opens if the electrolyte return to tank 2 valve (43-LV-02B) is
open while electrolyte return valve to tank 1 (43-LV-01B) is closed together with
pregnant to EW from tank 1 valve (43-XV-01).
 Filter Feed Pump will stop on Filter High Pressure (43-PAHH-01)
 Filter feed pump (43-PUMP-09) will only start or run if:

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o Suction valve (43-XV-05) is open and

o One of the delivery valves (43-XV-06 on the recircuilation to gold sludge tank) or (43-
XV-07 on the feed line to the filter press) is open.

14.6 OPERATING PROCEDURES

14.6.1 Electrowinning
The electro-winning process sequences are controlled manually from SCADA and require coordination
between the field operator and control room operator. The various steps are described in detail below:

Step 1: Electro-winning

The Control room operator, in constant radio contact with the field operator perfoms the following

 Select Pregnant tank (43-TANK-01or 43-TANK-02)

 If pregnant tank 1 (43-TANK-01), select EW cell feed pump (43-PUMP-01/2) and if Tank 2 (43-
TANK-02), select EW cell feed pump (43-PUMP-03/4)
 Confirm with the field operator that suction and delivery valves of selected pumps are open.
 Ensure the electrolyte return to the selected pregnant tank valve (43-LV-01B/2B) is open.
 Ensure that Feed valves to Barren tank (43-XV-02/04) are closed.
 Ensure that Feed valves to Cell Feed Tank (43-FCV-04/5)
 Starts Cell Fume extraction Fan ( 43-FAN-01)
 Starts selected cell feed pump ( 43-PUMP-01/02/03/04)

The Field operator performs the following actions

 Checks all valve positions around the cells.

 Ensures that all the cathodes and anodes are connected correctly and the electrowinning cell
canopy is closed in position.
 Reports readiness to receive pregnant solution from the pregnant tanks.
 The Control room operator notifies the field operator when solution is pumped to the cells.
 Checks flow of solution to the cells on the feed line flowmeter.
 Adjust manual valve on the pump delivery to required flow rate)
 Starts the rectifier & sets current & voltage
 Checks amperage and voltage and make the necessary adjustments.
 Takes hourly samples of the feed to the cells & return from the cells & submit these timeously to
the Lab.
 When return solution is less than 5ppm, advises control room operator to transfer solution to
the Barren tank.

The Control room operator is then required to do the following

 Check that the Barren tank has capacity, if not, open barren tank to CIL valve ( 43-V-08)
 Close barren tank to elution valve ( 43-V-15)

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 Confirm with field operator that suction & delivery valves to the selected barren pump (43-
PUMP-05/6) are open.
 Start selected Barren pump.
 When level in Barren tank (43-LT-03) reaches low, the duty barren pump stops automatically.
The operator then closes the barren to CIL valve (43-V-08).
 If Pregnant tank 1 was operating then open feed valve to barren Tank (43-XV-02)
 Close feed valve to Cell feed tank (43-XV-01)
 If Pregnant Tank 2 was operating, then open feed valve to barren tank (43-XV-04)
 Close feed valve to Cell feed tank (43-XV-03)
 At low level in the duty pregnant tank, the duty pump automatically stops (43-LALL-01/2)

The Gold room operator performs the following actions when removing loaded cathodes:

 Stop the rectifier for the EW cell to be worked on.

 Stops the extraction fan 43-FAN-01.
 Unlock and open the cell canopy.
 Disconnect terminals and removes the first cathode with the electric hoist 43-HYST-01/2 and
brings it over the electrode wash tank 43-TANK-05.
 Wash off Gold sludge until electrode has been totally cleaned.
 Replace electrode in position and reconnect terminals correctly.
 Repeat the procedure until all cathodes of the first cell have been washed.
 Hose cell tank to flush any Gold settled on the sloped bottom.
 Replace cell canopy in position and lock.
 Repeat operation with second electro-winning cell.

14.6.2 Filter Press Operating Procedures

 Dewatering Sequence
 The operator ensures that the hydraulic manual pump directional control valve is in the closed
position.
 The operator selects “CLOSE PRESS” LEVER
 The operator pumps the lever mounted on the hydraulic power pack. The cylinder extends to
pressurize the plate pack to 24MPa.
 The operator opens the feed valve manually. The filtration cycle starts.
 If the hydraulic pressure drops below the minimum setpoint of 18MPa on the visual gauge, the
operator must pump the hydraulic power pack until; the required 24MPa is achieved.
 Once the press fill sequence is complete, the operator closes the feed valve

Air Blow Sequence

 When the dewatering cycle is complete, air blow is introduced through the cake to reduce the
final moisture.
 The bottom port filtrate valve is closed.
 The air inlet valve is opened.
 After a set time, the air inlet valve is closed.
 The bottom port filtrate valve is opened.

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Cake Discharge Sequence

 The operator manually relieves the pressure of the system via a relief valve (PRV1)
 The operator selects the “ Open Press” lever
 The operator pumps the lever mounted on the hydraulic power pack. The cylinder retracts.
 The operator then shifts the plates manually and discharges the cake from the frames.
 The condition of each plate and its filter cloth must be examined and problems rectified if
necessary.
 Once the operator is satisfied with the cake discharge and the cleanliness of the plates, a new
filtration cycle may be initiated.

Routine Checks

 Busbar and Lead Contacts

 Ensure good firm fit but do not over-tighten
 Use small amount of silicone grease on contacts.
 Loose contacts or dirty connecting points will cause high voltage drop, low current and will
result in hot connecting leads and poor electrowinning efficiency.
 The red busbar (positive) should always be connected to the anode frames whilst the black
busbar (negative) must be connected to the cathode hanger bars.

Anode Maintenance

 Dirty and corroded/passivated surfaces will severely affect voltage and current flow resulting in
poor electrowinning efficiency. It may be necessary to clean anodes during an electrowinning
campaign if they are badly coated. This is indicated by high voltage and low amps. This should
be carried out on a one-by-one basis using a spare anode as replacement whilst the dirty one is
cleaned. In this way electrowinning is not stopped.

Cathode Maintenance

 The cathodes may be slightly coated with gold onto the distributor frame. This may be
periodically cleaned off with sanding paper and all sweepings are to be collected for adding to
the smelt.

Completion of Electrowinning

 Samples taken during the electrowinning cycle should be submitted for immediate gold assay
(by reading on the Atomic Adsorption spectrophotometer) as soon as possible. The latest
available sample should be read first to enable the operator to determine whether the
electrowinning is complete.

Removing & Washing Cathodes and Cells

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 After disconnecting the current leads, slowly raise the cathode basket. Allow excess solution to
drain. The cathodes are then hoisted into Cathode Wash Tank, 43-TANK-05 and lowered into
the slots to support the cathode frame. The operator then uses the High Pressure Wash Pump,
43-PUMP-08 to remove the gold sludge adhering to the mesh.

During operation, sludge will build up in the cells. This must be removed periodically to prevent short-
circuit between anodes and cathodes at the bottom of the cells. Sludge that has collected in the bottom
of the electrowinning cell is washed out to the gold Cathode Sludge Tank (43-TANK-06) for collection.
The contents of the sludge tank are transferred to the Electrowinning Cathode Sludge Filter (43-Tank -
01) to remove excess water before calcining.

14.6.3 Care of Filter Cloths

The efficiency of the press may be seriously affected if the condition of the cloths is allowed to
deteriorate. Lack of care will reduce the life of the cloths, therefore it is important to observe the
following points.

 Change the papers after every cycle.

 When discharging the press, any cake adhering to the cloths should be removed using a smooth
bladed spatula free from sharp edges and corners, preferably of plastic construction.
 Each cloth should be examined during discharge for any creasing or damage. Any creasing must
be removed immediately since, if allowed to become ‘ironed in’ it becomes increasingly difficult
to remove them. The ties should be adjusted as required. Damaged cloths should be removed
immediately.
 Particular note should be made of the plate sealing edges. In addition to the removal of creases,
cake build up must be removed, and the ties should be checked to ensure that they do not foul
the sealing area. Tighten all loose ties and replace any which are missing.

Failure to take adequate care of the sealing edges can result in leakage of slurry from the press at high
pressure.

The cloth surfaces should be examined for build up of cake in the pores. This will reduce their efficiency
and the cloths should be washed as soon as possible. A further indication for the need to wash the
cloths is the increasing cycle times or wet cakes occurring, although the feed has not changed.

14.6.4 Cloth Washing

Soiled cloths may be cleaned in two basic ways, either in-situ, or by removal. Further options are
detailed below.

If the cloths are to be cleaned in-situ, it is important to remember that fine particles may be forced
through the cloth on to the filtration surface of the plate. Care should be taken to ensure that there is
not a build up on the plate since this will impair efficiency. The cloths should be removed at intervals to
enable the plates to be cleaned.

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When the cloths are removed, the drainage surface, feed cake washing, and drainage ports should all be
thoroughly cleaned. Unpainted metal plates may require the use of a wire brush.

Cloths can be kept clean by using a sponge or soft brush and water at frequent intervals. This method
will remove light soiling.

Soiled cloths may be cleaned in-situ by hosing down manually at normal mains pressure, but the use of a
high pressure washing machine will give better results in reduced time and will generally use less water.
These machines often have facilities for the addition of cleansing agents and heating water. Unless the
press maintenance manual states otherwise, use only mild detergent and limit the temperature to 65°C.

When washing in-situ, precautions should be taken to ensure that the wash water is collected by the
press drainage trays. If the trays are fitted, adequate protection should be provided for equipment and
personnel beneath the press. When manual high-pressure machines are used, the operator should wear
suitable protective clothing and suitable screening provided to avoid splashing the surrounding area.
The high-pressure jet must never be directed at personnel as serious injury may result.

Heavily soiled cloths may not be sufficiently cleaned by the above methods. In this case, the cloths
should be removed for washing using a mild detergent in water at 65°C, followed by rinsing. Industrial
washing machines for this purpose are available.

On completion of washing, the cloths should be hung up to dry. Do not attempt to dry rapidly by
application of direct heat.

Refer to the appropriate instructions when re-fitting the cloths to the press.

14.6.5 Electrowinning Troubleshooting

Observation Possible Problem Action Required

1 Poor electrowinning Check current density Adjust voltage/amperage

efficiency
Flow rate too high Check flow rate

Low conductivity Add Caustic Soda

Cathodes overloaded Change cathodes

Anodes corroded Change anodes

Eddy currents Check earthing

2 Electroplating on anodes Anodes corroded Change anodes

Surface corrosion inhibitor lost Re-apply inhibitor

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14.6.6 SCADA Display

14.7 APPENDICES
 ELECTRO-WINNING PFD FD 4300 Rev. 5
 ELECTRO-WINNING P&ID PD 4310, 20, 30 & 40 Rev. 3
 ELECTRO-WINNING CELLS VENDOR O & M MANUALS.
 RECTIFIERS VENDOR O & M MANUALS.
 HIGH PRESSURE WASH PUMP O & M MANUALS.
 GOLD SLUDGE FILTER PRESS VENDOR O & M MANUAL.

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15. GOLDROOM
15.1 SUMMARY DESCRIPTION
The Gold Room is labelled “High-Security area” as all operations conducted there entailing handling of
“High-Grade” products, such as:

 Cathode gold sludge.

 Filter press cake.
 Calcine.
 Gold bullion bars.

The Gold Room is housed in a secure brick building with restricted access and clean and dirty change
house facilities. One shower is provided in the dirty change house. No visitors are allowed into the Gold
Room. Vehicular access is by an airlock system. Vehicle drivers are not allowed to leave the vehicle
cab. The doors for vehicle access to the Gold room are electrically powered roller shutter type with
battery backup.

An area for oxy-acetylene gas bottles and welding machine is provided outside the Gold room in “No-
man’s land” and hoses and cables are piped through the wall. A store area is provided in the Gold Room
for storage of artisan tools required for maintenance inside. This removes the need for such items to be
moved in and out of the Gold Room with the inherent security risk.

Except for the supervision of the electro winning cells all other operations are conducted during the day
shift by the specially trained and security screened gold room personnel in the “High-Security” area.
Access during the other two shifts can only be gained with special authorisation and following strict
procedures in the presence of both designated senior management and security official.

Security procedures formulated by the mine management cover all aspects of operating procedures,
screening of authorised personnel and access to the gold room.

The scope of this operating manual covers the following:

 Handling of the gold sludge removed from the electro-winning cell’s cathodes.
 Drying and calcination of the filter cakes Smelting.
 Handling of the gold bullion.

The gold room operators are exposed to a number of potential hazards, as listed below:

 Toxic and corrosive eluant solutions flowing under pressure in pipelines and at high
temperatures, in the electro-winning section.
 Possible evolution of toxic gasses such as ammonia (NH3), SO2, CO etc…
 Danger of explosion from the production of Hydrogen and Oxygen gasses in the electro winning
cells.
 Emissions of high temperature gasses and dust from the oven and furnace.

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 Emissions of Arsenic fumes from the Calcine ovens.

 Molten slag and gold bullion.
 High ambient temperatures in the gold room.

Operators must be aware of these potential hazards, wear the specified PPE and follow the operating
procedures, issued by the management and explained during their training, to the letter.

15.2 SAFETY AND SECURITY PROCEDURES

15.2.1 Cathode Wash and Pressure Filtration Operations

15.2.1.1 PPE Required

 Hard Hat.
 Safety Glasses.
 Rubber Gloves.
 Ear Protection.
 Safety Boots.
 Protective Clothing.

Typical safety signs are shown in the figure below.

Figure 15-1: Cathode Wash PPE signs

WEAR HARD WEAR EYE

WEAR GLOVES
HAT PROTECTION

WEAR
WEAR EAR WEAR SAFETY PROTECTIVE
PROTECTION BOOTS CLOTHING

Fire extinguishers and high pressure hosing water must be available in the event of an emergency. The
operators shall ensure that these are available before starting cathode wash operations.

Any spillages must be cleaned up immediately and thoroughly ensuring that no gold particles are left in
dead areas, on the floor or escaping from the gold room area in any way. The spillage area must then be
hosed down and the water pumped back into circuit.

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15.2.2 Calcine Oven Operation

15.2.2.1 PPE Required

 Hard Hat.
 Safety Glasses.
 Full Face Visor.
 Dust Masks.
 Heat Resistant Gloves.
 Heat Resistant Safety Boots.
 Heat Resistant Overalls.

Work around the Calcine oven is manual in nature, such as loading and unloading the Calcine trays,
cleaning the oven, setting the oven controls and supervising its operation. Fire extinguishers must be
available in the area. No work shall be done to the oven electrical supply system by unauthorised
persons.

Required PPE safety signs for this section are shown in the figure below

Figure 15-2: Calcine Oven PPE signs

WEAR EYE WEAR HEAT

WEAR HARD RESISTANT
PROTECTION WEAR APRON
HAT GLOVES

WEAR HEAT WEAR

WEAR FACE PROTECTIVE WEAR DUST
RESISTANT
VISOR CLOTHING MASK
SAFETY BOOTS

In very rare occasions Mercury can be found in the Gold recovery process. This originates from either
the presence of Cinnabar (HgS) in the ore (Very rare but possible) or from illegal operations. If present,
Mercury would be captured on the cathodes and would report with the gold sludge. It would probably
be visible in the filter cake and the oven trays. Mercury evaporates at low temperatures and is highly
toxic. This paragraph only serves as a warning for operators in the unlikely event of Mercury appearing
in the filter cake trays. If this were to happen then operations must be interrupted immediately and

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management must be notified immediately. Mercury must always be stored under water because some
evaporation takes place even at ambient temperatures.

15.2.3 Smelting Furnace Operation

The smelting furnace operates at temperatures of up to 1 250 o C. Heat-resistant safety clothing must be
worn by the operator when working with molten materials. Aluminised fibreglass cloth garments are
commonly used for heat protection, in addition to the required PPE. Examples of such garments are
shown in the figure below.

A heat resistant apron, face shield and heat resistant gloves shall be worn when operating the Smelting
Furnace.

Whenever looking into the furnace, green shaded filters must be used. Tongs or other tools shall be
preheated prior to using them to touch hot metal. Every precaution shall be taken to prevent water or
wet material from coming into contact with molten metal. Moulds and slag pots must be thoroughly
dried (by heating) before use to ensure that all absorbed moisture has been driven off.

Fire extinguishers must be available in the area. No work shall be done to the furnace whilst in operation
and by unauthorised persons.

Figure 15-3: Furnace Operator Protective Clothing

15.2.4 The additional PPE is listed below

15.2.4.1 PPE Required

 Hard Hat.
 Safety Glasses.
 Full Face Visor.
 Dust Masks.
 Heat Resistant Gloves.
 Heat Resistant Safety Boots.
 Heat Resistant Overalls.
 Heat resistant Apron.

Required PPE safety signs for this section are shown in the figure below.

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Figure 15-4: Smelting Furnace PPE

WEAR EYE WEAR HEAT

WEAR HARD RESISTANT
HAT PROTECTION
GLOVES

WEAR HEAT WEAR

WEAR FACE RESISTANT PROTECTIVE
VISOR SAFETY BOOTS CLOTHING

WEAR DUST
MASK WEAR APRON

15.2.5 Handling of gold bars

Gold bars are sometimes hammered to remove adhering slag causing glass splinters to fly off. The
operator must therefore wear eye protection during the gold bars cleaning up and sampling operations.

Most work around the smelting operation is manual, such as:

 Weighing the fluxes.

 Preparing the charge.
 Inspect condition of the smelting charge.
 Inspect diesel burner’s operation.
 Pouring the molten charge.
 Cleaning the gold bars.
 Visually monitoring and assessing the smelt operation and the equipment.

Warning:

 Do not attempt to dislodge blockages in the crucible during the smelting operation.
 Use non-asbestos heat resistant PPE.
 Watch but do not touch the furnace.

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 Ensure that positive ventilation is switched on in the smelt house prior to firing the furnace
burners.

15.3 TREATMENT OF THE GOLD SLUDGE PRODUCED FROM THE ELECTRO-

WINNING CELLS
15.3.1 Theoretical Background

15.3.1.1 Filter cake handling

Filtration of the gold sludge is essentially a manual operation normally carried out during the day shift.
Gold sludge recovered from the electro-winning cells cathodes is collected in a tank from where it is
pumped at high pressure to a manually operated filter press . The filter cake, retained on filter cloth is
recovered manually from the filter press and loaded onto stainless steel trays. The cakes with moistures
of 8 to 10% by mass have a high consistency. This will avoid splatter from boiling of water in the oven.
The cakes are spread evenly over the area of the tray to provide equal drying over the whole surface.
Great care is exercised in handling the filter cake to avoid any spillage as this material is of smeltable
grade.

15.3.1.2 Drying and calcination

The objective of calcination is to remove moisture, burn off combustible impurities and to oxidize base
metals such as iron, zinc, copper and lead to their oxides in order to obtain a high quality bullion and
clean slag in the subsequent smelting step.

Calcining of the gold loaded steel wool cathodes is achieved at temperatures ranging from 600 to 800
0C. It is essential to feed bone dry material to the furnace. The drying operation therefore needs to be
carried out over a sufficiently long period of time (periods up to 16hrs) to remove any free and bound
moisture. Volatiles such as SO2, CO2 and Arsenic fumes (If any) are driven off at higher temperatures
over a period of time. An oxidizing environment is created by forcing air through the calcine oven during
calcination.

15.3.1.3 Smelting
Gold melts at 1063o C. The smelting operation required to achieve the following objectives:

 Produce molten gold-silver bullion with minimum impurities.

 Produce a fluid slag with minimum entrained bullion prills.

This is achieved by mixing the Calcine with fluxes in the correct proportions to achieve:

 Maximum extraction of impurities such as Iron, Copper, Arsenic, Sulphur, Silica etc… from the
gold bullion.
 Achieve as low a slag melting point as possible by correct flux formulation depending on the
average composition of the Calcine.

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 Achieve lowest possible slag viscosity thus ensuring precise separation between bullion and slag
in the moulds, with minimum capture of gold prills in the slag.
 Low crucible wear.

15.3.2 Fluxes are usually made up of a mixture of the following ingredients:

15.3.2.1 Silica (Sand)

Formula SiO2

Melting Point >1700°C

pH Strongly acidic

Silica combines readily with base metal oxides to form silicates. It can however not be used on its own as
the melting temperature is too high.

15.3.2.2 Soda Ash

Formula Na2CO3

Melting Point 851°C

pH Strongly basic

Soda ash reacts with silica to form sodium meta-silicate and reduces the slag melting temperature whilst
increasing the melt fluidity considerably. It also promotes oxidization and desulphurization. Soda ash
neutralizes the acidic nature of both borax and silica. It does however reduce the metal oxides solubility
of the melt. This can be overcome by using fused Borax.

15.3.2.3 Borax
Formula B2O3

Melting Point 577°C

pH Strongly acidic (Slightly less than Silica).

Borax lowers the slag melting temperature and increases the melt fluidity. It also enhances the capacity
of the slag to react with metal oxides and other impurities.

15.3.2.4 Oxidizing Agent

These are used if incomplete oxidization is achieved in calcination. Manganese dioxide (MnO 2) or
Potassium Nitrate (Nitre) can be used as oxidizing agents in the melt.

Fluxing recipes are not critical as long as the flux melting temperature and viscosity do not result in
excessive capture of gold prills within the slag.

The following recipe is recommended per kg of gold sludge:

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 Borax = 250 g.
 Silica = 125 g
 Soda Ash = 125 g.

Flux requirements vary from operation to operation as a function of the composition of the Calcine and
some adjustments to the above recipe may be necessary to achieve the best smelting conditions.

When the charge is smelted in the furnace at temperatures of ±1250o C two phases form, namely:

15.3.2.5 Bullion
Molten Gold/Silver alloy with some impurities.

The bullion sinks at the bottom of the crucible due to the high density (R.D. 15 to 18) of the noble
metals.

15.3.2.6 Slag
Glass like phase of low density (R.D. ± 3) and low fluidity which floats on top of the bullion.

The following processes take place during the smelting operation:

 Fusion of the Calcine/flux mix.

 Formation of the two phases.
 Oxidation of base metals in the metallic melt.
 Reaction of the base metal oxides (and other impurities) with the slag phase.
 Near complete phase separation based in density.

When the smelting process is completed the furnace is tilted and the melt is poured into moulds as
shown in the figure below.

Figure 15-5: Gold Bullion Pouring Operation

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The heavy metallic phase sinks to the bottom of the moulds whilst the light slag phase floats on top of
the metallic phase. When both phases cool and solidify the glassy slag phase can be easily broken away
from the metallic phase, leaving a relatively pure gold bar.

Gold bars (Doré) are cleaned by hammering to remove any traces of adhering slag, sampled, labeled and
weighed. They are then stored in a safe prior to dispatch to the refinery.

15.3.3 Main Equipment Used

Equipment kw
Description Size/Type Supplier
No
45-DRIL-01 Prill Drill
75.5 6 trays,1000 deg Celc (max)
45-CALO-01 Calcine furnace Auto temperature control

A80/A100/A120 Crucible size

Unduction fce, max temp 1200 deg
45-SMFU-01 Smelting furnace
Celc

45-FAN-01 Smelting furnace fan 100

45-MOLD-01 Bullion moulds 25kg capacity
45-MOLD-02 Slag mould 25kg capacity
45-WEIG-01 Bullion scale 0-50kg , 1.0g accuracy ,
45-WEIG-02 Flux scale 0-1000kg, 1000g accuracy
45-WEIG-03 Prill scale 0-0.5kg, 0.001g accuracy
45-SAFE-01 Bullion safe
45-TABL-01 Bar cleaning table
45-TABL-02 Flux preparation table
45-COTW-01 Furnace Cooling Tower
45-TRLY-01 Slag mould handling trolley
45-TRLY-02 Trolley
45-WASM-01 Wash machine 5.0
45-TDRY-01 Tumble dryer 5.0
45-BOX-01 Flux Storage box

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45-PUMP-01 Smelting furnace closed loop pump

45-PUMP-02 Furnace Cooling Tower Pump
45-TANK-01 Cooling water emergency tank
45-FILT-01 Dust Filter
45-FAN-02 Cooling Tower Fan
U type double column, platform Delta
45-SASH-01 Goldroom safety shower activated c/w hand operated side health &
mounted eyewash. Safety
45-VENT-01 Goldroom ventilation system 15

15.3.4 Operations
The operations in the Gold Room are under the control of the gold room supervisor.

Operations are largely conducted manually and the equipment is started and stopped locally.

Trays loaded with filter cake and redress table concentrates are fitted manually in the Calcine furnace
(45-CALO-01) which is fitted with timer and temperature control system. The furnace is equipped with a
flue to vent hot gases from the oven to the outside of the Gold Room. Compressed air can be injected in
the flue duct to create a “venturi” effect and assist with hot air extraction.

The smelting furnace (45-SMFU-01) is charged manually and started locally. It is fitted with temperature
control and tilting motor. The smelting furnace is covered by a fume hood with flue duct connected to
an extraction fan (45-FAN-01), mounted on the roof. Compressed air can be injected in the flue duct to
create a “venturi” effect and assist with hot gasses extraction.

Furnace cooling is achieved by circuilating cold water through the furnace jacket and out to the cooling
tower before being pumped back to the furnace.

Top loading electronic scales are used for weighing the gold bars (45-WEIG-01) and for flux formulation
(45-WEIG-02). An analytical electronic scale (45-WEIG-03) is used for weighing gold samples extracted
from the gold bars by means of an electric drill.

Fresh air is forced through the gold room by the action of a ventilation fan (45-VENT-01).

15.3.5 Calcination furnace operating procedures

Refer to vendor operating manuals filed in Appendix

Filtered cathode sludge is collected on the Calcine oven trays, dried and calcined, usually overnight
before smelting the following day.

The procedure is as follows

 Weigh an empty dry and clean tray.

 Spread the cathode sludge evenly onto the trays.
 Weigh and record the wet mass of each loaded tray.

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 Load the trays into the furnace and set the controls as described in the start-up procedures in
table 1 below:
 At the end of the operation unload each tray and allow cooling to ambient temperature.
 Weigh and record the mass of each tray loaded with Calcine.
 Empty the tray and weigh and record the mass of each empty tray.
 Calculate and record the mass of Calcine to enable the correct mass of flux to be added.

15.3.5.1 Calcine Furnace Operating Procedures.

STEP ACTIONS NOTES

1 CHECK personal protective equipment Minimum required as per section 15.3.5 above.

2 All tags have been removed after any

ENSURE all personnel are clear of the equipment.
maintenance activity.
3 SWITCH on the Calcine furnace extraction fan 45-FAN-01

4 TURN OFF the main switch the trays are being

loaded:

LOAD the trays into the drying oven:

DO NOT overload trays because

complete drying and oxidization may
not take effect

6 CLOSE the furnace door and secure the latches.

7 TURN ON the main switch

8 SET the TIMER for the required drying time 4 -6 hours.

9 SET the DRYING temperature 105-120 degrees Celsius.

10 SET the TIMER for the required calcination time 4 -6 hours.

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STEP ACTIONS NOTES

11 SET the CALCINATION temperature 600-800 degrees Celsius.

Power will switch off automatically after the set

12
period of time.
o
Allow cooling to temperature of 50 C before
13
opening the furnace and remove the trays.

15.3.5.2 Operator Check List

ITEM FREQUENCY KEY ISSUE ACTION

Internal surfaces/ After each batch of

Check for damage Inform Maintenance as required
elements drying
Ensure correct drying &
Drying & Calcination Start of drying each
calcination temperatures and Check oven controller
time and temperature batch
time
Start of drying each Ensure oven fume removal fan is
Fume extraction Oven fume removal
batch operating when furnace on

15.3.6 Smelting furnace operating procedures

Refer to vendor operating manuals filed in Appendix

Calcine is mixed with fluxes in the following proportions:

 Calcine = 1000 g.
 Borax = 250 g.
 Silica = 125 g
 Soda Ash = 125 g.

The mix is carefully placed into the smelting furnace crucible to avoid any losses of high-grade dust.
Operating procedures are described in Table 3 below.

15.3.7 Smelting Furnace Operating Procedures

STEP ACTIONS NOTES

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STEP ACTIONS NOTES

1 CHECK PPE. Minimum required as per section 15.3.6 above.

New crucibles should be dried in a calcining oven

overnight to ensure any moisture is slowly driven off.
2 Pre-treat the crucibles. The rapid heating rate of the furnace can cause crucibles
to crack or explode

Start the smelting furnace cooling system

and open raw water to cooling tower 45-PUMP-01 ,45-PUMP-02 & 45-FAN-02
supply
3 START the smelting furnace and gold room 45-FAN-01 & 45-VENT-01
ventilation fans.
Place all the moulds that will be used for the pour
4 around the perimeter of the furnace lid – this will ensure
Drying of moulds.
there is no moisture in the moulds.

The furnace will need to run for approximately 4 hours

5 Smelt duration time.
to complete the gold smelt.

Prior to pouring the gold remove the moulds and set

6 Arrange moulds.
them up in the correct cascade sequence.

When the crucible load has melted switch

7
the Furnace switch to OFF.

PRESS the START TILT button.

The furnace will slowly tilt as long as the TILT button is

pressed down.
8

The melt should be poured into the moulds at a

9 Pouring the melt
continuous rate that does not cause splashing.

Continue tilting the furnace until all the contents are

10 Empty furnace.
removed.

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STEP ACTIONS NOTES

11 RETURN the furnace to the lower position By pressing the LOWER button.

ALLOW the furnace to cool for 15 minutes before

12 SWITCH the main switch OFF
TURNING OFF the cooling system.

When the gold bars have solidified the moulds are

13 Emptying the moulds. turned over (upside down) on the steel floor and the
gold bars are freed from the slag.

Gold bars are then picked up with tongs and placed on

14 Collection of gold bars
the bar cleaning table.

When the gold bars have cooled down REMOVE any

16 Cleaning of gold bars
remaining slag.

17 STOP the smelting furnace extraction fan.

18 INSPECT furnace for damage prior to next

smelt.

15.3.8 Operator Check List

ITEM FREQUENCY KEY ISSUE ACTION

Before Check moulds are clean and Clean moulds with a wire brush and dry by placing
Moulds
pouring contain no moisture next to the furnace during the heating cycle
Flux reagents erode the Monitor erosion then set up a regular crucible change
After each
Crucible crucible and reduce its out schedule to ensure crucibles do not crack and spill
smelt
thickness molten metal in the furnace
When slag no longer sticks to steel stirring rod and
Smelt Hourly during Stir melt, check
temperature is at least 1,250°C (approx 4 hours)
progress heat up temperature
pouring can take place.
Weights of
fluxes, dry
Record all weights in the
sludge, gold Each smelt Submit copies of weights to Plant Superintendent
Gold Room log book
bars,
samples

15.3.9 Handling of gold bars

Each gold bar is carefully cleaned from any trace of slag by means of hammer and wire brush.

A sample is extracted using an electric drill.

The clean bar is stamped with its identification label, weighed on the bullion scale and stored in the safe.

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15.3.10 Handling of slag

Slags contain small droplets of bullion (prills) and require re-treatment. All slag particles are carefully
collected and transported manually to the mill feed hopper.

15.4 INSTRUMENTATION AND AUTOMATIC CONTROLS

The operations are essentially done manually but incorporate a few alarms and interlocks

15.4.1 Automatic operations:

The calcine furnace (45-CALO-01) and smelting furnaces (45-SMFU-01) will be equipped with vendor
supplied temperature control systems.

15.4.1.1 Alarms
 Safety shower flow alarm.

15.4.1.2 Interlocks
 Calcine furnace door switch must be healthy before the furnace can be switched on.
 Ventilation fan (45-FAN-01) must be running before the gold room furnaces can be switched on.

15.4.1.3 Scada display

15.5 APPENDICES
 GOLD ROOM PFD FD 4500 Rev. 05
 GOLD ROOM P&ID PD 4510 Rev. 03
 CALCINE FURNACE VENDOR O & M MANUALS.
 SMELTING FURNACE VENDOR O & M MANUALS
 FURNACE COOLING SYSTEM VENDOR O & M MANUAL
 WASH MACHINE & TUMBLE DRYER O & M MANUALS

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16. SERVICES
16.1 INTRODUCTION
Read in conjunction with SERVICES PFD FD 5500 Rev. 05 (See Appendices).

This section deals with the handling of Diesel fuel used mainly in the firing of:

 the elution heat exchanger heaters,

 the carbon regeneration kiln,
 the assay laboratory.

And the production and distribution of compressed air which is used mainly for injection into the CIL
tanks. The purpose is to provide dissolved oxygen essential in the gold dissolution reaction. Compressed
air is also used on the detox section in combination with sodium metabisulphite in the oxidation of
cyanide.

16.2 DIESEL
16.2.1 Safety
Normal precautions shall be taken for handling of diesel. Cleaning of spills must be done with sand.
Diesel must never be fed to the CIL process as is prevents gold attachment to activated carbon.

16.2.1.1 PPE Required

 Hard Hat
 Safety Boots (rubber)
 Safety Glasses (Chemical)
 Leather Work Gloves
 Dust Masks.
 Hi Visibility Safety Vests or Jackets
 Approved respirator
 Rubber rain suit
 Face shield

16.2.2 Introduction
Diesel is common fuel for heavy vehicles. It is flammable and the vapour is explosive. Do not inhale the
vapours. Use in well ventilated areas. In poorly ventilated areas, mechanical explosion proof extraction
ventilation is recommended.

16.2.3 Instructions
Prior to working around diesel fuel, know the location of the nearest emergency shower and eyewash
station.

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16.2.4 Health Hazards

Eye Contact: Unlikely to cause more than transient stinging or redness if accidental eye contact occurs.

Skin Contact: Unlikely to cause harm to the skin on brief or occasional contact but prolonged or
repeated exposure may lead to dermatitis. This material contains significant quantities of polycyclic
aromatic hydrocarbons (PAHs), some of which have been shown by experimental studies to induce skin
cancer.

Inhalation: Inhalation may cause irritation to eyes, nose and throat due to exposure to high
concentrations of vapour, mists or fumes.

Ingestion: Unlikely to cause harm if accidentally swallowed in small doses, though larger quantities may
cause nausea and diarrhoea.

Hazard summary: Toxic. Use safe work practices to avoid eye-skin contact and vapour inhalation. Due to
the use of strict engineering controls when dispensing fuel (i.e. bowsers), the adverse health effects
outlined above are not anticipated.

16.2.4.1 First aid

Eye Contact: Flush with running water, holding eyelids open for 15 minutes. Obtain immediate medical
attention.

Skin Contact: Gently flush affected area with soap and water. Seek medical attention if irritation
develops.

Inhalation: If over exposure occurs, leave exposure area immediately. If other than minor symptoms are
displayed, seek immediate medical attention.

Ingestion: Seek prompt medical attention.

16.2.4.2 Safe handling and use

Spills: If spilt (bulk), contact emergency services. Wear protective equipment. Ventilate and clear area of
all unprotected personnel. Eliminate heat and ignition sources, absorb spill with sand or similar and
place in sealable containers for disposal. Prevent spill entering drains or waterways. Only trained
emergency personnel should undertake cleanup.

Equipment kw
Description Size/Type Supplier
No
55-TANK-01 Diesel tank 14m3 Diesel Tank
55-PUMP-01 Diesel Pump 2.2
55-TANK-02 Elution/Regen Diesel Header tank
55-TANK-03 Laboratory diesel header tank 4.5m3 Diesel tank
55-FILT-01 Diesel filter

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16.3 PLANT DESCRIPTION

16.3.1 Diesel
Diesel will be delivered on site by road tankers and offloaded into two diesel tanks on the mine (55-
TANK-01) which supplies the elution and regeneration header tank (55-TANK-02). Diesel is pumped from
diesel tank (55-TANK-01) by pump 55-PUMP-01 to the elution and regeneration header tank (55-TANK-
02). Overflow from the elution and regeneration header tank gravitates back to the diesel tank (55-
TANK-01). Diesel supply to elution and regeneration is through an offtake to each area from the base of
the header tank and is ensured by opening a 25mm valve on a line to each area. Excess diesel from both
elution heaters and regeneration kiln flows back to the diesel tank (55-TANK-01). The tanker also
offloads into the dedicated laboratory diesel header tank (55-TANK-03).

16.3.1.1 Controls
Read in conjunction with SERVICES-DIESEL P&ID PD 5510 Rev. 03. (See Appendices).

The diesel tank (55-TANK-01), Elution/regeneration header tank (55-TANK-02) and the laboratory
header tank (55-TANK-03) are fitted with sight glasses (SG) for visual level assessment of the individual
tanks.

Diesel flowrate to the diesel tank (55-TANK-01) and laboratory header tank (55-TANK-03) is measured
and totallised by use of flow transmitters (55-FT-01 for the diesel tank and 55-FT-02 for the laboratory
header tank).

Level in the diesel tank (55-TANK-01) will be measured by the ultrasonic level transmitter (55-LT-01) and
the diesel level will be maintained by opening the level control valve (55-V-01) at low level and closing it
at high level.

Level in the diesel header tank (55-TANK-02) will be measured by the ultrasonic level transmitter (55-LT-
02) and the diesel level will be maintained by starting diesel pump (55-PUMP-01) at low level and
stopping it at high level.

Level in the lab diesel tank (55-TANK-03) will be measured by the ultrasonic level transmitter (55-LT-03)
and the diesel level will be maintained by opening the level control valve (55-V-11) at low level and
closing it at high level. A simplified P&ID is shown in figure below:

Figure 16-1: Diesel Reticulation and Controls

16.3.1.2 Interlocks
 Diesel pump (55-PUMP-01) will be stopped on:
o Diesel tank (55-TANK-01) low level alarm (55-LALL-01)

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o Elution/Regeneration header tank (55-TANK-02) full (55-LAHH-02).

16.3.1.3 SCADA Display

16.4 COMPRESSED AIR

16.4.1 Compressed air services
The air services provide compressed air to the LEACH tanks, milling area , Detox section & other areas
that require compressed air. In addition, instrument air is provided to pneumatically control valves and
instruments.

16.4.2 Compressed Air Safety

General plant safety procedures must be followed in this section. Specific safety requirements are
included in the vendor operating manual supplied with the equipment. The safety instructions given
below should be read in conjunction with the vendor operating manual.

 The compressors should not be operated with protective guards fitted.

 Never breath in compressed air from the compressors
 The compressors should never be operated with open doors or loose access panels
 Compressors generally have hot surfaces so precaution against hot surfaces should be taken
 The whole compressed air system is pressurized including piping so should be treated as
pressure vessels
 Compressors can start up automatically from idle mode so even if stationery, they should be
treated as if they are running
 Safety valves must be checked and satisfied by a qualified person before the compressor can be
put into use
 Where hoses are to be used, use only the specified hoses
 Only use recommended hose couplings and fittings
 Before blowing air through a hose make sure the open end is positively secured
 Never aim compressed air at your/ another person’s skin or eyes
 Never use compressed air to clean your clothes
 Always read and follow the prescribed safety measures before performing any function with the
compressors
 Depressurise all system sections and pressure pipes in accordance with specific instructions
before carrying out any work on the compressors

Air Services Major Equipment

Equipment kw
Description Size/Type Supplier
No
230 L200, Rotary Screw Comnpressor,
56-COMP-01 Compressor 1 CompAir
2196m3/h, 750Kpa
56-COMP-02 Compressor 2 230 L200, Rotary Screw Comnpressor, CompAir

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2196m3/h, 750Kpa
230 L200, Rotary Screw Comnpressor,
56-COMP-03 Compressor 3 CompAir
2196m3/h, 750Kpa
56-FILT-01 Air Filter 1 CompAir
56-FILT-02 Air Filter 2 CompAir
3.85m3, 750KPa, with pressure
56-RECV-01 Leach Plant air Receiver CompAir
gauge, Air relief valve & autodrain
3.85m3, 750KPa, with pressure
56-RECV-02 Leach Plant air Receiver CompAir
gauge, Air relief valve & autodrain
3.85m3, 750KPa, with pressure
56-RECV-03 Leach Plant air Receiver CompAir
gauge, Air relief valve & autodrain
L22A/S Rotary Screw Compressor,
56-COMP-04 Instruments Compressor CompAir
207.6m3/h, 750KPa
3.85m3, 750KPa, with pressure
56-RECV-04 Leach Plant air Receiver CompAir
gauge, Air relief valve & autodrain
56-ADRY-01
56-FILT-03 Air Filter 3 CompAir
56-FILT-04 Air Filter 4 CompAir
56-FILT-05 Air Filter 5 CompAir
56-FILT-06 Air Filter 6 CompAir

16.4.3 Plant Air process description

A total of 4 compressors will be situated inside the plant area. Three of the compressors (56-COMP-
01/2/3) will be dedicated to supplying plant air while the fourth compressor (56-COMP-04) will be
dedicated to instruments air supply. An offtake is available on the Plant air header to the instruments air
dryer (56-ADRY-01) which ensures continued instruments air supply even with a problem on the
instruments air compressor. Two of the three plant air units will run with the other compressor on
standby. The compressors will be sized to be capable of delivering ± 2196 Nm³/h of air each. Four air
receivers are provided for Leach Plant air (56-RECV-01), Detox Air (56-RECV-02) and General Plant Air
(56-RECV-03) and Instrument Air (56-RECV-04).

16.4.3.1 Controls:
Read in conjunction with SERVICES-AIR P&ID PD 5610 Rev. 03

The controls in this section come with the equipment and mainly apply to safety so as not to exceed the
design pressures, which might otherwise damage equipment and personnel. In certain instances
operator intervention is required as outlined below.

The compressors are controlled by their own internal control system which monitors system pressure,
compressor oil level and temperature. These will start and stop automatically depending on the system
pressure as recorded by the pressure transmitter.

Each air receiver is fitted with pressure gauge for pressure indication, safety relief valve which blows off
if pressure of 750 kPa is exceeded and a manual condensate drain valve for the removal of water. The
section operator has to ensure that the receivers are drained of water on a daily basis.

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The air drier (56-ADRY-01) will refrigerate the compressed air required for automated valves to a
specified dew point and causes any water vapour to condense, drying the air delivered by the
Instrument air compressor (56-COMP-04) to process instruments. The condensate will be discharged
from the air drier and air filters (56-FILT-01/2/3/4/5/6) periodically by an automatic condensate drain
valve. Air filters (56-FILT-01/2/3/4/5/6) will remove any fine particulate contamination that may affect
the actuators.

The compressors (56-COMP-01/2/3) will have an automatic controller, which senses the system
pressure and starts and stops the unit when required which will be part of the Vendor package. This
controller alternates between the two compressors and will start both compressors when the system
pressure requires it. The operator should only need to restart the machine after shutdown.

The air receivers (56-RECV-01/2/3) will be fitted with an automatic condensate drain valve that drains
any accumulated moisture from the vessel as well as a pressure gauge and pressure relief valve to
prevent overpressure in the receivers.

The pressure switch (56-PSL-11/12) will alarm on low pressure on the General Plant air system and
Instrument Air system respectively. Maintenance must include checking for air leaks.

A simplified P&ID is shown in the figure below

Figure 16-2: Compressed air Reticulation and Controls

16.4.4 Plant Air Start Up

 Check oil level in the compressor reservoir
 Check all protection equipment is installed, and in good working order
 Select the duty compressor 56-COMP-01, 56-COMP-02 or 56-COMP-03 and 56-COMP-04
 Check and clear the air passage to the Plant air receivers by opening the relevant valves
including valves on the selected filters to be used. Ensure valves on the standby filter are closed.
 Check and ensure that the condensate drain valves (PD5610-V-16/23/29 and PD5620-V-17) on
the air receivers are closed
 Compressors are operated in the automatic mode.
 Start the duty compressors
 START the instrument air dryer (56-ADRY-01) as per vendor start up procedures

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 Allow the pressure to build up to design pressure

16.5 APPENDICES
 SERVICES PFD FD 5500, 5600 Rev. 05
 SERVICES-DIESEL P&ID PD 5510 Rev. 03
 SERVICES-AIR P&ID PD 5510, 5520 Rev. 03
 SERVICES-AIR P&ID PD 5520 Rev. 03
 COMPRESSORS O & M MANUAL

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17. WATER CIRCUITS

17.1 INTRODUCTION
Water circuits are designed to optimise the usage of water in the various sections of the plant.

The following objectives must be met by a successful water circuit design:

 Optimisation of water utilisation

 Optimisation of reagents utilisation
 Optimisation of water reticulation equipment

Raw water is pumped from the water supply boreholes through two staging tanks to a staging pond
where it combines with water coming from the dewatering boreholes. The combined raw water supply
is then pumped to the raw water pond from where it is used as make-up to the process water circuit as
well as in all operations requiring clean uncontaminated water, such as reagents make-up, Fire water,
mill cooling, Gland water, ablutions etc…

Raw water is treated in a water purification plant to produce potable water for use in the offices,
ablution bloc and for supply of clean treated water to the safety showers and drinking water stations.

Raw water consumption is reduced by recycling the preleach thickener overflow, tailings thickener
overflow and slimes dam decant waters. These streams are collected in a process water Pond.

Water Services Major Equipment : Dewatering Water Supply

Equipment kw
Description Size/Type Supplier
No
63-POND-01
63-PUMP-01 Dewatering Transfer Pump 1 30
63-PUMP-02 Dewatering Transfer Pump 2 30
63-PUMP-03 Dewatering Transfer Pump 3 30
63-PUMP-04 Dewatering Transfer Pump 4 22
63-PUMP-05 Dewatering Transfer Pump 5 22
63-PUMP-06 Dewatering Transfer Pump 6 22
63-PUMP-07 Dewatering Transfer Pump 7 22
63-PUMP-08 Dewatering Transfer Pump 8 22
63-PUMP-09 Dewatering Transfer Pump 9 22
63-PUMP-10 Dewatering Transfer Pump 10 22
63-PUMP-11 Dewatering Transfer Pump 11 22
63-PUMP-12 Dewatering Transfer Pump 12 22
63-PUMP-01 Dewatering Transfer Pump 1 22
63-PUMP-01 Dewatering Transfer Pump 1 22
63-PUMP-01 Dewatering Transfer Pump 1 22
BOREHOLE
64-POND-01 Borehole water staging pond 1

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64-PUMP-01 Borehole water transfer pump 1 55

64-PUMP-02 Borehole water transfer pump 2 55
64-PUMP-03 Borehole water pump 1 22
64-PUMP-04 Borehole water pump 1 18.5
64-PUMP-05 Borehole water pump 1 18.5
64-PUMP-06 Borehole water pump 1 22
64-PUMP-07 Borehole water pump 1 30
64-PUMP-08 Borehole water pump 1 30
64-PUMP-09 Borehole water pump 1 18.5
64-POND-02 Borehole water staging pond 2
64-PUMP-10 Borehole transfer pump 4 75

Process Water

Equipment kw
Description Size/Type Supplier
No
2000m3, Pond with 45 deg wall,
61-POND-01 Process Water Pond (Thickener Overflow)
Lined, 41.3mL, 30mW, 4.4mH
348.2m3, Pond with 45 deg wall,
61-POND-02 Process water silt trap
Lined, 11.6mL, 30mW, 1.5mH
61-PUMP-01 Process water pump 1 110
61-PUMP-02 Process water pump 2 110
61-PUMP-03 Spray water pump 1 30
61-PUMP-04 Spray water pump 2 30
61-PUMP-05 Hosing water pump 22

17.2 PLANT DESCRIPTION

Read in conjunction with WATER STORAGE PFD: FD 6100, 6200, 6300, 6400 Rev.05 and WATER SUPPLY

17.2.1 Raw Water Circuit

Borehole water is pumped from the water supply boreholes using (64-PUMP-03/4/5/6/7/8/9). Water
from borehole pumps (64-PUMP-06/7/8/9) is directed to a staging tank (64-TANK-02) from where it is
pumped to Staging tank 1 (64-TANK-01) using the borehole transfer pump (64-PUMP-10). Water from
borehole pumps (64-PUMP-03/4/5) is pumped directly into staging tank 1 (64-TANK-01) from the
combined borehole water is pumped by Borehole water transfer pump (64-PUMP-01/2) to a Dewatering
staging pond (63-POND-01) combining with streams from the 10 dewatering boreholes (63-PUMP-03 to
63-PUMP-12). Dewatering transfer pump (63-PUMP-01/2) is then used to pump water from the
dewatering staging pond to the raw water pond (62-POND 01) which is fitted with an overflow from
where the excess water flows into the process water pond (61-POND-01). Five pumps are installed to
draw water from the raw water pond with 3 pumps (62-PUMP-09/10/11) dedicated to the fire
reticulation water system and the other 2 pumps (62-PUMP-07/8) for supplying water for dust
suppression, interstage screen wash section, cathode wash, hosing water, smelting furnace cooling

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tower, reagents, carbon transfer, and process water pond makeup and supply water to the gland water
where the potable water treatment plant (62-WATP-01) facility draws feed from. Two pumps (62-PUMP-
12/13) with one running at a time and the other on standby, draw water from the gland water tank and
supply gland water to milling, preleach, Detoxification, Tailings and Lime areas of the plant.

Equipment kw
Description Size/Type Supplier
No
4000m3, Pond with 45deg angle,
62-POND-01 Raw water pond
Lined, 41.3mL, 30mW, 4.4mH
62-PUMP-07 Raw water pump 1 75
62-PUMP-08 Raw water pump 2 75
62-PUMP-09 Fire water pump 1 90
62-PUMP-10 Fire water pump 2 Diesel powered
62-PUMP-11 Fire water jockey pump 2.2
62-FHYD-01 Fire hydrant 1
62-FHYD-02 Fire hydrant 2
62-FHYD-03 Fire hydrant 3
62-FHYD-04 Fire hydrant 4
62-FHYD-05 Fire hydrant 5
62-FHYD-06 Fire hydrant 6
62-FHYD-07 Fire hydrant 7
62-FHYD-08 Fire hydrant 8
62-FHYD-09 Fire hydrant 9
62-FOAM-01 Foam canon (Diesel storage area)
62-TANK-01 Gland water tank
62-PUMP-12 Gland water pump 1 11
62-PUMP-13 Gland water pump 2 7.5
62-FILT-01 Gland water filter 1
62-FILT-02 Gland water filter 2
62-WATP-01 Water treatment plant 5
62-TANK-02 Portable water storage tank
62-PUMP-14 Portable water pump 1 5.5
62-PUMP-15 Portable water pump 2 5.5
62-TANK-03 Hydrosphere portable water control
62-TANK-04 Safety water Tank

17.2.1.1 Controls
Read in conjunction with RAW WATER P&ID PD 6210 Rev. 03.

Raw and process water distributions are equipped with minimum level of instrumentation to achieve the
following

 Protect the pumps against running dry

 Ensuring there is sufficient level in the tanks and to give an indication to the operator on the
state of water supply to both raw and process water tanks and make corrective action on time
to avoid interruptions to the process

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The raw water tank (62-POND-01) is equipped with an ultrasonic level transmitter (62-LT-01) used with
the level control valve (62-LV-01) to maintain the level in the pond. The signal from this will be used to
start and stop the transfer pump (63-PUMP-01/2) in field to top up water in the tank as and when
required. Low & high level alarms will activate an audible siren for the operator to take action. In the
event that no such action is taken (low-low level alarm) after a set period (to be agreed) and process
water tank level is low it will stop the ore feed to the SAG mill.

Raw water pumps will stop and start from the SCADA as and when required.

A fire water reserve in the raw water pond will ensure enough fire water at all times.

A simplified P&ID is shown in the figure below to illustrate the raw water circuit controls described
above.

Figure 17-1: Raw Water Circuit Controls

17.2.1.2 Interlocks
 Raw water pumps (62-PUMP-07/8) will be stopped on raw water pond (62-POND-01) low level
(62-LALL-01).
 Fire water pumps (62-PUMP-09/10 will stop on high high pressure (62-PAHH-01) in the
reticulation system and restart on low pressure (62-PALL-01).
 Fire water jockey pump (62-PUMP-11) will stop on high pressure (62-PAH-01) in the reticulation
system and restart on low pressure (62-PALL-01).
 Dewatering borehole pump (63-PUMP-03/4/5/6/7/8/9/10/11) will stop on:
o Low flow (63-FAL-01/2/3/4/5/6/7/8/9) in the delivery line of the individual borehole.
o When the dewatering staging pond (63-POND-01) is full (63-LAHH-01)
 Dewatering transfer pump (63-PUMP-01/2) will stop on:
o Dewatering transfer pond (63-POND-01) level low (63-LALL-01)
o Raw water pond (62-POND-01) level high (62-LAHH-01)
 Borehole water pump (64-PUMP-03/4/5) will stop on:
o Low flow (64-FAL-01/2/3) on the delivery line of the individual borehole.
o When borehole water staging pond (64-POND-01) is full (64-LAHH-01)
 Borehole water transfer water pump (64-PUMP-01/2) will stop on:
o Low borehole water transfer pond level (64-LALL-01)
o When dewatering staging pond is full (63-LAHH-01)
 Borehole transfer water pump (64-PUMP-10) will stop on :
o Low level (64-LALL-02) in the borehole water staging pond 2 (64-POND-02)
o When the borehole water staging pond 1 (64-POND-01) is full (64-LAHH-01)
 Borehole water pumps 1-4 will stop on:
o Low flow in the delivery line of the individual borehole
o When the borehole staging pond 2 (64-POND-02) is full (64-LAHH-02)

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17.2.2 SCADA Display

Figure 17-2: Typical Raw Water SCADA Display

17.2.3 Process Water Circuit

The process water pond (61-POND-01) is fed, via the process water silt trap (61-POND-02), with recycled
contaminated water from the preleach thickener and tailings thickener overflow and slimes dam decant
water pond. Make up water overflows from the raw water pond (62-POND-01). There is provision to
pump water from the raw water pump to the process water pond using raw water pumps (62-PUMP-
07/8). Water from the dewatering transfer pumps can also be directed the process water pond by
manipulation of relevant valve (Closing valve PID6210-200-V-46 and opening PID6210-200-V-47).

Process water is used mainly in the milling, preleach and tailings thickeners, and detoxification circuit
and as service water for flushing, hosing and spraying applications where decontaminated water is not
required.

Five pumps (61-PUMP-01/2/3/4/5) draw water from the process water pond through a common
manifold connected to the process water pond (61-POND-01). Two of these pumps (61-PUMP-01/2)
supply the process water requirements to milling, detoxification, preleach &tailings thickening while
pumps (61-PUMP-03/4) are spray water pumps and pump (61-PUMP-05) supplies hosing water.

17.2.3.1 Controls
Refer to PROCESS WATER P&ID PD 6110 Rev. 03

An ultrasonic level transmitter (61-LT-01) will be installed in the process water pond (61-POND-01). The
signal from this will be used to open and or close the raw water top up air actuated valve (62-LV-01) as
and when required. Low (61-LAL-01) & high level (61-LAH-01) alarms will activate an audible siren for
the operator to take action. In the event that no such action is taken (low-low level alarm) after a set
period (to be agreed) it will stop the ore feed to the SAG mill (21-MILL-01).

Actuated valves on the suction and discharge of the process water pumps (61-PUMP-01/2) enable easy
selection of the standby and duty pumps from SCADA.

17.2.3.2 Interlocks
 Process water spillage pump (61-PUMP-06) stops on low level in the sump (61-LSL-02)
 All pumps drawing water from the process water pond (61-PUMP-01/2/3/4/5) will stop on low
process water pond level (61-LALL-01).

Figure 17-3: Typical Process Water SCADA Display.

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17.2.4 Potable Water Circuit

Refer to POTABLE WATER P&ID PD 6220 Rev. 03. Vendor O & M Manuals, in Appendix

Raw water is treated in the potable water treatment plant (62-WATP-01) from where it is pumped to the
potable water storage tank (62-TANK-02). Potable water distribution is by means of pumps (62-PUMP-
14/15) and a hydrosphere/balloon pump (63-TANK-03) to maintain the required pressure in the line. A
standpipe (62-STPP-01) will ensure that safety shower water is available during a power failure. The
portable water is distributed to all safety showers in the plant

The potable water tank (61-TANK-02) will be equipped with an ultrasonic level transmitter (62-LT-03)
that will be used together with the potable water treatment plant (62-WATP-01) control system to
maintain the level in the tank, stopping the water treatment plant when the portable water tank is full
and starting it when the tank is empty (62-LALL-03).

Pressure in the potable water lines will be maintained by the hydrosphere (62-TANK-03) operation. The
hydrosphere will reduce the continuous stop and starting of the potable water pumps. The potable
water pumps (62-PUMP-14/15) will be automatically stopped and started from the high and low
pressure alarms from the pressure switch (62-PSH/L-06) on the hydrosphere (62-TANK-03).

17.2.4.1 Controls

Figure 17-4: Portable Water Circuit Controls.

17.2.5 SCADA Display

17.2.5.1 Interlocks
 Portable water pumps (62-PUMP-14/15) will stop on low level (62-LALL-03) in the portable
water tank (62-TANK-02).
 Portable water pumps (62-PUMP-14/15) will stop on high pressure (62-PAH-06) and start on low
pressure (62-PAL-06) in the hydrosphere.
 Water treatment plant (62-WATP-01) will stop on high level (62-LAH-03) and start on low level
(62-LALL-03) in the portable water tank.

Figure 17-5: Typical Potable Water SCADA Display.

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17.2.6 Gland Water

Refer to Gland and Portable Water P &ID PD 6210.

The gland water tank (62-TANK- 01) is fed from the raw water pond by raw water pumps (62-PUMP-
07/8). The portable water plant is fed from this tank (62-TANK-01) by opening valve manual valve
(PID6220—50-V-33). Two gland water pumps (62-PUMP-12/13), are installed to pump and distribute
gland water to slurry pumps in milling, preleach and tailings thickeners, cyanide preparation, Lime and
detoxification.

17.2.6.1 Controls
An ultrasonic level transmitter (62-LT-02) will be installed in the gland water tank (62-TANK-01). The
signal from this will be used to open and or close the raw water top up air actuated valve (62-LV-02) as
and when required.

A pressure gauge (62-PI-07) is installed on the gland service line after the filters for local indication of
gland water pressure.

A filter (62-FILT-01/2) is installed on each gland water pump discharge to remove any particulates from
the gland water. A pressure switch on the filter unit (62-PSL-02/3) is mused to stop the duty gland
service pump (62-PUMP-12/13) on low pressure (62-PAL-02/03) in the line after the filter which may
indicate that the filter is clogged. The standby pump is started while the dirty unit is cleaned.

17.2.6.2 Interlocks
 Gland water pumps (62-PUMP-12/13) will stop on low level (62-LALL-02) in the gland water tank
(62-TANK-01)
 Gland water pump (62-PUMP-12/13) will stop on low pressure water pressure (62-PAL-02/03)
 Selected duty gland water (62-PUMP-12/13) will only start or run if the suction and delivery
valve are open while the suction and delivery valve for the standby pump are both closed.

Figure 17-6: Typical Gland Water SCADA Display.

17.2.7 Fire Water

Read in conjunction with raw water P&ID PD6210 and Fire water reticulation P&ID PD6211.

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The fire water system consists of two electric pumps (duty and standby) (62-PUMP-09 & 11) and a diesel
pump (62-PUMP-10). The diesel fire water pump (62-PUMP-10) is only used in the event of a fire that
would have affected power supply to the plant; where the electric fire water pump cannot be used.

A Bleed line is installed on the common pump delivery with a pressure regulating valve (PID6210-100-V-
44) allows some recycle back into the raw water pond when there is excess pressure in the fire water
system. The pressure transmitter (62-PT-01) measures the pressure in the fire line and this is used to
start and stop the duty fire water pump as necessary.

17.2.7.1 Interlocks
 Fire water pumps (62-PUMP-09/10 will stop on high high pressure (62-PAHH-01) in the
reticulation system and restart on low pressure (62-PALL-01).
 Fire water jockey pump (62-PUMP-11) will stop on high pressure (62-PAH-01) in the reticulation
system and restart on low pressure (62-PALL-01).

17.3 EQUIPMENT LIST

17.4 APPENDICES
 Vendor O & M Manuals.
 WATER SUPPLY PFD: FD 6200, 6300 Rev.05
 RAW WATER P&ID PD 6210 Rev. 03
 PROCESS WATER P&ID PD 6110 Rev. 03

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18. REAGENTS
18.1 INTRODUCTION
This section deals with all aspects of reagents handling, from storage to preparation and dosing in the
various sections of the plant. Reagents used in the gold recovery process include extremely toxic and
potentially lethal substances such as cyanide as well as other harmful chemicals in the form of dusts,
gasses or liquids.

The work place is however totally safe if the operating procedures are strictly adhered to.

Hazards and emergency procedures as well as standard operating procedures are described in detail in
the following paragraphs of this document.

The reagents currently used in the plant are as follows:

 Burnt lime or quicklime (CaO).

 Hydrochloric acid (HCl).
 Caustic soda (NaOH).
 Sodium Cyanide (NaCN).
 Flocculant
 Fluxes (SiO2, NaCO3, Borax)
 Sodium Metabisulphite (Na2S2O5)
 Copper Sulphate (Cu2SO4)

Reagents are prepared in different locations of the plant and their handling has already been described
in other sections. Any operating procedure already described in other sections of the operating manual
are however repeated in this section.

Other reagents such as:

 Viscosity modifiers.
 Anti-scaling.
 De-scaling.

Etc... May be used at a later stage and can be added to this document.

18.2 SUMMARY DESCRIPTION

Reagents are delivered to site by road transport in bulk packaging and are offloaded from the trucks in
the offloading area where each delivery is checked and cleared. Each shipment is then transferred to
the relevant in plant store through the security gates. Reagents are safely stored under cover in secure
and well ventilated areas protected from the elements and direct sun light.

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Cyanide is stored separately in an enclosed and restricted area adjacent to the caustic soda and
flocculant store. Acid is stored at a distance to avoid any acid spill reaching the cyanide storage area. The
operating procedures for each reagent are described in detail in the following paragraphs:

18.3 REAGENTS HANDLING OPERATING PROCEDURES

Paragraph 18.4.1: Hydrochloric Acid.

Paragraph 18.4.2: Lime.

Paragraph 18.4.3: Caustic Soda.

Paragraph 18.4.4: Cyanide.

Paragraph 18.4.5: Flocculant.

Paragraph 18.4.6: Copper Sulphate

Paragraph 18.4.7: Sodium Metabisulphite.

18.3.1 Hydrochloric Acid (HCl).

18.3.1.1 Function and use of Hydrochloric Acid in the gold recovery process
Acid solutions of 3% strength are used for the “acid wash” treatment of the loaded carbon prior to
elution. The ”acid wash” process is described in detail in the Acid Wash Section of the operating manual.
The preparation of the dilute HCl solution from the 33% concentrated solution is covered in the
following paragraphs.

18.3.1.2 Safety
Hydrochloric acid is a dangerous and corrosive liquid. It can react with a variety of materials to generate
gases that, if not properly vented, can endanger anyone in the area. For example, hydrochloric acid
reacts with cyanide salts to generate poisonous hydrogen cyanide gas, and it reacts with most metals to
generate explosive hydrogen gas. Thus, there is not only the danger of a violent eruption that could
result in acid burns, but also the possibility of generating a poisonous or explosive atmosphere that
would present additional hazards. Therefore, handle and store hydrochloric acid with great care to avoid
accidental spills.

WARNING!
Figure 18-1: Danger Signs for Concentrated Acid

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PPE REQUIRED:

 Hard Hat
 Safety Boots (rubber).
 Safety Glasses (Chemical). WEAR
RESPIRATOR
WEAR EAR WEAR RUBBER WEAR HARD
PROTECTION OR PVC GLOVES HAT
 Hearing Protection
 Rubber Gloves (Arm length).
 Respirator approved for the duty.
 PVC rain gear (Coat and trousers).
 Face shield
WEAR
WEAR EYE WEAR RUBBER PROTECTIVE
WEAR FACE VISOR SAFETY BOOTS
PROTECTION CLOTHING

Principal hazards:

HCL is highly corrosive and toxic if taken internally. Safe work must be practiced to avoid eye or skin
contact and vapour or spray mist inhalation. Chronic or acute exposure at high levels may result in
severe skin, eye and respiratory burns with permanent lung and tissue damage. Upon dilution, the risk
of adverse health effects is greatly reduced. Concentrated acid will react violently and explosively with
water, causing splatter and vapours. Water must therefore never be added to concentrated acid.
Concentrated acid is added slowly to a large volume of water. The acid constitutes a serious health
hazard on exposure of body parts or taken internally, as described below:

Eye Contact: Exposure may result in pain, redness, corneal burns and ulceration with possible
permanent damage.

Skin Contact: Exposure may result in skin rash, dermatitis, blistering, severe burns and discolouration.
Note that the burning sensation may be delayed.

Inhalation: Over exposure to acid vapour/fumes may result in mucous membrane irritation and
coughing. At high levels; bronchitis, ulceration, intense thirst, lung tissue damage, chemical pneumonitis
and pulmonary oedema may occur. Note that symptoms may be delayed following exposure.

Ingestion: Ingestion may result in burns to the mouth and throat, nausea, vomiting, with ulceration of
the gastro-intestinal tract, oedema, rapid pulse, shock, unconsciousness, convulsions and death.

Emergency Procedures:

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Eye contact: Wash eyes immediately with plenty of running water for no less than 15 minutes, including
under the eyelids and all surfaces. Speed in rinsing out the eyes with water after contact is extremely
important if permanent injury is to be avoided. Get medical attention promptly.

Skin contact: Wash contaminated area promptly with large quantities of water. Remove contaminated
clothing while washing. Prolong washing in serious cases until medical help arrives - even for an hour or
longer. A physician should see all cases other than minor exposures to small areas of the skin.

Ingestion: Immediately give patient large quantities of water or milk to drink. Never give anything to an
unconscious person or a person convulsing. DO NOT induce vomiting. Get medical attention
immediately.

Operators must become familiar with the positions of all safety showers in their working area and
ensure that the shower and eye wash operate correctly before starting any work involving handling of
acids.

Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in Figure 3.4.1 below. The shower shall be used in
all instances where any body part or clothing has been splashed or exposed in any way to the acid
solution.

Figure 18-2: Safety Shower Features

EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

18.3.1.3 Safe handling procedures

Spillage handling procedures:

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Small spills of acid solutions occurring within the acid wash bund area should be neutralized with lime
and pumped to the tailings screen box (34-LISC-01) using the area floor spillage pump (41-PUMP-03).

The site emergency response team must be contacted immediately if major a spill or leak was to occur.
All personnel must be evacuated from the area or moved upwind until any harmful gas that mat have
formed has been dispersed.

Large spills of hydrochloric acid must be hosed down with large quantities of water mixed with lime or
caustic soda. The neutralized solution is pumped to tailings by the normal route, as with the small spills
described above.

Storage:

Concentrated Hydrochloric Acid is delivered to site in 1 m³ Isotainer or 200 Litre drum and stored in a
dry area, protected from the elements and direct sunlight. Ensure containers are adequately labelled,
protected from physical damage and sealed when not in use. The stores should be well ventilated and
the containers checked on a regular basis for leaks or spills. The containers must be stored separately
from any oxidizing reagents (e.g. Hydrogen Peroxide, Hypochlorite…) and well away fro the cyanide
storage area.

Fire:

Hydrochloric acid by itself is not combustible, but it is highly reactive and is capable of igniting finely
divided combustible materials on contact. It will react with metals producing hydrogen. Fires involving
small amounts of combustible materials may be smothered with a suitable dry chemical. Water can be
used to cool the exterior of storage tanks to avoid rupture.

Hydrochloride acid mists and vapours from the fire area are very corrosive and harmful to health.

Fire-fighters must wear self-contained breathing equipment and full protective clothing and equipment.

18.3.1.4 Make-up Procedures for dilute acid batch

Read in conjunction with ACID WASH PFD (See Appendix).

Mixing of Hydrochloric Acid is a two-person operation. The operation must never be conducted at
night or in adverse weather conditions such as rain storms or high winds.

General procedure:

When the acid batch is spent, usually after 3 or 4 “acid wash” operations, a new batch must be
prepared. The required number of containers is drawn from the stores for each batch make-up
operation. The acid tank (41-TANK-01) is filled with clean raw water to a pre-determined level whilst
concentrated hydrochloric acid is pumped (41-PUMP-03) from an acid drum into the acid tank to make
up a 1.5 to 3.0 % solution. The dilute acid solution will be circulated through the acid wash tank (60-

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TNK-01) and back to the acid tank in closed circuit during the “acid wash” operation preceding the
elution.

Major equipment:

The major equipment in the dilute acid make-up area is listed in the Table below.

Table 18-1: Dilute Acid Make-up Plant Equipment Schedule

Item Equipment
Description Size/Type Supplier
No No
1 42-COLM-01 Acid Wash Column 14 m3, FRP ,closed column tank,
2 41-SASH-01 Safety Shower Foot Pedal, Eyewash ,
3 41-TANK-01 Dilute Acid Tank 14 m3,closed flat bottom tank, FRP.
4 41-POT-01 Acid Overflow Pot m³, FRP
5 41-PUMP- Acid Wash Pump
01/2
6 41-PUMP-03 Acid Wash Spillage Pump
7 41-PUMP-04 Acid Transfer Pump

Instrumentation and controls:

Read in conjunction with ACID WASH PFD FD4100 and P&ID PD4110, 4120 (See Appendix).

The acid make-up operation is essentially carried out manually. The level in the tank is displayed on the
SCADA screen (41-LI-01). The required amount of concentrated acid can be calculated and transferred to
the Acid Wash Tank (41-TANK-01) to produce the required diluted concentration (1.5 to 3%) as required.
The amount of acid transferred is monitored by looking at the level change in the acid wash tank.

The tank is fitted with an ultrasonic level detector interlocked with the acid pump (60-PMP-01), which
will trip on low level (60-LALL-01). The simplified P&ID shown in Figure 3.1.3, below, is used to explain
the overall operation.

18.3.1.5 Interlocks
 Acid pump (41-PUMP-01/2) will trip on low level alarm (41-LAL-01).
 Acid spillage pump (41-PUMP-03) will stop on low level (41-LSL-02).

Figure 18-3: Acid Wash Plant Arrangement.

Figure 18-4: Acid Make-up System.

18.3.1.6 SCADA screen

A typical SCADA screen for the Acid wash plant is shown in the figure, below. VDU displays and controls
are listed below.

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Figure 18-5: Typical Acid Wash SCADA Screen.

18.3.1.7 VDU displays

 Status (stopped/running/healthy/interlocked) of all drives where applicable.
 Acid Mixing Tank (41-TANK-01) level (%).
 Acid Mixing Tank (41-TNK-01) low-level alarm.
 Activation of Safety Showers where applicable.
 Acid wash column (41-COLM-01) high level alarm
 Open/Close position of all actuated valves

18.3.1.8 VDU controls

 SCADA Start/Stop of all main drives where applicable.
 Acid Mixing Tank (41-TANK-01) low-level alarm set point (Administrator access).
 Acid Mixing Tank (41-TANK-01) high level alarm set point (Administrator access).
 Acid wash solutions Flow rate setpoint

18.3.1.9 Caustic acid solution step-by-step make-up instructions

The step by step operating procedures and instructions are listed in the table below.

PPE requirements described in section 18.3.1.2 above are repeated here:

 Chemical goggles
 Reagent Specific overalls
 PVC or rubber boots
 PVC or rubber apron
 PVC or rubber gloves
 Face mask
 Hard hat.
 Approved respirator.

Table 18-2: Acid Solution Make-up Procedure.

ACID MAKE-UP PROCEDURE

THE ACID MAKE-UP OPERATION IS A “TWO-MAN” OPERATION.

ALL NON-ESSENTIAL PERSONNEL MUST CLEAR OF THE WORKING AREA.
THE IMMEDIATE AREA MUST BE BARRICADED USING A CHAIN AND AN “ACID MAKE-UP IN PROGRESS”
SAFETY SIGN MUST BE DISPLAYED.

STEP ACTIONS INSTRUCTION/COMMENTS

DO NOT MIX ACID AT NIGHT OR DURING
1 CHECK WEATHER CONDITIONS
RAIN OR HIGH WIND SITUATIONS
CHECK personal protective equipment (PPE)
Minimum required PPE as above. Ensure first
2 and first aid equipment. Establish radio
aid kit complete and in working order.
contact with control room.

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CHECK Emergency showers and breathing air Acid mixing safety shower
3
supply points. (41-SSH-01/2). Air points.
The level in the tank can be read on the
CHECK the level of the acid tank (41-TANK-01) SCADA display (41-LIC-01). The required
4 and CALCULATE the concentrated acid volume of concentrated acid is calculated
volume required. from the required batch volume and
concentration.
The required number of containers is
TRANSPORTED from the store and PLACED 5.5 off 200L containers of 33% concentrated
5
next to the acid tank inside the bunded floor acid usually used per batch.
sump.
Operator acknowledges Start Acid
Preparation on Scada & PLC intiates: Opens
6 CR Operator checks the level from Scada.
raw water actuated valve 41-LV-01A and
FILLS tank to the 70% mark
STEP ACTIONS INSTRUCTION/COMMENTS
HOSE whole floor sump area until clean. The acid make-up operation should not be
7 CHECK operation of spillage pump (41-PMP- started unless the spillage pump operates
03). satisfactorily!
Place portable drum pump (41-PUMP-03) Operator 1 opens the manual valve V 20 and
suction hose in the container opening and controls the slow acid discharge whilst
8
START transferring concentrated acid to the operator 2 is ready to assist in an
acid wash tank (41-TNK-03). emergency.
The level change in the acid wash tank is
monitored in order to transfer the desired
Slowly FEED concentrated acid to the acid
9 volume of concentrated acid. When the
tank
operation is completed the suction hose is
placed on the floor for hosing.
The operation might be repeated a number of Always empty the container completely by
10 times depending on the number of containers tilting and allowing the suction hose to
required. collect the remaining amount.
CR Operator acknowledges Proceed and Raw
water valve (41-LV-01A) opens, fills the tank
to capacity (100%) and closes.
The new diluted acid batch is now ready for
11 Mixing valve (41-XV-01) opens and selected
the next “acid wash” operation.
duty pump (41-PUMP-01/2) starts. Recycling
and mixing is allowed to continue while
waiting for the next acid wash.
Fill each container about ⅓ full with water.
Lay the container on its side and swish round
once.
12 WASH & STORE the empty HCl containers Turn container upside down and allow
draining.
Seal cleaned empty container and return to
stores.
CLEAN acid transfer pump (41-PUMP-03)
Return cleaned acid transfer pump to the
13 suction hose and HOSE down floor sump to
stores.
remove any trace of spilled acid.
The operators must remove the respirator
14 SHOWER any spilled acid from the rain suit.
and shower with rain suit, rubber gloves and

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rubber boots on. The hood is raised to keep

dry.
15 CLEAN and store all PPE Ensure all is in working order for next mixing

Operator Check List:

Detailed below in table 3.4.3 is a list of routine operating checks that should be completed by the
operators responsible for the acid make-up, mixing and dosing system.

Table 18-3: Acid Make-up Operators Checklist.

ITEM FREQ. KEY ISSUE ACTION

Check for leakages Locate source of any leakage, isolate if

Mixing tank
Shift around valves & pipe possible, clean spillage and inform
(41-TANK-01)
work. Maintenance as required
Safety shower Ensure good flows to
Shift Inform Maintenance as required
(41-SASH-01/2) shower and eyewash.

Before mixing Check tank level to

HCl acid tank The Shift Supervisor should confirm the
batches determine the amount of
level amount of concentrated HCl that is required.
HCl to add.

Trouble Shooting:

Typical problems that may be experienced in the acid mixing and distribution system are listed below:

18.3.1.10 Appendices
 ACID WASH PFD: Drawing No SP327 FD 4100 Rev. 5.
 ACID WASH P&ID: Drawing No SP327 PD 4110, 4120 Rev. 03

18.3.2 Lime

18.3.2.1 Function and use of lime in the gold recovery process

Quicklime or “Burnt-lime” is the product of calcination of ground limestone and conversion of calcium
carbonate (CaCO3) into Calcium Oxide (CaO) in this process. Quicklime is highly hygroscopic and also
reacts exothermically when mixed with water to form a suspension of hydrated Calcium Hydroxide
Ca(OH)2 called “slaked lime” or “milk of lime”. Milk of lime has a strong alkalising effect on the slurry. Its
main function is to maintain the CIL pulp pH above 10.5 thus preventing harmful Hydrogen Cyanide gas
emissions. It also provides the calcium ions which facilitate gold adsorption on the activated carbon
particles.

Calcium hydroxide has low solubility at high pH and may cause scaling in pipes and heat exchangers.

Lime is added in slurry form to the mill feed at controlled feed rate. It is thoroughly mixed with the ore
and more with water (Slaked) in the SAG mill and reports in diluted form in the CIL feed slurry.

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Precautions, as described in the next paragraph, must be taken when working in all lime handling areas.
However once mixed with slurry in the mill the lime becomes relatively harmless.

The design lime consumption is 3.0 kg Lime as 100% CaO per dry ton ore fed to the mill, as stated in the
plant design criteria. The consumption will naturally vary as a function of the acid generating properties
of the ore. Sulphide ores will require higher dosing rates.

Lime specification: ~ 90% available CaO m/m.

18.3.2.2 Safety
When handling lime, personnel shall take special precautions to avoid injury that can result from
prolonged and repeated contact with this highly reactive reagent.

If lime contacts the skin or eyes, a chemical burn can result from the lime combining with body fluids.
Milk of lime will also cause irritation to the skin or eyes because of its high alkalinity.

All required PPE shall be worn at all times in the lime working areas.

Prior to working in the lime area the operator must identify and satisfy himself of the functioning of the
nearest source of clean water, such as the nearest emergency shower and eyewash station.

PPE Requirements:

When handling any form of quicklime the following PPE are required:

 Dust respirator or preferably a full

face respirator
 Dust mask and chemical goggles (if
not using full face respirator)

WEAR WEAR RUBBER WEAR HARD WEAR EYE
Protective clothing. RESPIRATOR OR PVC GLOVES HAT PROTECTION

 PVC rain coat

 PVC or rubber gloves (Arm length).
 Safety boots (Rubber or PVC).
 Hearing protection.
 Face shield. WEAR
PROTECTIVE WEAR EAR WEAR RUBBER
WEAR FACE VISOR SAFETY BOOTS
CLOTHING PROTECTION

Hazards associated with lime:

 Contact with eyes will cause severe burning. Exposure may result in pain, redness, corneal
burns and ulceration with possible permanent damage on prolonged contact.
 Contact with skin will cause burns and irritation. Prolonged and repeated contact may result in
skin rash, dermatitis and ulceration.
 Quicklime dust inhalation will cause burning sensations to the nose, throat and respirator
system. Over exposure to powder (when mixing) may result in severe mucous membrane
irritation of the nose and throat, coughing and bronchitis.

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If ingested quicklime causes severe irritation and burns and ulcerations to the mouth and throat. The
patient may become nauseous and may vomit blood. He may also experience constriction of the throat,
breathing difficulties, abdominal pain and diarrhoea. Shock and convulsions may follow.

First Aid Procedures for exposure to lime in any form:

Eye contact: Flush face and eyes copiously with clean running water (e.g. safety shower eye wash
station), holding eyelids open, for at least 15 minutes. The patient must then seek immediate medical
attention.

Skin contact: If skin is exposed to quicklime the area must first be brushed clean and then flushed with
copious amounts of clean water for 15 to 20 minutes. Note that severe skin damage may occur if water
is applied in small amounts to the calcium oxide on the skin. The patient must then seek immediate
medical attention.

Ingestion: If lime is ingested (swallowed) do not induce vomiting. The patient is given 2 glasses of milk or
water and is immediately driven to the clinic for medical attention.

Inhalation: If lime is inhaled the patient must leave the area immediately and seek prompt medical
attention.

18.3.2.3 Safe handling procedures

Bulk spills:

If a bulk spill occurs notify the control room and evacuate all unnecessary personnel from the area.
Wear required PPE, especially the respirator where inhalation risks exist. Prevent the spill entering
water drains and channels. Collect and place spill in sealable containers for safe disposal avoiding
generating dust.

Storage:

Quicklime is delivered to site in 1 tonne bulk bags and

stored in a lay down area. The bags are stacked on
pallets and covered with plastic sheeting to prevent
wetting from contact with rain water.

Fire:

In small quantities, the presence of dry lime does not hinder the use of any standard fire extinguishing
agent.

In large quantities, dry lime in contact with water, steam, or acid will generate sufficient heat to ignite
wood or other materials.

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WARNING: Use dry chemical or carbon dioxide extinguishers only.

Equipment kw
Description Size/Type Supplier
No
53-HYST-01 Lime roller conveyor hoist
53-CONV-01 Lime bag roller conveyor
53-FILT-01 Lime bag hopper dust filter
53-HOPR-01 Lime bag hopper
53-VIBR-01 Lime hopper vibrator
53-HYST-02 Lime hopper loading hoist
53-AIBL-01 Lime transfer blower
53-FEDR-01 Lime blower rotary feeder
53-FILT-02 Lime silo dust filter
53-SILO-01 Lime silo
53-FEDR-02 Lime silo rotary feeder
53-FEDR-03 Lime screw feeder

18.3.3 Lime Slaking process description

A lime slaking plant is used to produce sufficient lime slurry for the Leach process. The lime slaker
converts dry powdered calcium oxide (CaO - quicklime) into calcium hydroxide or slaked lime (Ca (OH)2)
in the form of slurry of controlled consistency, and then dilutes it to the required density concentration
of 12% solids.

The Lime 1 ton bags are moved from the lime store with a forklift to the lime slacking plant and dumped
on a roller conveyor (53-CONV-01). The individual bags can then be moved on the roller conveyor and
lifted with an electric hoist (53-HYST-01) and discharged into the pneumatic conveying system feed bin
(53-HOPR-01). The operators and drivers will ensure that no lime is spilled and that dust emissions are

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kept to a minimum. Each hoisted lime bag is positioned on a bag breaker, with the powder being
allowed to gravitate into the lime bag hopper at a controlled rate. Excess air escaping the lime silo is
filtered by means of a pulsating bag filter (53-FILT-01).

Lime powder is drawn from the lime bag hopper using a rotary vane feeder (53-FEDR-01) and driven to
the lime silo (53-SILO-01) though a pipe line by means of an air blower (53-AIBL-01). Excess air escaping
the lime silo is filtered by means of a pulsating bag filter (53-FILT-02).

The lime level in the silo will be monitored by a level switch (53-LSH-01) which stops the lime blower
rotary feeder (53-FEDR-01) when the lime silo level is high, stopping lime transfer from the hopper to
the silo. The silo will be topped up on a regular basis to maintain a high level, especially at the end of the
day shift. Lime is drawn from the lime silo by means of rotary vane feeder (53-FEDR-02). Lime
discharged from the rotary vane feeder is transported to the Lime twin modular slacker system (53-
SLAK-01) via a screw feeder (53-FEDR-03). The slacker system has a grit removal facility. Process water
and lime powder are added to each slaker in measured proportions and vigorously agitated by a mixer
(53-MIXR-01/2). The shape of the vessel promotes a turnover flow to improve slaking efficiency and
overflow into the adjacent compartment similarly agitated, ensure the necessary retention time and
prevents the discharge of unslaked material. The temperature will be between 60° and 65 ° and
depends on the temperature of the incoming water, as well as the characteristics of the lime.

The slacked lime overflows from the second compartment of the slaking unit onto a vibrating screen
(53-SCRN-01) which removes grit as oversize. The grit is fed back into the SAG mill via the mill feed
conveyor (11-CONV-03). The lime slurry (screen undersize) gravitates into an agitated slaked lime sump
(53-TANK-02).

The slaked lime slurry will be pumped by the Lime Transfer Pumps (53-PMP-01/02) to the Lime Storage
and Dosing Tank (53-TANK-03). The tank is equipped with an agitator (53-MIXR-03) which ensures the
lime slurry is kept adequately suspended in the storage and dosing tank. The dosing tank has capacity
for 40 hours worth of lime slurry for plant operation.

Lime slurry is pumped though a ringmain by the Lime Dosing Pump (53-PUMP-03/04) with offtakes to
the SAG mill (21-MILL-01) feed , the Leach Feed splitter box (32-BOX-01), Detox splitter box (34-BOX-01)
and if required the Detox Tank 2 934-TANK-03). Unused lime slurry is returned to the dosing tanks from
the ring main.

A safety shower (53-SASH-01) is provided in the lime area. The safety shower is activated by a foot pedal
and is equipped with an eye bath.

Lime slaking area Spillage pump (53-PUMP-06) is directed to the lime vibrating grit removal screen (53-
SCRN-01) or to the mill bund spillage pump (21-PUMP-03). Spillage generated in the lime storage and
dosing area is pumped by 53-PUMP-05 to the either the lime dosing tank or the mill bund.

Dry compressed air is supplied at 6 Bar G to the bag filter 53-FILT-01 and 53-FILT-02.

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18.3.3.1 Controls and Interlocks

Lime make up will be automated and is part of the vendor control philosophy. Dosing of lime will be on
a ring main. The actual control philosophy regarding dosing into the SAG Mill and/or leach is discussed
under milling.

See Vendor’s functional specification for detailed operation of the lime dosing system (See Appendix)
and simplified P&ID in Figure below. The relevant SCADA screen in represented in the figure below.

18.3.3.2 The main interlocks will be as follows

Rotary vane feeder 53-FEDR-01 stops if:

Lime transfer Blower 53-AIBL-01 stops.

 Bag filter not operating (Fan stopped or insufficient compressed air pressure of < 6 Bar).
 Silo full (53-LAHH-01).

Lime Silo Rotary vane feeder 53-FEDR-02 stops if:

 Lime level at 53-LAL-02.

 Screw feeder 53-FEDR-03 stopped.
 Bag filter not operating (Fan stopped or insufficient compressed air pressure of < 6 Bar).

Lime Screw Feeder (53-FEDR-03) stops if:

 Slaker Lime mixer (53-MIXR-01/2) stops.

 Lime vibrating grit classifier (53-SCRN-01) stops
 Slaked lime sump (53-TANK-02) is full (53-LAHH-03)
Operator should ensure that the spray water pump (61-PUMP-05) is running to provide water on the grit
classifier screen.

Lime spillage pump (53-PUMP-06) stops on low level and is started manually when sump level is high

Duty Lime transfer Pump (53-PUMP-01/2) stops on:

 Low level (53-LALL-03) in slaked lime sump (53-TANK-02)

 High level (53-LAHH-04) in the storage/dosing tank (53-TANK-03)
 Lime dosing pump

Duty Lime dosing pump (53-PUMP-03/4) will only start or run if:

 Both suction (53-XV-01/03) and delivery (53-HV-02/04) for the selected pump are open with
suction and delivery valves for the standby unit closed.
 Dosing Tank level is high. The pump will stop on low level in the dosing tank (53-LALL-04)
 Flushing valve (53-XV-05) is closed and

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 Flush drain valve (53-XV-06) is closed.

Slaked lime sump mixer (53-MIXR-04) stops on low level (53-LAL-03) in the sump (53-TANK-02)

Lime dosing tank mixer (53-MIXR-03) stops on low level (53-LAL-04) in the lime dosing tank (53-TANK-
03)

Lime storage spillage pump stops on low level in the sump (53-LSL-06)

18.3.3.3 Appendices
 LIME SYSTEM P&ID: Drawing No SP327 PD 5310, 20, 30 Rev. 03
 Vendor O & M Manuals.

18.3.4 Caustic Soda (Sodium Hydroxide-NaOH).

18.3.4.1 Function and use of caustic soda in the gold recovery process
Caustic soda solutions are used for the following purposes in the gold recovery process:

 Neutralization of acid solutions:

o After acid washing.
o Disposal of spent acid solutions.
o Acid spillages.
 Preparation of caustic cyanide solutions for the elution process.
 NaOH increases Electro winning solution conductivity and can be added to the circuit, if
required.

Strong caustic solutions are prepared by mixing Sodium Hydroxide pearls (approximately 5 mm
granules) with clean raw water in a tank fitted with an agitator. The solutions are strongly alkaline and
may be hazardous to health when improperly handled causing severe burns when coming in contact
with skin or eyes.

Caustic soda consumption rates:

Neutralization caustic consumption ~ 6.9 t/month

Number of Elution per reagent batch ~4

Eluate caustic consumption ~ 25.2 t/month (100 % NaOH)

18.3.4.2 Safety
When handling caustic soda, personnel shall take special precautions to avoid injury that can result from
contact with this highly reactive reagent.

NaOH pearls or caustic solutions are highly corrosive. Dissolution in water is highly exothermic and may
heat the solution to dangerously high temperatures. Safe work practice must be used to avoid eye or
skin contact and inhalation of vapor or mist.

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Concentrated caustic solutions appear as a white, odourless solution which is non-volatile. These
solutions are extremely corrosive and dangerous to health. Exposure will result in severe burns with
permanent damage to eye, skin, or lungs tissue. It can cause blindness, permanent scarring and death.
Aerosols can cause lung injury. However upon dilution, the risk of adverse health effects is greatly
reduced.

The working conditions will however be totally safe if the operating procedures outlined in the next
paragraphs are strictly adhered to.

The following precautions must be taken when preparing a new batch of caustic solution or working
in any area where this reagent is used:

 Specified PPE must be worn at all times when handling caustic soda substances
 The operator must become familiar with the sources of clean water available in the area,
especially the position of the safety shower with its eye bath station.
 The operator must insure that the safety shower and any other clean water supplies are
functioning properly before starting the reagent preparation operations.
 The operator must check availability and condition of first aid equipment and instrument air
supply points for connection to breathing apparatus.
 Keep a container with acetic acid on hand to wash contaminated skin and to assist in
neutralization of the contaminated skin.
 The operator must be trained and tested to ensure that he is fully familiarized with the plant
operating procedures.
 The operator must never work alone in case of loosing consciousness from exposure to gasses
or fumes. A colleague must remain in visual contact for the duration of the operation.
 The operator must never eat, drink or smoke in the reagents storage and working areas. Hands
must be washed working with reagents.

PPE requirements:

 Hard Hat
 Safety Boots (rubber).
 Safety Glasses (Chemical).
 Hearing Protection WEAR WEAR RUBBER WEAR HARD WEAR EYE
OR PVC GLOVES

RESPIRATOR HAT PROTECTION
Rubber Gloves (Arm length).
 Dust Mask (If respirator not
available).
 Respirator approved for the
duty.
 PVC rain gear (Coat and
WEAR
trousers). WEAR FACE VISOR PROTECTIVE WEAR EAR WEAR RUBBER
SAFETY BOOTS
CLOTHING PROTECTION
 Face shield
 Breathing apparatus in the area
for Emergencies only.

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Hazards associated with caustic soda:

Eye Contact: This will result in severe irritation. Exposure may result in pain, redness, corneal burns and
ulceration with possible permanent damage with prolonged contact.

Skin Contact: Prolonged and repeated contact may result in skin rash, dermatitis, blistering, severe
burns and discoloration. Note that the effects (e.g. burning sensation) may be delayed.

Inhalation: Exposure to dust or mist may result in mouth and throat irritation, coughing and bronchitis.
At high levels the victim will experience intense thirst, ulceration, lung tissue damage, chemical
pneumonitis and pulmonary oedema. Symptoms may be delayed following exposure. Low volatility
considerably reduces inhalation hazard unless the solution is sprayed or heated to produce vapour.

Ingestion: Ingestion will result in burns to the mouth and throat, nausea, vomiting, abdominal pain and
diarrhoea. Large doses may result in ulceration of the gastrointestinal tract, unconsciousness and
convulsions.

First Aid Procedures for exposure to caustic soda in any form:

Eye Contact: Wash eyes immediately with plenty of running water for no less than 15 minutes, including
under the eyelids and all surfaces. Speed in rinsing out the eyes with water after contact is extremely
important if permanent injury is to be avoided. Get medical attention promptly.

Skin Contact: Wash contaminated area promptly with large quantities of water. Remove contaminated
clothing while washing. Prolong washing in serious cases until medical help arrives - even for an hour or
longer. A physician should see all cases other than minor exposures to small areas of the skin.

Inhalation: Leave area of exposure immediately. If assisting a victim, avoid becoming a casualty; wear a
full-face air-line respirator where an inhalation risk exists. Remove victim from exposure area & keep
warm. If victim is not breathing apply artificial respiration and seek urgent medical attention.

Ingestion: Immediately give patient large quantities of water or milk to drink. Never give anything to an
unconscious person or a person convulsing. DO NOT induce vomiting. Get medical attention
immediately.

18.3.4.3 Safe handling procedures

Bulk spills:

In the event of a spill the field operator must immediately notify the control room. Personnel involved in
clean up operations must wear the prescribed PPE and all other procedures for handling caustic soda
must be adhered to.

If pearl bags are spilled the spillage must be collected in a sealed plastic container for re-use or safe
disposal. This does not normally constitute a major problem as the pearls are delivered in 25 kg sealed
bags.

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Solution spills will generally occur inside bunded floor sumps and the solutions can be pumped back into
circuit or to the tailings disposal system via vertical spindle spillage pumps.

If however the solution spills occurs outside the bunded floor sump plant area

The spill must be absorbed with sand or wood chips. Contact with combustible or organic materials
must be avoided.

The spill must be collected and transferred to a sealable container for re-use or disposal. Note that spill
sites may be slippery. Contaminated surfaces must be flushed with copious amounts of water and
neutralize with dilute acid, preferably acetic acid, to remove final traces. Finally, the area is rinsed with
water.

Storage:

Caustic soda pearls are delivered in 25 kg bags mounted on pallets. These are stored in the Caustic and
flocculants reagents store located next to the reagents make-up tanks. The store should be well
ventilated and protected from the elements. The positions of the stores and make-up tanks are shown
in the plan view in the figure below

The stores should be checked regularly to ensure that no water damage from water or any other cause
has occurred to the bags.

The bags must be accessible for collection and transport to the caustic soda make-up tank.

Fire:

Caustic soda is non flammable but will evolve flammable hydrogen gas in contact with some metals.
Toxic gases may be evolving when exposed to fire. If this occurs the area must be evacuated
immediately and the emergency services must be notified.

All persons must remain upwind and notify those downwind of the hazard. Emergency personnel must
wear protective equipment including SCBA (SELF-CONTAINED BREATHING APPARATUS) when combating
fire. Use water fog to cool intact containers and nearby storage areas.

Figure 18-6: Sites of the Reagents Stores and Make-up plant.

18.3.4.4 Caustic Soda Make-up and Dosing System Operating Procedures

Mixing of caustic soda is a two-person operation. The operation must never be conducted at night or in
adverse weather conditions such as rain storms or high winds.

General procedure:

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Read in conjunction with REAGENTS PFD FD5100 and P&ID PD5120 (See Appendix). The required
number of 25 kg caustic soda bags will be transported from the stores, lifted with the electric hoist (51-
HYST-01) and placed on the walkway next to the caustic tank feed hopper. See elevation drawing in the
figure, below. The caustic tank (51-TANK-03) is filled with clean raw water to a pre-determined level
3
(65%) corresponding to a volume of 9.75m . The covered tank is fitted with an agitator (51-MIXR-02).
The caustic soda bags are torn open one at the time using a bag breaker (51-BBRK-02) and the pearls are
slowly fed to the agitated water via the feed hopper. A total of 144 bags corresponding to (3600 kg) are
fed to the agitated caustic make-up tank, which will generate a 20% NaOH solution. Total dissolution is
normally achieved after 30 minutes.

The tank also serves as a caustic soda solution storage tank, with intermittent dosing to the
Elution/Electrowinning, Cyanide makeup and Acid Wash areas being achieved directly from the tank
using the caustic dosing pump (51-PUMP-05/6).

Caustic spillage from the caustic tank bunded area flows into the cyanide bunded floor sump and can be
pumped to the CIL feed box (32-BOX-01) by the Cyanide spillage pump (51-PUMP-04) or into the
Cyanide makeup tank (51-TANK-01).

Major equipment:

The major equipment in the caustic soda mixing and distribution area is shown in the table below.

Table 18-4: Caustic Make-up Plant Equipment Schedule.

Item No. Description KW Size/Specification Supplier

51-TANK-03 Caustic tank 15m3
51-BBRK-02 Caustic bag breaker Caustic bag breaker
51-MIXR-02 Caustic Mixer 1.5 AMX 75, 1 blade, Kemix
2.79mDx3.19mH tank
51 PUMP-05 Caustic Pump 1 1.5
51-PUMP-06 Caustic Pump 2 1.5
51-SASH-02 Caustic Safety Shower U type double column, Delta health &
platform activated c/w hand Safety
operated side mounted
eyewash

Figure 18-7: Reagents Make-up plant Arrangement.

18.3.4.5 Instrumentation and controls

Read in conjunction with REAGENTS P&ID (See Appendix). The simplified P&ID shown in Figure 3.3.3
below is used to explain the controls used in the make-up operation. The caustic soda pearls are added

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manually (See above). The caustic tank (51-TANK-03) is equipped with an ultrasonic level transmitter
(51-LT-03) and a level control valve (51-LV-03).

The make-up operation is conducted as follows:

CRO acknowledges START Caustic Preparation on Scada. PLC initiates the following:

 LCV (51-LV-03) opens and the tank starts filling.

 The agitator starts automatically when the water level exceeds the LAL level (40%?).
 LCV (51-LV-03) closes when the water level reaches 65%.
 The field operator slowly loads the caustic soda pearl charge.
 LCV (51-LV-03) opens and the tank continues filling.
 LCV (51-LV-03) closes when the water level reaches 100%.

Caustic dosing to elution/electrowinning, cyanide makeup and acid wash must be stopped during the
solution make-up sequence. Field operator should make sure the caustic pump suction valves (51-V-
03/08) are closed during makeup. The caustic solution is ready for use 30 minutes after addition of the
last caustic bag.

A combination of flow transmitter (51-FT-03) and flow control valve (on the line to an individual area)
works to regulate the quantity of caustic delivered to particular section. This quantity is also is verifiable
by using the level change in the destination tank.

Figure 18-8: Caustic Soda Make-up System P&ID.

18.3.4.6 Interlocks
 Caustic pump (51-PUMP-05) will be stopped on caustic tank (51-TANK-03) low level alarm 51-
LALL-03.
 Caustic Mixer (51-MIXR-02) stops at 51-LAL-03.
 Caustic pump (51-PUMP-05/6) starts automatically as part of the elution control cycle.
 Caustic pump (51-PUMP-05/6) will not start or run if all the possible recipient tanks are full.
 (51-LAHH-01, 41-LAHH-01, 42-LAHH-01, 43-LAHH-01 and 43-LAHH-02)

18.3.4.7 SCADA screen

A typical SCADA screen for the Cyanide and caustic reagents make-up plant is shown in the figure,
below. VDU displays and controls are listed below.

18.3.4.8 VDU displays

 Status (stopped/running/healthy/interlocked) of all drives where applicable.
 Caustic Tank (51-TANK-03) level (%).
 Caustic Tank (51-TANK-03) low-level alarm.
 Caustic Tank (51-TANK-03) low-low-level alarm.
 Caustic Tank (51-TANK-03) high-high-level alarm.

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 Level control valve (51-LV-03) position switches not healthy alarm.

 Safety shower (51-SASH-01) flow alarm (51-FA-02)

18.3.4.9 VDU controls

 SCADA Start/Stop of all main drives where applicable.
 Caustic Tank (51-TANK-03) low-level alarm set point (Administrator access).
 Caustic Tank (51-TANK-03) low-low-level alarm set point (Administrator access).
 Caustic Tank (51-TANK-03) high-high-level alarm set point (Administrator access).

Figure 18-9: Typical SCADA Screen for Caustic and Cyanide solutions make-up.

18.3.4.10 Caustic Soda make-up instructions:

The step by step operating procedures and instructions are listed in the table below.

PPE requirements described in section 18.3.1.2 above are repeated here:

 Chemical goggles
 PVC or rubber gloves
 Approved respirator.
 Reagent Specific overalls
 PVC or rubber boots
 PVC or rubber apron
 Hard hat.

Table 18-5: Caustic Solution Make-up Procedure.

CAUSTIC SODA MAKE-UP PROCEDURE

CAUSTIC SODA IS A SEVERELY CORROSIVE REAGENT.
PRIOR TO STARTING CAUSTIC SOLUTION MAKE-UP PROCEDURES THE OPERATOR MUST CHECK
TO ENSURE ALL EMERGENCY SHOWERS AND EYE/FACE WASH STATIONS ARE WORKING.
ALL NON-ESSENTIAL PERSONNEL MUST CLEAR OF THE WORKING AREA
STEP ACTIONS COMMENTS
DO NOT MIX CAUSTIC AT NIGHT OR DURING
1 CHECK WEATHER CONDITIONS
RAIN OR HIGH WIND SITUATIONS
2 CHECK personal protective equipment Minimum required as above
Caustic mixing safety shower
3 Check Emergency showers 51-SASH-02 & Cyanide mixing safety shower
51-SASH-01
CHECK the level of the caustic tank 51- The level can be checked on the SCADA
4
TANK-03 display 51-LIC-03.
The tank will never be empty on starting the
new batch make-up, unless it is drained on
5
the floor. The tank will normally require
topping up.
The required number of bags are The number of bags to be added will be
6
carried from the store to the walkway dependent upon the amount of fresh water

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next to the tank feed hopper. addition. For each 10% of tank level 15 25kg
bags will be added.
START water addition to the tank.
7
Open valve 70-LCV-03 from the SCADA.
LCV 51-LV-03 CLOSES when water level Ensure flow stops. If required close manual
8
reached 65% . valve to stop flow
Agitator 51-MIXR-02 STARTS when
The agitator may be running due to the fact
9 the water level reaches above the LAL
that the tank is not emptied.
(51-LIC-03).
Each bag is ripped open using the bag
ADD the required number of bags of
breaker 51-BBRK-02) and the caustic soda
10 caustic pearls for the volume of water
pearls are poured in the tank via a feed
added
chute.
When the required bags have been
added, Operator acknowledges Ensure flow stops when LCV 51-LV-03 closes
11 Proceed on Scada. Valve 51-LV—3 at the 100% level. If required close manual
opens and fills the Caustic Mix Tank to valve to stop flow
100%.
Allow the solution to mix for approximately 1
12 MIX the Caustic solution hour before running the caustic dosing pump
51-PUMP-05/6.
STEP ACTIONS COMMENTS
REMOVE empty caustic bags and clean Ensure the empty caustic bags are removed
13
up any spillage and taken to the approved disposal area
14 CHECK Caustic agitator is running The caustic agitator is usually kept running
The dosing pump is started automatically
CHECK the suction valves to dosing
during the stripping sequence. Ensure the
15 pump 50-PMP-05 are in the correct
pump suction valve remains open to stop the
positions:
pump running dry
16 CLEAN and store all PPE Ensure all is in working order for next mixing

Operator Check List:

Detailed below in the table is a list of routine operating checks that should be completed by the
operators responsible for the caustic make-up, mixing and dosing system.

Table 18-6: Caustic Make-up Operator Checklist.

ITEM FREQ. KEY ISSUE ACTION

Check for leakages around Locate source of any leakage, isolate if

Mixing tank (51-
Shift valves, pipe work etc… possible, clean spillage and inform
TANK-03)
Maintenance as required
Ensure good flows to shower
Safety showers Shift Inform Maintenance as required
and eyewash
Before The Shift Supervisor should confirm the
Check tank level to determine
Caustic tank level mixing amount of raw water and caustic that is
the amount of caustic to add
batches required

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If cyanide above 10 ppm full face respirator

HCN gas levels Hourly Check using HCN detector and canister required. Inform Shift
Supervisor

Trouble Shooting:

Typical problems that may be experienced in the caustic mixing and distribution system are listed below:

In the event of a power failure while mixing caustic the following should occur:

Check that LCV 51-LV-03 feeding raw water to the mixing tank has failed closed or close if instrument air
pressure is still available. When power is restored and instrument air is available the mixing sequence
can be restarted from the last step in the procedure prior to the power failure. Ensure the agitator is
restarted.

Table 18-7: Caustic Solution Make-up Trouble Shooting.

PROBLEM PROBABLE CAUSES PROPOSED ACTIONS

Check plant air compressors
No instrument air operating and air isolation valves
Raw water line actuated valve around actuated valves
not opening or closing
Valve sticking Inform Maintenance as required

18.3.4.11 Appendices
 REAGENTS PFD: Drawing No SP327 FD 5100 Rev. 03
 REAGENTS P&ID: Drawing No SP327 PD 5120 Rev. 03.

18.3.5 Cyanide (Sodium Cyanide-NaCN)

18.3.5.1 Function and use of Sodium Cyanide in the gold recovery process
Cyanide solutions are used for the following purposes in the gold recovery process:

 Continuous dosing to the CIL process where Cyanide is essential in the dissolution of gold.
 Make-up a new batch for the elution tank from where the solution is used in the elution and
electrowinning processes.

Strong caustic cyanide solutions (25% m/m NaCN) are prepared by

mixing Cyanide briquettes with a strong Sodium Hydroxide solution
(20% m/m NaOH).

Cyanide is the most hazardous chemical used in the plant. It can

however be used with complete safety if the prescribed safety
procedures are strictly adhered to. However, exposure to even

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minute quantities of Cyanide in solid, liquid or gaseous form may result in serious health hazard and
even a fatality.

All activities involving handling of cyanide briquettes and preparation of solutions must therefore follow
strict safety procedures. These are described in detail in the following sections. Solutions must always be
prepared with concentrated caustic solutions as Hydro-Cyanide gas (HCN) evaporates in the gaseous
form at ever increasing rates as the pH of the solution decreases.

Design consumption rates:

CIL Cyanide addition (maximum): 0.5 kg NaCN as 100% NaCN per t of dry ore.

Addition rates depend on the ore characteristics and will require adjustment as the ores treated vary
from one area of the mine to the next.

18.3.5.2 Safety

18.3.5.2.1 Sodium Cyanide (NaCN):

Cyanide is potentially the most hazardous chemical on site. It is a fast acting poison and can be lethal
even at low doses if taken internally. However, if the required safety procedures are implemented it can
be used with complete safety.

WARNING!
ALL FORMS OF CYANIDE ARE POISONOUS WHETHER IT IS IN THE SOLID FORM, DISSOLVED AS A LIQUID
OR GIVEN OFF AS HYDROGEN CYANIDE (HCN) GAS.

Figure 18-10: Danger Signs for Cyanide

Principal hazards:

Cyanide poisoning can occur as a result of:

 Inhalation of gas, dust or fine spray into the lungs.

 Ingestion (swallowing) of cyanide dust or solution.
 Absorption through the skin via contact with solution or dust.

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Cyanide poisoning results from cyanide ions (CN-) entering the bloodstream and preventing oxygen
supply to the red blood cells. As a result, the body cells are starved from oxygen and begin to die. The
effect is identical to suffocation.

Cyanide is however not a cumulative poison such as heavy metals (e.g. Lead and Mercury) nor is it a
carcinogen. The body can therefore detoxify itself naturally if exposed to traces of cyanide. With prompt
treatment, recovery from overexposure is normally quick and complete. High doses cause death by
respiratory failure.

Early Warning Symptoms of Mild Cyanide Poisoning

 Irritation of the nose and throat.

 Difficulty in breathing.
 Metallic taste in mouth, burning tongue sensation.
 Forehead pressure / headache, dizziness, nausea and vomiting.
 General weakness and heaviness in arms and legs.
 Skin and eye irritation (burning sensation).
 Initial rapid breathing followed by a sense of suffocation.
 Breath may smell of bitter almonds.

Symptoms of Severe Poisoning

 Flushed complexion.
 Nausea and vomiting.
 Gasping for breath or breathing stopped.
 Unconsciousness.

Rescue Procedure

 Summon medical help.

 Check the atmosphere.
 Use appropriate respiratory protection.
 Remove the patient to fresh air.
 Give first aid.
 Give cardiac pulmonary resuscitation (CPR).

Emergency Procedures:

Eye contact: Contact may result in pain, redness, corneal burns and ulceration with possibly permanent
damage. In the safety shower, flush the eyes immediately with plenty of water keeping eyelids open for
15 minutes. Seek immediate medical attention.

Skin contact: Direct contact may result in irritation, skin rash and possibly burns. Cyanide can be
absorbed through the skin, especially in the presence of cuts or abrasions. In the safety shower, wash off
with plenty of water and soap, if available. Remove any contaminated clothing. Call for medical help.

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If swallowed: Ingestion may result in burns to the mouth and throat, nausea, vomiting breathing
difficulties, convulsions and death. Induce vomiting and call for immediate medical help. Dispense first
aid immediately (CPR or oxygen). Do not give any fluids.

Inhalation of HCN gas: Wear breathing apparatus immediately. Notify control room and emergency
services. Warn all personnel in the area and downwind. Victims must be given oxygen or CPR, if
required. The rescuer should never give mouth to mouth resuscitation as he may be poisoned himself.

Check gas concentrations: > 10 ppm: Wear Gas Mask with correct cartridge.

>60 ppm: Wear full face cover respiration apparatus.

Cyanide solutions are prepared with Caustic Soda, which is a highly corrosive reagent. The safety
procedures for caustic soda are therefore repeated here for the sake of completion.

18.3.5.2.2 Caustic Soda (NaOH):

Principal hazards:

 Contact with the eyes can cause serious long-term damage.

 The solid and its solutions are corrosive.
 Significant heat is released when sodium hydroxide dissolves in water.

Figure 18-11: Danger Signs for Caustic Soda

Emergency Procedures:

Eye contact: In the emergency shower, flush the eyes immediately with plenty of water. Continue for at
least ten minutes and call for immediate medical help.

Skin contact: Wash off with plenty of water. Remove any contaminated clothing. If the skin reddens or
appears damaged, call for medical aid.

If swallowed: If the patient is conscious, wash out the mouth well with water. Do not try to induce
vomiting. Call for immediate medical help

Personnel shall take note of the location of the potable water safety shower and eye wash station
located in the area.

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Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in the figure below. The shower shall be used in
all instances where any body part or clothing has been splashed or exposed in any way to the acid
solution.

Figure 18-12: Safety Shower Features

EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

Personnel shall also take note of the instrument air connections to be used for air supply to breathing
apparatus, used in an emergency.

REQUIRED PPE

 Hard Hat
 Safety Boots (rubber)
 Safety Glasses (Chemical)
 Hearing Protection
 Rubber Gloves (Arm length) WEAR
RESPIRATOR
WEAR EAR
PROTECTION
WEAR RUBBER
OR PVC GLOVES
WEAR HARD
HAT

 Hi Visibility Safety Vests or

Jackets
 Approved respirator
 Rubber rain suit
 Face shield WEAR EYE WEAR RUBBER
WEAR
PROTECTIVE
WEAR FACE VISOR SAFETY BOOTS
PROTECTION CLOTHING

18.3.5.3 Safe handling procedures:

Spillage handling procedures:

Small spills of cyanide solutions occurring within the cyanide and caustic soda bund area should be
pumped back into the CIL circuit using the area spillage pump.

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Briquettes and contaminated soil should be collected with shovels and placed in sealable containers for
re-use or safe disposal.

In plant liquid spills must be hosed down with copious amounts of water to the nearest spillage pump
and pumped back into circuit. Lime should be added for additional safety.

Cyanide should never come in contact with acids.

The site emergency response team must be contacted immediately if major a spill was to occur. All
personnel must be evacuated from the area.

Storage:

Sodium Cyanide is delivered to site in 1 ton bulk bags packed into wooden crates, to limit the danger of
spillages during transportation. The bulk bags are stored in a fenced, locked and well ventilated store.
Access to the cyanide storage area is restricted to authorized and trained personnel.

The positions of the stores and make-up tanks are shown in the plan view in Figure 3.4.2 below:

The stores should be checked regularly to ensure that no damage from water or any other cause has
occurred to the bags. The bags must be accessible for collection and transport to the cyanide make-up
tank.

Fire:

Sodium Cyanide does not burn. In case of exposure to fire use dry agents as far as possible. Do not use
carbon dioxide fire extinguishers. Avoid the use of water unless containers are intact.

Run-off water may constitute an environmental hazard as NaCN is readily soluble.

18.3.5.4 Cyanide Make-up and Dosing System Operating Procedures:

Read in conjunction with REAGENTS P&ID PD5110 (See Appendix).

Mixing of Sodium Cyanide is a two-person operation. The operation must never be conducted at night
or in adverse weather conditions such as rain storms or high winds.

General procedure:

18.3.5.4.1 Sodium Cyanide

Cyanide solution is made up once per day. It is made up as a 20% solution by mass in the cyanide mixing
tank (51-TANK-01) and when required transferred to the cyanide dosing tank (51-TANK-02).

To make up a batch of cyanide the immediate area is barricaded using a chain and a “Cyanide Make-up in
Progress” safety sign is displayed. The solution can be made up by automatic sequence or manual
operation of the valves.

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The required number of 1 t bulk bags will be transported from the stores and lifted into position above
the cyanide mixing tank (51-TANK-01) inlet hopper using an electric hoist (51-HYST-01). The cyanide
mixing tank (51-TANK-01) is filled to a pre-determined level with strong caustic soda solution pumped
from caustic tank (51-TANK-03) to ensure that the pH remains above 13, even after top up with clean
raw water. This is to prevent evolution of the deadly HCN gas during the operation. The cyanide tank is
then filled up with clean raw water up to the 65% level, corresponding to a volume of 16 m3. The
covered tank is fitted with an agitator (51-MIXR-01) which ensures sufficient mixing in the tank. The
cyanide bulk bags are torn open, one at the time, using a bag breaker (51-BBRK-01) and the briquettes
are discharged into the hopper basket from where they will dissolve in the caustic solution. See plant
arrangement drawing in Figure 3.4.3, below. A total of 7 bags corresponding to (7 000 kg) are fed to the
agitated cyanide make-up tank, which will generate a 25 m3 batch of 25% NaCN caustic solution. Total
dissolution is normally achieved after about one hour.

Figure 18-13: Sites of the Reagents Stores and Make-up plant.

Figure 18-14: Reagents Make-up plant Arrangement.

Cyanide solution spillage is collected within the bund of the floor sump and can be pumped to either the
Cyanide Mixing tank (51-TANK-01) or the CIL feed box (32-BOX-01) by the Cyanide spillage pump (51-
PUMP-04).

Major equipment:

The major equipment in the cyanide mixing and distribution area is shown in the table below.

Table 18-8: Caustic Make-up Plant Equipment Schedule.

Equipment No. Description kW Size/Specification Supplier

51-HYST-01 Reagents gantry hoist 30
51-TANK-01 Cyanide mixing tank
51-BBRK-01 Cyanide bag breaker
51-MIXR-01 Cyanide mixer 2.2 AMX 110, 1 blade, Kemix
3.17mDx3.57mH tank
51-HCND-01 Cyanide gas detector
51-PUMP-01 Cyanide transfer pump 7.5
51-TANK-02 Cyanide dosing tank
51-PUMP-02 Cyanide dosing pump 1 4
51-PUMP-03 Cyanide dosing pump 2 4
51-PUMP-04 Cyanide spillage pump 2.2
51-SASH-01 Cyanide safety shower U type double column, Delta health &
platform activated c/w hand Safety
operated side mounted
eyewash

Instrumentation and controls:

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The simplified P&ID shown in Figure 3.4.4 below is used to explain the controls used in the make-up
operation. The cyanide briquettes are added manually (See above). Both the cyanide mixing (51-TANK-
01) and cyanide dosing tanks (51-TANK-02) are equipped with an ultrasonic level transmitter and level
control valves.

A pH transmitter (51-AT-01) allows monitoring and control of ph value in the mixing tank (51-TANK-01)
by opening the caustic valve (51-LV-01B) to add caustic when pH is lower than setpoint.

Excess pressure on the cyanide transfer line is relieved back into the mixing tank (51-TANK-01) by using
pressure relief valve (51-PSV-01). Pressure relief valves (51-PSV-02/3) on the dosing pump (51-PUMP-
02/3) delivery lines relieve back into the dosing tank (51-TANK-02).

A Hydrogen Cyanide Gas Detector (51-HCND-01) with SCADA indication alarms on high HCN gas levels
(51-AAH-01) and a siren sounds in the cyanide area.

Flow detection (51-FA-01) on the cyanide safety shower (51-SASH-01) triggers a siren and a flashing
light.

The make-up operation is conducted as follows:

In the automatic sequence mode, the operator selects Start Cyanide Make-up on the PLC and the PLC
will initiate the following:

 Starts Caustic pump (51-PUMP-05/6)

 Opens caustic make-up to cyanide valve (51-LV-01B)
 When calculated volume is reached, closes 51-LV-01B
 Stop Caustic pump (51-PUMP-02/3) if no other caustic outlet valve is open.
 Confirm Raw water pump (62-PUMP-07/8) running
 Opens Raw water make-up valve (51-LV-01A)
 The agitator starts automatically when the solution level exceeds the LAL level (Say 42%).
 At volume set level (65%), closes (51-LV-01A)
 If pH in the mixing tank is lower than set (13), opens caustic valve (51-LV-01B), only closing when
pH gets to setpoint.
 Prompts Field Operator to add number of bags of cyanide.
 The field operator slowly drops the bulk bags one at the time onto the bag breaker (Using the
electric hoist) and allows to charge to drop into the hopped basket. The operation continues
until the 7 bags have been fed to the cyanide tank.
 LCV (51-LV-01A) opens and the tank continues filling.
 LCV (51-LV-0A) closes when the water level reaches 100%.
 The cyanide is allowed to dissolve completely, usually taking about one hour.
 Operator acknowledges Cyanide Solution Prepared.

The level of the dosing tank (51-TANK-02) is monitored via level transmitter (51-LT-02) which will start
transfer pump (51-PUMP-01) on a low level alarm (51-LAL-02) and stop it on a high level alarm (51-LAH-

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02) in the dosing tank. A new batch is made up during day shift, once a low-level alarm (51-LALL-01) in
the mixing tank (51-TANK-01) is indicated on the SCADA.

Figure 18-15: Cyanide Make-up Plant Controls.

Cyanide dosing to the CIL, Elution and electrowinning will be via the ring main and flow control valves.

Interlocks

 Cyanide transfer pump will not start or run if the suction valve (51-HV-01) is closed.
 Cyanide spillage pump (51-PUMP-04) will stop on low level (51-LSL-04) in the sump.
 Duty cyanide transfer pump (51-PUMP-02/3) will not start or run if:
o Gland water flow to the pulp is low (51-FAL-05/6)
o Dosing tank level is low (51-LALL-02)
o Either the suction (51-HV-02/3) or delivery (51-HV-04/5) for the selected duty pump is
closed. Valves for the standby pump should be closed.
 Cyanide mixer (51-MIXR-01) stops at 51-LAL-01.
 Cyanide transfer Pump (51-PUMP-01) will stop on:
o Low level (51-LALL-01) in the Cyanide mixing tank (51-TANK-01)
o High level (51-LAHH-02) in the cyanide dosing tank (51-TANK-02)
o Low gland water flow (51-FAL-04) to the transfer pump

SCADA screen:

A typical SCADA screen for the Cyanide and caustic reagents make-up plant is shown in the figure,
below. VDU displays and controls are listed below.

VDU displays:

 Status (stopped/running/healthy/interlocked) of all drives where applicable.

 Cyanide Mixing Tank (51-TANK-01) level (%).
 Cyanide Mixing Tank (51-TANK-01) low-level alarm.
 Cyanide Mixing Tank (51-TANK-01) low-low-level alarm.
 Cyanide Mixing Tank (51-TANK-01) high-high-level alarm.
 Activation of Safety Showers where applicable.
 Cyanide Dosing Tank (51-TANK-02) level (%).
 Cyanide Dosing Tank (51-TANK-02) low-level alarm.
 Cyanide Dosing Tank (51-TANK-02) low-low-level alarm.
 Cyanide Dosing Tank (51-TANK-02) high-high-level alarm
 Activation of Cyanide gas monitor.
 Open/Close position of all actuated valves
 Instantaneous pH (51-AIC-01) value in the cyanide mixing tank.

VDU controls:

 SCADA Start/Stop of all main drives where applicable.

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 Cyanide Mixing Tank (51-TANK-01) low-level alarm set point (Administrator access).
 Cyanide Mixing Tank (51-TANK-01) low-low-level alarm set point (Administrator access).
 Cyanide Mixing Tank (51-TANK-01) caustic addition level set point (Administrator access).
 Cyanide Mixing Tank (51-TANK-01) water addition level set point (Administrator access).
 Cyanide dosing tank (51-TANK-02) low level alarm set point (For cyanide transfer to start)

Figure 18-16: Typical SCADA Screen for Caustic and Cyanide solutions make-up.

Caustic cyanide solution step-by-step make-up instructions:

The step by step operating procedures and instructions are listed in the table below.

PPE requirements described in section 18.3.1.2 above are repeated here:

 Chemical goggles
 Reagent Specific overalls
 PVC or rubber apron
 PVC or rubber gloves
 PVC or rubber boots
 Hard hat
 Approved respirator
 Face mask

Table 18-9: Caustic Cyanide Solution Make-up Procedure.

CAUSTIC CYANIDE MAKE-UP PROCEDURE

ALL FORMS OF CYANIDE ARE POISONOUS WHETHER IT IS IN THE SOLID FORM, DISSOLVED AS A
LIQUID OR GIVEN OFF AS HYDROGEN CYANIDE (HCN) GAS.
THE CYANIDE MAKE-UP OPEARATION IS A “TWO-MAN” OPERATION.
ALL NON-ESSENTIAL PERSONNEL MUST CLEAR OF THE WORKING AREA.
THE IMMEDIATE AREA MUST BE BARRICADED USING A CHAIN AND A “CYANIDE MAKE-UP IN
PROGRESS” SAFETY SIGN MUST BE DISPLAYED.
STEP ACTIONS INSTRUCTION/COMMENTS
DO NOT MIX CYANIDE AT NIGHT OR
1 CHECK WEATHER CONDITIONS
DURING RAIN OR HIGH WIND SITUATIONS
CHECK personal protective equipment
Minimum required PPE as above. Ensure first
2 (PPE) and first aid equipment. Establish
aid kit complete and in working order.
radio contact with control room.
Caustic mixing safety shower
CHECK Emergency showers and
3 51-SASH-02 & Cyanide mixing safety shower
breathing air supply points.
51-SASH-01. Air points.
CHECK the level of the cyanide tank The level can be read on the SCADA display
4
(51-TANK-01) (51-LIC-01).
ENSURE that the cyanide dosing to CIL Check valve positions and operation of the
5 is not interrupted during the make-up cyanide dosing system.
operation.
6 The required number of bags are 7 x 1 t bulk bags are normally used per

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transported from the store and lifted batch.

above the bag breaker.
Operator acknowledges START Set manual valves in correct positions.
7 Cyanide preparation : caustic soda Start caustic pump 51-PUMP-05/6 starts.
solution transfer.
8 Agitator 70-AGT-01 STARTS. As the level rises above LAL.
9 Caustic pump STOPS at pre-set level. Level setting at 50%.
Ensure flow stops when LCV 51-LV-01 closes
Raw water valve 51-LV-01 OPENS and
10 at the 65% level. If required close manual
fills the tank to 65%.
valve to stop flow
ADD cyanide bags, one by one, to the
11 tank. After completion, Operator
acknowledges Proceed on Scada
Ensure flow stops when LCV 51-LV-01 closes
TOP-UP with raw water to 100% level at the 100% level. If required close manual
12
with valve 70-LCV-01. valve to stop flow. After 1hr, operator
acknowledges Cyanide Solution Prepared.
REMOVE empty cyanide bags and Ensure the empty cyanide bags are removed
13
clean up any spillage and taken to the approved disposal area
14 CHECK agitator 51-MIXR-01 is running. The cyanide agitator is usually kept running
15 CLEAN and store all PPE Ensure all is in working order for next mixing

Operator Check List:

Detailed below in the table below is a list of routine operating checks that should be completed by the
operators responsible for the cyanide make-up, mixing and dosing system.

Table 18-10: Cyanide Make-up Operator Checklist.

ITEM FREQ. KEY ISSUE ACTION

Check for leakages Locate source of any leakage, isolate if
Mixing & Dosing tanks
Shift around valves, pipe possible, clean spillage and inform
(51-TANK-01/2)
work Maintenance as required
Ensure good flows to
Safety showers (2) Shift shower and eyewash Inform Maintenance as required
basin
If HCN gas levels are above 20 ppm evacuate
HCN gas levels Hourly Check using Monitox the area and restrict access. Inform Shift
Supervisor

Trouble Shooting:

Typical problems that may be experienced in the cyanide mixing and distribution system are listed
below:

In the event of a power failure while mixing cyanide the following should occur:

Check that LCV 51-LV-01A feeding raw water to the mixing tank has failed closed or close if instrument
air pressure is still available. Do the same with the caustic addition valve to mixing tank (Ensure the

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valve has failed closed). When power is restored and instrument air is available the mixing sequence can
be restarted from the last step in the procedure prior to the power failure. Ensure the agitator is
restarted.

Table 18-11: Cyanide Solution Make-up Trouble Shooting.

PROBLEM PROBABLE CAUSES PROPOSED ACTIONS

Check plant air compressors

Raw water line actuated valve No instrument air operating and air isolation valves
not opening or closing. around actuated valves
Caustic line actuated valve
not opening or closing Valve sticking Inform Maintenance as required

Close manual valves

Level detection problem
Cyanide mixing/Dosing tank Stop cyanide transfer, clean up
Raw water or Caustic valve not
overflowing spillage and Inform Maintenance
closing
to trouble shoot level instrument

18.3.6 Appendices
 REAGENTS PFD: Drawing No SP327 FD 5100 Rev. 03
 REAGENTS P&ID: Drawing No SP327 PD 5110 Rev. 03

18.3.7 Flocculants

18.3.7.1 Function and use of flocculants

The flocculant is made up of long chain, high molecular weight polymers capable of agglomerating fine
particles in suspension. The dry powder dissolves slowly in water over a period of 2 to 3 hours and forms
a solution which is dosed in a dilute form to the thickener feed slurry. The flocculant make-up operation
is done in a specially designed and automated plant consisting of a make-up and a dosing tank.

18.3.7.2 Safety
General comments:

Flocculant is generally considered to be of low toxicity and adverse health effects are not normally
anticipated. Dry flocculants are generally supplied as a dry powder although some suppliers supply a
concentrated solution.

Dry flocculants are non-flammable, and do not react with oxidising agents and acids. Inhalation of dust /
powder from solid flocculant should be avoided. Spillage of liquid flocculant should be cleaned up by
hosing at the earliest opportunity, as the spillage is at first slippery and then extremely sticky.

Instructions:

 Prescribed PPE must be worn when working with flocculants.

 Check position and operation of nearest safety shower and eye wash station.

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Health Hazards:

Eye Contact: Exposure to dust / powder may result in mechanical irritation.

Skin Contact: Prolonged contact may result in irritation.

Inhalation: Over exposure at high levels may result in irritation of nose and throat mucous membrane
and coughing.

Ingestion: Due to product form, ingestion is considered unlikely; however contamination via hand
mouth transfer may result in gastrointestinal irritation. Good personal hygiene standards should be
maintained.

First aid procedures:

Eye Contact: Flush with running water, holding eyelids open for 15 minute periods. Obtain immediate
medical attention.

Skin Contact: Gently flush affected area with soap and water. Seek medical attention if irritation
develops.

Inhalation: If over exposure occurs, leave exposure area immediately. If other than minor symptoms are
displayed, seek immediate medical attention.

Ingestion: Seek prompt medical attention.

PPE REQUIRED:

 Hard Hat
 Anti-slip safety Boots (rubber)

WEAR WEAR EAR WEAR RUBBER WEAR HARD
Safety Glasses (Chemical) RESPIRATOR PROTECTION OR PVC GLOVES HAT

 Hearing Protection
 Leather Work Gloves
 Dust Masks.
 Approved respirator
 Rubber rain suit WEAR EYE
WEAR FACE VISOR
WEAR RUBBER
WEAR
PROTECTIVE
PROTECTION SAFETY BOOTS CLOTHING

18.3.7.3 Safe handling and use

Spills:

If flocculant powder is spilled or if packaging is damaged, collect and dispose of to land fill. For large
amounts, prescribed PPE must be worn prior to clean the spill. Cover spill with moist sand or similar,
collect and place in sealable containers for disposal. Avoid generating dust.

Storage:

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Flocculant is delivered to the stores in 25 kg bags packed on pallets. The pallets are stored undercover in
the caustic soda store in a dry area, protected from the elements. Ensure that the pallets are adequately
labelled, protected from physical damage and sealed when not in use.

Fire / explosion:

Flocculant is non flammable but the dust in high concentrations is potentially explosive. Evacuate area
and contact emergency services. Toxic gases may be evolved when heated. Remain upwind and notify
those downwind of hazard. Wear full protective equipment including SCBA (self contained breathing
apparatus) when combating fire. Use water fog to cool intact containers and nearby storage areas.

18.3.7.4 Flocculant solution Make-up Procedures

Read in conjunction with the REAGENTS PFD FD5200 (See Appendix 3.5.5).

Overview:

Flocculant bags are carried to the flocculant plant feed hopper (52-TANK-02). The hopper is filled
through an open hatch, which is closed after filling is complete to avoid water ingress and formation of
lumps. The make-up operation is controlled automatically and consists of the following stages:

 Water filling of make-up tank to a level above the agitator blades.

 Feeding the required amount of dry flocculant powder into the agitated tank via a wetting and
dispersing device.
 Filling of the tank to capacity.
 Maturation of the concentrated flocculant solution.
 Transfer of the new batch to either the preleach thickener dosing tank or tailings thickener
dosing tank

The concentrated flocculant solution is dosed to the thickener via a variable speed positive displacement
pump and diluted by raw water injection regulated by manual valve fitted to a rotameter.

Vendor design parameters are shown in the figure below

Figure 18-17: Flocculant Plant Vendor Design Parameters

The equipment is listed in the table below:

Equipment Description kW Size/Specification Supplier

No.
52-TANK-01 Flocculant mixing tank
52-MIXR-01 Flocculant mixer 3
52-TANK-02 Flocculant feed hopper
52-FEDR-01 Flocculant screw feeder 0.55
52-AIBL-01 Flocculant hot air blower 4
52-EDUC-01 Flocculant eductor
52-PUMP-01 Flocculant transfer pump 11

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52-TANK-03 Flocculant dosing tank

52-PUMP-02 Flocculant transfer pump 11
52-PUMP-03 Flocculant dosing pump 1 5.5
52-PUMP-04 Flocculant dosing pump 2 5.5
52-MIXR-02 Flocculant mixer 0.55
52-PUMP-05 Flocculant dosing pump 3 5.5
52-PUMP-06 Flocculant dosing pump 4 5.5
52-ROTA-01 Flocculant rotameter 1
52-ROTA-02 Flocculant rotameter 2
52-ROTA-03 Flocculant rotameter 3
52-ROTA-04 Flocculant rotameter 4

18.3.7.5 Flocculant Solution Make-up Plant Equipment Schedule.

Flocculant Make-up Controls:

Read in conjunction with REAGENTS P&ID PD 5210 Rev. 03

The flocculant mixing tank (52-TANK-01) will is equipped with an ultrasonic level transmitter (52-LT-01)
used to control the water addition during make-up by opening and closing the level control valves (52-
LV-01A/B).

 The Flocculant bags are emptied into the feed hopper (52-TANK-02) from where it will be fed via
a screw feeder (52-FEDR-01) into an eductor driven by high pressure water. The screw feeder is
programmed to operate on a timer calibrated to deliver the required amount of dry flocculant
to prepare a batch of desired concentration. The flocculant powder is dispersed and wetted in
the eductor and discharges into the mixing tank (52-TANK-03), fitted with “low-shear” agitator
(52-MIXR-01). The fast fill level control valve (52-LV-01B) will open until the make-up level is
reached. After 2 hours of mixing the concentrated flocculant solution is transferred by pump 1
(52-PUMP-01/2) to either the preleach thickener dosing tank (52-TANK-04) or tailings thickener
dosing tank (52-TANK-03).

A simplified P&ID is shown in the figure below to illustrate the make-up and dosing operations and their
controls.

Figure 18-18: Flocculant Plant Simplified P&ID.

Flocculant Dosing Controls:

Flocculant dosing to the Tailings thickener (35-THCK-01) is controlled by varying the speed of the
flocculant pumps (52-PUMP-03/4) and using the manual rotameter (52-FI-01/3) readings for setting the
correct dilution water.

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Flocculant dosing to the Preleach thickener (31-THCK-01) is controlled by varying the speed of the
flocculant pumps (52-PUMP-05/6) and using the manual rotameter (52-FI-02/4) readings for setting the
correct dilution water.

Interlocks:

 Flocculant pump (52-PUMP-01/2) will be stopped on flocculant mixing tank (52-TANK-01) low
level alarm.
 Flocculant transfer pump (52-PUMP-01/2) will be stopped on flocculant dosing tank (52-TANK-
03/4) high level alarm during transfer.
 Flocculant pump (52-PUMP-03/4/5/6) will be stopped on flocculant dosing tank (52-TANK-03/4)
low level alarm.
 Flocculant transfer pump (52-PUMP01/2) will only start or run if the duty pump suction valve
(52-HV-01/6) is open.
 Flocculant mixer (52-MIXR-01) stops on low level (52-LAL-01) in the mixing tank (52-TANK-01)
 Duty Flocculant dosing pump (52-PUMP-03/4/5/6) will only start or run if both the suction and
delivery valves for the selected duty pump are open. The suction and delivery valves for the
standby unit should be closed.

Figure 18-19: Typical Flocculant Plant SCADA Screen.

VDU Pages Features:

VDU Pages Controls:

18.3.8 Appendices:
 REAGENTS PFD: Drawing No SP327 FD 5200 Rev. 03
 REAGENTS P&ID: Drawing No SP327 PD 5210 Rev. 03.
 VENDOR O & M MANUALS.

18.3.9 Copper Sulphate (CuSo4)

18.3.9.1 Function and use of copper sulphate

Copper sulphate is used in the detoxification section as a catalyst in the cyanide destruction process.

Physical properties

White hygroscopic crystals which decompose below boiling point at 650oC.

18.3.9.2 Safety
Environmental hazards

The substance is very toxic to aquatic organisms. Bioaccumulation of this chemical may occur along the
food chain, for example in fish. It is strongly advised that this substance does not enter the environment.

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Occupational hazards

Reacts violently with hydroxylamine causing fire hazard. Reacts with magnesium forming
flammable/explosive gas (hydrogen - see ICSC0001).Attacks iron and zinc in the presence of water.

Effects of short term exposure

The substance is severely irritating to the eyes and the skin. The aerosol is irritating to the respiratory
tract. Corrosive on ingestion. If ingested, the substance may cause effects on the blood, kidneys and
liver, resulting in hemolytic anemia, kidney impairment and liver impairment.

Effects of long term exposure

Lungs may be affected by repeated or prolonged exposure to the aerosol. The substance may have
effects on the liver when ingested.

Routes of exposure

The substance can be absorbed into the body by inhalation of its aerosol and by ingestion.

Inhalation risk

Evaporation at 20°C is negligible; a harmful concentration of airborne particles can, however, be

reached quickly when dispersed, especially if powdered.

18.3.9.3 Hazards, Symptoms of Exposure, Prevention Measures and First AID measures
Type of hazard/
Acute Hazards/ Symptoms Prevention First Aid/Fire Fighting
Exposure
Not combustible. Gives off In case of fire in the
Fire irritating or toxic fumes (or surroundings: use appropriate
gases) in a fire. extinguishing media.
Explosion
Exposure Prevent dispersion of dust
Cough. Sore throat. Local exhaust or breathing Fresh air, rest.
Inhalation
protection.
Redness. Pain. Protective gloves. Rinse skin with plenty of water
Skin
or shower.
Redness. Pain. Blurred vision. Face shield, or eye protection First rinse with plenty of water
in combination with for several minutes (remove
Eyes
breathing protection. contact lenses if easily possible),
then take to a doctor.

18.3.9.4 Safe handling procedures

Packaging

The copper sulphate is delivered in 1 ton bulk bags.

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Storage

The bags should be stored in a well closed and dry place..

Spillage Disposal

Sweep spilled substance into sealable containers; if appropriate, moisten first to prevent dusting then
remove to safe place. (Extra personal protection: P2 filter respirator for harmful particles.) Do NOT let
this chemical enter the environment.

Personnel shall take note of the location of the potable water safety shower and eye wash station
located in the area.

Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in Figure below. The shower shall be used in all
instances where any body part or clothing has been splashed or exposed in any way to the acid
solution.

Figure 18-20: Safety Shower Features

EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

Personnel shall also take note of the instrument air connections to be used for air supply to breathing
apparatus, used in an emergency.

REQUIRED PPE

 Hard Hat
 Safety Boots (rubber)
 Safety Glasses (Chemical)
 Hearing Protection WEAR
RESPIRATOR
WEAR EAR
PROTECTION
WEAR RUBBER WEAR HARD
OR PVC GLOVES HAT
 Rubber Gloves (Arm length)
 Hi Visibility Safety Vests or Jackets
 Approved respirator

WEAR
WEAR EYE WEAR RUBBER PROTECTIVE
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 Rubber rain suit

 Face shield

18.3.9.5 Copper Sulphate solution Make-up Procedures:

Read in conjunction with the REAGENTS PFD FD5200 (See Appendix).

Copper sulphate solution is made up once per day. It is made up as a 15% solution by mass in the copper
sulphate mixing tank (54-TANK-01) and when required transferred to the copper sulphate dosing tank
(54-TANK-02).

To make up a batch of copper sulphate, the immediate area is barricaded using a chain and a “Copper
sulphate Make-up in Progress” safety sign is displayed. The solution can be made up by automatic
sequence or manual operation of the valves.

The required number of 1 t bulk bags will be transported from the stores and lifted into position above
the Copper sulphate mixing tank (54-TANK-01) inlet hopper using an electric hoist (54-HYST-01). The
copper sulphate mixing tank (54-TANK-01) is filled to a pre-determined level with raw water up (70%)
level, corresponding to a volume of 21 m3. The covered tank is fitted with an agitator (54-MIXR-01)
which ensures sufficient mixing in the tank. The cyanide bulk bags are torn open, one at the time, using
a bag breaker (54-BBRK-01) and the crystals are discharged into the hopper basket from where they will
fall into and dissolve in the raw water in the mixing tank.. One bag corresponding to (1 000 kg) is fed to
the agitated copper sulphate make-up tank, which will generate a 30m3 batch of 15% CuSO4 solution.
Total dissolution is normally achieved after about one hour.

Once dissolved, the copper sulphate solution is ready for transfer to copper sulphate dosing tank (54-
TANK-02).

Copper sulphate solution spillage is collected within the bund of the floor sump and is pumped to the
detox section via the Detox splitter box (34-BOX-01) by the copper sulphate spillage pump (54-PUMP-
07).

Major equipment:

The major equipment in the Copper Sulphate mixing and distribution area is shown in the table below.

Table 18-12: Copper Sulphate Make-up Plant Equipment Schedule.

Equipment No. Description kW Size/Specification Supplier

54-TANK-01 Copper Sulphate mixing tank
54-BBRK-01 Copper Sulphate bag breaker
54-MIXR-01 Copper Sulphate mixer 3 AMX 37, 2 blades, Kemix
1.97mDx2.37mH tank
54-PUMP-01 Copper Sulphate transfer pump 1.5

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54-TANK-02 Copper Sulphate dosing tank

54-PUMP-02 Copper Sulphate dosing pump 1 1.1
54-PUMP-03 Copper Sulphate dosing pump 2 1.1
54-PUMP-07 Copper Sulphate spillage pump 2.2
54-SASH-01 Safety shower U type double column, Delta health &
platform activated c/w hand Safety
operated side mounted
eyewash
54-HYST-01 Detox reagent gantry hoist

Instrumentation and controls:

The simplified P&ID shown in the figure below is used to explain the controls used in the make-up
operation. The Copper sulphate crystals are added manually (See above). Both the Copper sulphate
mixing (54-TANK-01) and copper sulphate dosing tanks (54-TANK-02) are equipped with an ultrasonic
level transmitter and level control valves.

Pressure relief valves (51-PSV-01/2) on the copper sulphate solution dosing pump (54-PUMP-02/3)
delivery lines relieve back into the dosing tank (54-TANK-02).

Flow detection (54-FA-01) on the cyanide safety shower (54-SASH-01) triggers a siren and a flashing
light.

The make-up operation is conducted as follows:

In the automatic sequence mode, the operator selects Start Copper Sulphate Make-up on the PLC and
the PLC will initiate the following:

 Confirm Raw water pump (62-PUMP-07/8) running

 Opens Raw water make-up valve (54-LV-01)
 The agitator starts automatically when the solution level exceeds the LAL level (Say 45%).
 At volume set level (70%), closes (54-LV-01)
 Prompts Field Operator to add number of bags of Copper sulphate
 The field operator slowly drops the bulk bags one at the time onto the bag breaker (Using the
electric hoist) and allows to charge to drop into the hopped basket. The operation continues
until the required bags have been fed to the copper sulphate mixing tank.
 LCV (54-LV-01) opens and the tank continues filling.
 LCV (54-LV-0) closes when the water level reaches 100%.
 The copper sulphate is allowed to dissolve completely, usually taking about one hour.
 Operator acknowledges Copper Sulphate Solution Prepared.

The level of the dosing tank (54-TANK-02) is monitored via level transmitter (54-LT-02) which will start
transfer pump (54-PUMP-01) on a low level alarm (54-LAL-02) and stop it on a high level alarm (54-LAH-
02) in the dosing tank. A new batch is made up during day shift, once a low-level alarm (54-LALL-01) in
the mixing tank (54-TANK-01) is indicated on the SCADA.

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Figure 18-21: Copper Sulphate Make-up Plant Controls.

Interlocks

 Copper sulphate spillage pump (54-PUMP-04) will stop on low level (51-LSL-05) in the sump.
 Copper sulphate transfer pump (54-PUMP-01) will not start or run if:
o Dosing tank level is high (54-LAHH-02)
o Copper sulphate mixing tank level is low (54-LALL-01)
 Copper sulphate mixer (54-MIXR-01) stops at 54-LAL-01.
 Copper sulphate Dosing Pump (54-PUMP-02/3) will stop on Low level (54-LALL-02) in the copper
sulphate dosing tank (54-TANK-02)
 Duty copper sulphate dosing pump 1 (54-PUMP-02) will only start or run if both the suction (54-
HV-01) and delivery (54-HV-02) valves are open.
 Duty copper sulphate dosing pump 2 (54-PUMP-03) will only start or run if both the suction (54-
HV-03 and delivery (54-HV-05) valves are open.

SCADA screen:

A typical SCADA screen for the Copper sulphate reagents make-up plant is shown in Figure 3.6.4, below.
VDU displays and controls are listed below.

VDU displays:

 Status (stopped/running/healthy/interlocked) of all drives where applicable.

 Copper sulphate Mixing Tank (54-TANK-01) level (%).
 Copper sulphate Mixing Tank (54-TANK-01) low-level alarm.
 Copper sulphate Mixing Tank (54-TANK-01) low-low-level alarm.
 Copper sulphate Mixing Tank (54-TANK-01) high-high-level alarm.
 Activation of Safety Showers where applicable.
 Copper sulphate Dosing Tank (54-TANK-02) level (%).
 Copper sulphate Dosing Tank (54-TANK-02) low-level alarm.
 Copper sulphate Dosing Tank (54-TANK-02) low-low-level alarm.
 Copper sulphate Dosing Tank (54-TANK-02) high-high-level alarm
 Open/Close position of all actuated valves

VDU controls:

 SCADA Start/Stop of all main drives where applicable.

 Copper sulphate Mixing Tank (54-TANK-01) low-level alarm set point (Administrator access).
 Copper sulphate Mixing Tank (54-TANK-01) low-low-level alarm set point (Administrator
access).
 Copper sulphate Mixing Tank (54-TANK-01) water addition level set point (Administrator
access).
 Copper sulphate dosing tank (54-TANK-02) low level alarm set point (For copper sulphate
solution transfer from mixing tank to start)

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Figure 18-22: Typical SCADA Screen for Copper Sulphate solutions make-up.

Operator Check List:

Detailed below in the table below is a list of routine operating checks that should be completed by the
operators responsible for the cyanide make-up, mixing and dosing system.

Table 18-13: Copper Sulphate Make-up Operator Checklist.

ITEM FREQ. KEY ISSUE ACTION

Check for leakages Locate source of any leakage, isolate if
Mixing & Dosing tanks
Shift around valves, pipe possible, clean spillage and inform
(54-TANK-01/2)
work Maintenance as required
Ensure good flows to
Safety showers Shift shower and eyewash Inform Maintenance as required
basin

Trouble Shooting:

Typical problems that may be experienced in the Copper Sulphate mixing and distribution system are
listed below:

In the event of a power failure while mixing cyanide the following should occur:

Check that LCV 54-LV-01 feeding raw water to the mixing tank has failed closed or close if instrument air
pressure is still available. When power is restored and instrument air is available the mixing sequence
can be restarted from the last step in the procedure prior to the power failure. Ensure the agitator is
restarted.

Table 18-14: Copper Sulphate Solution Make-up Trouble Shooting.

PROBLEM PROBABLE CAUSES PROPOSED ACTIONS

Check plant air compressors

Raw water line actuated valve No instrument air operating and air isolation valves
not opening or closing. around actuated valves
Caustic line actuated valve
not opening or closing Valve sticking Inform Maintenance as required

Close manual valves

Copper sulphate Stop copper sulphate transfer,
Level detection problem
mixing/Dosing tank clean up spillage and Inform
Raw water valve not closing
overflowing Maintenance to trouble shoot
level instrument

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18.3.10 Appendices
 REAGENTS PFD: Drawing No SP327 FD 5400 Rev. 05
 REAGENTS P&ID: Drawing No SP327 PD 5410 Rev. 03

18.3.11 Sodium Metabisulphite (Na2S2O5)

18.3.11.1 Function and use of sodium metabisulphite

Sodium metabisulphite is used to supply SO2 in the SO2/AIR Cyanide Detoxification Process which
results in the oxidation of both free cyanide (CN-) and cyanide weakly complexed with metals such as
copper, zinc and nickel to cyanate (OCN-).

Sodium metabisulphite is delivered 1 ton bulk bags as solid crystals or powder. It is easily soluble in both
cold and hot water.

Strong Sodium metabisulphite solutions (25% m/m Sodium Metabisulphite) are prepared by dissolving
sodium metabisulphite crystals in raw water.

18.3.11.2 Safety
Emergency overview

Sodium Metabisulphite may cause irritation or burns to the eyes. It is harmful if swallowed or inhaled.
May cause severe and possibly fatal allergic reactions if inhaled or swallowed by some asthmatics and
other sulphite sensitive individuals. Reacts with acids to form toxic and irritating sulphur dioxide gas.
Releases sulphur dioxide if heated above 300oF.

Potential health hazards

Skin: Repeated or prolonged contact with dust may cause irritation. Contact with solutions will cause
skin irritation.

Eyes : Dust or mist may irritate or burn the eyes. Solutions will irritate or burn.

Inhalation: Contact with acids, water and/or ice, releases sulphur dioxide gas which may be harmful or
deadly if inhaled. May cause severe or deadly allergic reactions in some asthmatics and other sulphite
sensitive individuals. Inhalation of dust or mist can irritate the respiratory tract. Possible sign and
symptoms of allergic reactions include bronchoconstriction, sweating, flushing, hives, rapid heart rate,
decreased blood pressure and anaphylaxis.

Ingestion: may irritate the gastrointestinal tract. May cause severe or deadly allergic reactions in some
asthmatics and sulphite sensitive individuals. Very large doses may cause violent colic, diarrhea,
depression and even death.

First Aid measures

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Skin: Immediately wash skin with plenty of water and soap. Remove contaminated clothing and wash
before reuse. Get medical attention if irritation persists.

Eyes: Flush eyes immediately with water for at least 15 minutes. Get medical attention.

Inhalation: Promptly remove to fresh air. Get immediate medical attention if signs of suffocation,
irritation or other symptoms develop.

Ingestion: If conscious, immediately give a large quantity of water or milk and induce vomiting by
touching finger to back of throat. Get medical attention. Never give anything by mouth to an
unconscious person.

Fire

Sodium metabisulphite is non flammable. Releases toxic and irritating sulphur dioxide at fire
temperatures and decomposes on heating to form sodium sulfate when heated. Wear full protective
equipment including NIOSH (self contained breathing apparatus) when combating fire.

Spill

In case of spill or other release, promptly sweep up material with minimum dusting and shovel into an
empty container with a cover. Cautiously spray residue with plenty of water. Provide ventilation to clear
sulphur dioxide fumes which may be generated by contact with water.

Handling and Storage

Normal handling: Avoid contact with skin eyes and clothing. Do not breathe dust and do not eat or drink
in the work area. Use normal personal hygiene and housekeeping. Keep away from water, ice, acids,
heat and oxidizing agents.

Storage

Store in a cool dry, well ventilated area away from water, ice, acids and oxidizing agents. Releases
sulphur dioxide gas slowly at ambient temperatures.

Personnel shall take note of the location of the potable water safety shower and eye wash station
located in the area.

Operation of the shower is caused by stepping over the foot pedal or pushing down the bar in the eye
wash station. A picture of the safety shower is shown in Figure below. The shower shall be used in all
instances where any body part or clothing has been splashed or exposed in any way to the acid
solution.

Figure 18-23: Safety Shower Features

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EYE-WASH
BASIN AND
HANDLE

FOOT
PEDAL

Personnel shall also take note of the instrument air connections to be used for air supply to breathing
apparatus, used in an emergency.

REQUIRED PPE

 Hard Hat
 Safety Boots (rubber)
 Safety Glasses (Chemical)
 Hearing Protection
 Rubber Gloves (Arm length) WEAR
RESPIRATOR
WEAR EAR
PROTECTION
WEAR RUBBER
OR PVC GLOVES
WEAR HARD
HAT

 Hi Visibility Safety Vests or

Jackets
 Approved respirator
 Rubber rain suit
 Face shield WEAR EYE WEAR RUBBER
WEAR
PROTECTIVE
WEAR FACE VISOR SAFETY BOOTS
PROTECTION CLOTHING

18.3.11.3 Sodium metabisulphite solution Make-up Procedures:

Read in conjunction with the REAGENTS PFD FD5400 (See Appendix).

Sodium metabisulphite solution is made up once per day. It is made up as a 25% solution by mass in the
Sodium metabisulphite mixing tank (54-TANK-03) and when required transferred to the Sodium
metabisulphite dosing tank (54-TANK-04).

To make up a batch of Sodium metabisulphite, the immediate area is barricaded using a chain and a
“Sodium metabisulphite Make-up in Progress” safety sign is displayed. The solution can be made up by
automatic sequence or manual operation of the valves.

The required number of 1 t bulk bags will be transported from the stores and lifted into position above
the Sodium metabisulphite mixing tank (54-TANK-03) inlet hopper using an electric hoist (54-HYST-01).
The Sodium metabisulphite mixing tank (54-TANK-01) is filled to a pre-determined level with raw water

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up (70%) level, corresponding to a volume of 14 m3. The covered tank is fitted with an agitator (54-
MIXR-02) which ensures sufficient mixing in the tank. The cyanide bulk bags are torn open, one at the
time, using a bag breaker (54-BBRK-01) and the crystals are discharged into the hopper basket from
where they will fall into and dissolve in the raw water in the mixing tank.. 5 bags corresponding to (5 000
kg) is fed to the agitated Sodium metabisulphite make-up tank, which will generate a 20m3 batch of 25%
Sodium metabisulphite solution. Total dissolution is normally achieved after about one hour.

Once dissolved, the Sodium metabisulphite solution is ready for transfer to Sodium metabisulphite
dosing tank (54-TANK-04).

Sodium metabisulphite solution spillage is collected within the bund of the floor sump and is pumped to
the detoxification section via the Leach tails linear screen (34-LISC-01) by the Sodium metabisulphite
spillage pump (54-PUMP-07).

Major equipment:

The major equipment in the Sodium metabisulphite mixing and distribution area is shown in the table
below.

Table 18-15: Sodium metabisulphite Make-up Plant Equipment Schedule.

Equipment No. Description kW Size/Specification Supplier

54-TANK-03 Sodium metabisulphite mixing tank
54-BBRK-02 Sodium metabisulphite bag breaker
54-MIXR-02 Sodium metabisulphite mixer 2.2 AMX 55, 2 blades, Kemix
2.48mDx2.88mH
tank
54-PUMP-04 Sodium metabisulphite transfer pump 1.5
54-TANK-04 Sodium metabisulphite dosing tank
54-PUMP-05 Sodium metabisulphite dosing pump 1 1.1
54-PUMP-06 Sodium metabisulphite dosing pump 2 1.1

Instrumentation and controls:

The simplified P&ID shown in Figure 3.7.2 below is used to explain the controls used in the make-up
operation. The Sodium metabisulphite crystals are added manually (See above). Both the Sodium
metabisulphite mixing (54-TANK-03) and Sodium metabisulphite dosing tanks (54-TANK-04) are equipped
with an ultrasonic level transmitter and level control valves.

Pressure relief valves (51-PSV-03/4) on the Sodium metabisulphite solution dosing pump (54-PUMP-
05/6) delivery lines relieve back into the dosing tank (54-TANK-04).

Flow detection (54-FA-01) on the cyanide safety shower (54-SASH-01) triggers a siren and a flashing
light.

The make-up operation is conducted as follows:

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In the automatic sequence mode, the operator selects Start Sodium metabisulphite Make-up on the PLC
and the PLC will initiate the following:

 Confirm Raw water pump (62-PUMP-07/8) running

 Opens Raw water make-up valve (54-LV-03)
 The agitator starts automatically when the solution level exceeds the LAL level (Say 45%).
 At volume set level (70%), closes (54-LV-03)
 Prompts Field Operator to add number of bags of Sodium metabisulphite
 The field operator slowly drops the bulk bags one at the time onto the bag breaker (Using the
electric hoist) and allows to charge to drop into the hopped basket. The operation continues
until the required bags have been fed to the Sodium metabisulphite mixing tank.
 LCV (54-LV-03) opens and the tank continues filling.
 LCV (54-LV-03) closes when the tank level reaches 100%.
 The Sodium metabisulphite is allowed to dissolve completely, usually taking about one hour.
 Operator acknowledges Sodium metabisulphite Solution Prepared.

The level of the dosing tank (54-TANK-04) is monitored via level transmitter (54-LT-04) which will start
transfer pump (54-PUMP-04) on a low level alarm (54-LAL-04) and stop it on a high level alarm (54-LAH-
04) in the dosing tank. A new batch is made up during day shift, once a low-level alarm (54-LALL-03) in
the mixing tank (54-TANK-03) is indicated on the SCADA.

Interlocks

 Sodium metabisulphite transfer pump (54-PUMP-04) will not start or run if:
o Dosing tank level is high (54-LAHH-04)
o Sodium metabisulphite mixing tank level is low (54-LALL-03)
 Sodium metabisulphite mixer (54-MIXR-02) stops at 54-LAL-03.
 Sodium metabisulphite Dosing Pump (54-PUMP-05/6) will stop on Low level (54-LALL-04) in the
Sodium metabisulphite dosing tank (54-TANK-04)
 Duty Sodium metabisulphite dosing pump 1 (54-PUMP-05) will only start or run if both the
suction (54-HV-05) and delivery (54-HV-06) valves are open.
 Duty Sodium metabisulphite dosing pump 2 (54-PUMP-06) will only start or run if both the
suction (54-HV-07 and delivery (54-HV-08) valves are open.

Figure 18-24: Sodium metabisulphite Make-up Plant Controls.

SCADA screen:

A typical SCADA screen for the Sodium metabisulphite reagents make-up plant is shown in the figure
below. VDU displays and controls are listed below.

VDU displays:

 Status (stopped/running/healthy/interlocked) of all drives where applicable.

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 Sodium metabisulphite Mixing Tank (54-TANK-03) level (%).

 Sodium metabisulphite Mixing Tank (54-TANK-03) low-level alarm.
 Sodium metabisulphite Mixing Tank (54-TANK-03) low-low-level alarm.
 Sodium metabisulphite Mixing Tank (54-TANK-03) high-high-level alarm.
 Activation of Safety Showers where applicable.
 Sodium metabisulphite Dosing Tank (54-TANK-04) level (%).
 Sodium metabisulphite Dosing Tank (54-TANK-04) low-level alarm.
 Sodium metabisulphite Dosing Tank (54-TANK-04) low-low-level alarm.
 Sodium metabisulphite Dosing Tank (54-TANK-04) high-high-level alarm
 Open/Close position of all actuated valves

VDU controls:

 SCADA Start/Stop of all main drives where applicable.

 Sodium metabisulphite Mixing Tank (54-TANK-03) low-level alarm set point (Administrator
access).
 Sodium metabisulphite Mixing Tank (54-TANK-03) low-low-level alarm set point (Administrator
access).
 Sodium metabisulphite Mixing Tank (54-TANK-03) water addition level set point (Administrator
access).
 Sodium metabisulphite dosing tank (54-TANK-04) low level alarm set point (For copper sulphate
solution transfer from mixing tank to start)

Figure 18-25: Typical SCADA Screen for Sodium metabisulphite solutions make-up.

Operator Check List:

Detailed below in the table is a list of routine operating checks that should be completed by the
operators responsible for the Sodium metabisulphite make-up, mixing and dosing system.

Table 18-16: Sodium metabisulphite Make-up Operator Checklist.

ITEM FREQ. KEY ISSUE ACTION

Check for leakages Locate source of any leakage, isolate if
Mixing & Dosing tanks
Shift around valves, pipe possible, clean spillage and inform
(54-TANK-03/4
work Maintenance as required
Ensure good flows to
Safety showers Shift shower and eyewash Inform Maintenance as required
basin

Trouble Shooting:

Typical problems that may be experienced in the Sodium metabisulphite mixing and distribution system
are listed below:

Bisha Plant Operating Manual 18-302

 SP327: BISHA GOLD PLANT
PLANT OPERATING MANUAL
DRAFT REV 1 – 01/04/2010

In the event of a power failure while mixing Sodium metabisulphite the following should occur:

Check that LCV 54-LV-03 feeding raw water to the mixing tank has failed closed or close if instrument air
pressure is still available. When power is restored and instrument air is available the mixing sequence
can be restarted from the last step in the procedure prior to the power failure. Ensure the agitator is
restarted.

Table 18-17: Sodium metabisulphite Solution Make-up Trouble Shooting.

PROBLEM PROBABLE CAUSES PROPOSED ACTIONS

Check plant air compressors

No instrument air operating and air isolation valves
Raw water line actuated valve around actuated valves
not opening or closing.
Valve sticking Inform Maintenance as required

Close manual valves

Sodium metabisulphite Stop Sodium metabisulphite
Level detection problem
mixing/Dosing tank transfer, clean up spillage and
Raw water valve not closing
overflowing Inform Maintenance to trouble
shoot level instrument

18.3.12 Appendices
 REAGENTS PFD: Drawing No SP327 FD 5400 Rev. 05
 REAGENTS P&ID: Drawing No SP327 PD 5410 Rev. 03

Bisha Plant Operating Manual 18-303