Gekko Systems

Operations Training
FCF Minerals Corporation
Runruno Gold-Molybdenum Project
Batch InLine Leach Reactor Operation

Mxolisi “MX” Ntombela

Gekko Systems Global Footprint

Over 160 ILRs installed

SUMMARY

• Safety

• Batch ILR Operating Description

• Operating Procedure

• Maintenance
ILR SAFETY - REAGENTS

• Cyanide, Caustic solutions.

– Toxic, corrosive.
– Similar to electrowinning solution at room temperature
– Reacts with acids to form toxic HCN as a gas
• HCN
– Normally ~1ppm next to ILR; ~3ppm high splash zones (inside
sump, directly above drum discharge trunnion).
• Hydrogen Peroxide
– Oxidant. Corrosive.
– Can react with sulphide and cyanide to form acid and HCN gas.
– Must be kept outside the ILR bund, stored separately to NaCN.
• Oxygen
– Oxidant, Accelerates combustion.
– Pressurised gas.
ILR SAFETY - PRECAUTIONS

• General cleanliness. Wash exposed skin frequently and thoroughly.

• No Smoking, No Eating.
• PPE
– Glasses at all times.
– Gloves when sampling or handling reagents.
• HCN
– Exclude acids from area
– Maintain good ventilation.
– Use fixed or portable gas monitor when entering area.
– If indoors, respirators and escape route must be available.
• Maintenance
– Always check gas levels near area to be worked on.
– Use correct isolation and wash down before working on
ANY equipment on ILR. Assume ALL liquids are dangerous.
BATCH ILR OPERATION

• Description

• Operation Steps

• Operator Interface

• Manual Operation

• Automatic Operation
BATCH ILR DESCRIPTION

• Reactor drum

• Level controlled
sump and pump

• Concentrate Feed
Cone

• Solution Storage
Tank

• PLC Control panel

 BATCH ILR DESCRIPTION

Reactor Drum
• Reactor drum

• Feed seal

• Drum drive

• Drum rollers

• Discharge

• Drain

• Proximity Switch
 BATCH ILR DESCRIPTION

Reactor Drum
• Reactor drum

• Feed seal

• Drum drive

• Drum rollers

• Discharge

• Drain

• Proximity Switch
 BATCH ILR DESCRIPTION

Sump and Pump

• Sump

• Pump

• Level sensor

• pH probe

• Dump valve

• Overflow
 BATCH ILR DESCRIPTION

Feed Cone
• Feed Cone

• Overflow

• Discharge valve

• Flush valve

• Load cell
 BATCH ILR DESCRIPTION

Solution Cone
• Solution storage
tank

• Drain and decant

valves

• Reagent addition

• Load cell
 BATCH ILR DESCRIPTION

Control Valves
• All On/Off
• Tails valve
• Solution recirculation valve
• Solution Return valve
• Sample valves
• Wash water transfer valve
• Electrowinning transfer valve
• Reagents
 BATCH ILR OPERATING STEPS

Stage Duration
1. Load Concentrate – mass controlled ~ 20 min
2. Make up Leach Solution – mass & time ~ 20 min
3. Leach – time based 3 - 18 hr
4. 0. Clarify Solution – time based 50 - 70 min
5. 0. Transfer Pregnant Solution – mass based ~ 10 min
6. 1. Wash Leached Solids – mass based ~ 15 min
4. 1. Clarify Solution – time based 50 - 70 min
5. 1. Transfer Wash Solution – mass based ~ 10 min
7. Wash by Time (to CIL) – time based 20 min
8. Transfer Solid Tails – time based 45 - 60 min
9. Drain Drum 10 min

Total Batch Time ~ 22 - 24 hrs 1 batch per day - typical

~ 10 – 12 hrs 2 batches per day
~ 8 hrs 3 batches per day
 BATCH ILR OPERATING STEPS

STEP 0 - IDLE
• ILR is Idle, waiting
for start

• Gravity
concentrators
continue running,
filling feed cone

• Electrowinning
process
downstream
continues previous
ILR Batch
 BATCH ILR OPERATING STEPS

STEP 1 – Load Solids

• Feed cone knife-
gate valve pulses
open
• Pump starts
• Water is pumped to
the circuit
• Drum begins
turning in leaching
direction
• Feed cone
fluidisation water
pulses open
 BATCH ILR OPERATING STEPS

STEP 2 – Add Reagents

• Drum is running
forwards
• Water/solution is
pumped around
circuit
• Water is added to
solution cone
through XV16 until
a weight setpoint is
reached
• Caustic solution is
added to solution
cone until a pH
setpoint is reached
 BATCH ILR OPERATING STEPS

STEP 2 – Add Reagents

• When water and
caustic have
completed ,cyanide
solution is added to
solution cone
• When solution cone
weight setpoint is
reached, step is
complete
• Oxidant is dosed
during cyanide
addition
• ILR drum is rotating
forwards
• Pump is circulating
solution
 BATCH ILR OPERATING STEPS

STEP 3 – Leach
• Leaching continues
for a set time
period of 6 – 18
hours
• Oxidant is
continuously dosed
• Oxidant is initially
dosed at a high rate
and then slows
down towards end
of leach
• Drum is running
forwards, pump
circulates solution
 BATCH ILR OPERATING STEPS

Cyanide Leaching
Reaction rate dependent on:
• Particle size
• Diffusion of reactants and products
• Cyanide concentration
• This picture shows the
• Oxygen solubility of leachant
diffusion layer created in the
leach process
Cyanide Leaching Aids • Continuous removal of this
layer significantly improves
• Oxidants – Oxygen, Peroxide,
leach kinetics
• Leachwell, Lead Nitrate
 BATCH ILR OPERATING STEPS

Laboratory Test
Each concentrate has a unique leach response based on presence and nature
of valuable and non-valuable minerals.

The leach recovery and kinetics can be predicted

by a simple bottle roll leaching test.
Inputs
 Gravity concentrate
 Sodium Cyanide
 Sodium Hydroxide (Caustic)
 Hydrogen Peroxide or Oxygen
 Process water
Outputs
 Pregnant solution (dissolved gold)
 Solid residue
 Cyanide Consumption
 Kinetics
 Slurry for S/L separation tests
 BATCH ILR OPERATING STEPS

STEP 4 – Clarify – Floc Addition

• Drum forwards
then stops so that
solids stop mixing
(settle)
• Pump is running;
solution circulates
through drum,
sump and solution
cone
• Flocculant is dosed
for a set time
• Flocculant is pulsed
into system (sump)
 BATCH ILR OPERATING STEPS

Pregnant Solution Clarity

• Solid/Liquid separation stage
programmed into PLC

• Separation allows clear solution to

electrowinning

• Automated addition unit can be

supplied with ILR

• Settled solids prepared for wash stage

 BATCH ILR OPERATING STEPS

STEP 4 – Clarify – Settle

• Drum is stopped
• Flocculant addition
stops
• Pump continues to
run
• Solution overflow
from drum returns
to solution cone
• Recirculation valve
(XV03) closes
• XV03 pulses open
to allow settled
solids to return to
drum
• Settle time finishes
when time setpoint
is reached
 BATCH ILR OPERATING STEPS

STEP 4 – Clarify – Drain

• All solids, coarse
and fine material
should be inside ILR
drum and settled to
the base
• ILR drum drain
valve is opened;
solution decants
from top of drum
and is pumped to
solution cone
• Drum drain finishes
when time setpoint
is reached
 BATCH ILR OPERATING STEPS

Drum Drain Valve Position

 BATCH ILR OPERATING STEPS

STEP 5 – Transfer Preg

• Pregnant solution is
pumped directly
from solution cone
to the pregnant
tank
• Solution transfer
can be done
through XV08
(solution drain) or
XV17 (decant)
depending on
clarity
• Automatic samples
of pregnant
solution are taken
throughout step
 BATCH ILR OPERATING STEPS

STEP 6 – Wash by Mass

• Water addition to
solution cone
through XV16 until
weight setpoint is
reached
• Drum starts in
forward direction
• XV03 opens and
solution cone
circulates through
whole circuit
• Circulation
continues for a set
time setpoint
 BATCH ILR OPERATING STEPS

STEP 7 – Wash by Time

• Water is added in
high volumes to the
feed of the drum
• The drum runs in
forward direction,
allowing cyanide
solution to be
washed out
• Solution is pumped
directly to CIL
circuit
• Transfer occurs for
a set time setpoint
• Automatic samples
of solution are
taken throughput
step
 BATCH ILR OPERATING STEPS

STEP 8 – Empty Solids

• Water addition to
feed of drum helps
to remove solids
• Water addition to
discharge sump to
ensure pump speed
remains high
• Drum turns in
reverse (after
delay), discharging
solids
• Automatic sample
of slurry
• Remaining solution
in solution cone
drained
Lower drum speed – reduced chance of pump and pipeline blockages
 BATCH ILR OPERATING STEPS

Drum Discharge
 BATCH ILR OPERATING STEPS

STEP 9 – Drum Drain

• Drum drain valve
opens for a set
period to remove
solution form
system prior to next
batch
BATCH ILR VARIABLES

• Influence of key variables

OPERATOR INTERFACE

• Control Cabinet
• PLC
• HMI
• Other components / breakers
OPERATOR INTERFACE

• Electrical Cabinet
• Pump VSD
• Drum VSD
• Other components / breakers
OPERATOR INTERFACE

• Human Machine Interface (HMI)

– Main Control Page
– Animated Flowsheet with status and active alarm indications
– Mass (weight) indication on feed and solution cones
– Level indication on ILR sump
– pH indication
– Status of valves and drives shown
OPERATOR INTERFACE

• To Start a Batch in Auto

– Press “AUTO” the “START”
– The system will not start if
• Low Air Pressure
• Emergency Stop Active
– Any other alarms must be acknowledged
OPERATOR INTERFACE

• Alarms
– All alarms will bring up a banner on the PanelView.
– Shutdown Alarms – ILR switches into manual – drive faults, solution
loss, pump blocked and Low Low pH. Also EW Tank interlocks.
– Audible/Visual alarm will sound for most alarms. Accept All will
silence alarm for 10 minutes.
– Low Air Pressure Alarm will close all valves except XV05 and XV07.
Pump will continue to operate normally.
OPERATOR INTERFACE

• Settings Pages
• From Main Menu – takes you
to Settings Menu
• Settings are divided by type
– Valve timers and type of control
– Level settings for water addition
and drain points
– Cycle timers and options for
Steps
– Alarm settings and activation
METAL ACCOUNTING

• Record of Slurry and solution masses in each batch on

PanelView.
• Recorded at end of relevant step and overwritten during next
batch.
• Composite Pregnant/Wash solution sample and solid tails
samples are taken automatically.
• If separate pregnant and wash samples required then must
change bottle prior to transferring wash solution.
• Head grade is back calculated using the measured feed mass.
• “Feed Start Dry” is the dry mass calculated based on the wet
start mass, the feed tank being full of water and the solids SG.
• “Feed Added Dry” is calculated from “Feed Added Wet” and 60%
solids underflow.
• Use the lower of the two.
ILR MAINTENANCE SUMMARY

• Refer to O&M Manual for

details
INSTRUMENT CALIBRATION

• Load Cell Weight Transmitter Calibration (every 6 months)

– Feed / Solution cone must be emptied
– A “zero” routine is completed; when the cone is empty
– Fill cone with water until the overflow point (known volume / mass of
water)
– Close water inlet
– When water stops overflowing, complete “span” routine
• Feed cone = 2,500 kg
• Solution cone = 4,300 kg
– Calibration completed

– During this time (Feed Cone) NO FEED must enter the Feed Cone
from Knelson / Falcon concentrators.
INSTRUMENT CALIBRATION

• Load Cell Weight Transmitter Calibration (every 6 months)

Rinstrum Ranger 1203 Yokogawa UT520

INSTRUMENT CALIBRATION

• pH Probe / Meter Calibration (every week)

– Has to be done when ILR is NOT running the batch (pH control)
– Remove pH probe from bracket
– Inspect and clean with nitric or sulphamic acid solution (quick and
effective cleaning)
– Use buffer solution pH 7 and pH 10 to calibrate in Automatic mode
This is IMPORTANT FOR YOUR SAFETY
ISOLATION AND CLEANING
PROCEDURES
• ELECTRICAL AND PROCESS ISOLATION MUST BE DONE BEFORE
REPAIRING EQUIPMENT.

• Electrical isolation points are provided for every electrical drive in the
ILR. Use Danger Tags and Locks to LockOut / TagOut.

• Isolation and, if necessary, flushing of all equipment by operating staff

prior to access by maintenance staff is necessary to prevent contact with
hazardous solutions.

• All pipes around the ILR can be isolated and drained or flushed with
water. The following procedures are examples of some common or
hazardous tasks. The same principles apply to all maintenance
functions around the ILR.
ISOLATION AND CLEANING
PROCEDURES
Isolation and Wash Down – ILR Pump

• Always flush pump before performing any maintenance other than

lubrication or gland adjustment.
• Shut knifegate valve on suction side of pump.
• Connect water to 1”flush valve on suction side of valve
• Arrange discharge valves so water is directed either towards the solution
tank or close both butterfly valves and open flush valve on discharge
side of pump.
• Run water through pump for 1 to 3 minutes.
• Close valves on discharge of pump, drain out water through flush
valves.
• Wash down valves and work area.
• Check area for elevated HCN levels.
• If HCN less than 3 ppm, area is safe for maintenance.
ISOLATION AND CLEANING
PROCEDURES
Isolation and Wash Down – Recirculation Line
• Recirculation line (from XV03 / XV23 to drum feed)
• Isolate and clean to replace, repair or unblock this line. Note, if not
blocked the solution will drain to the drum.
• Close XV03 using the pneumatic controls.
• Open the blank flange on the T-piece directly downstream of XV03
(solution recirculation line valve).
• Flush with water into the blank flange. This will flow into the drum and
may overflow. If it does it should be pumped to the solution tank.
• Open flanges and clean, repair or replace pipe as required.
INSPECTING FEED AND
SOLUTION CONES
Normal Confined Space Entry Permits and associated procedures
MUST be followed before entering these tanks

• There is a possibility of HCN gas build up in these tanks.

• The covers should be raised and the HCN gas level checked before
inspecting.
• Allow for ventilation.
• Avoid placing your head inside the tank.
• Feed cone is likely to accumulate scaling (over time) on sides of the
tank. Inspect every 6 months.
• Solution cone – stores and circulates cyanide leach solution
INSPECTING ILR DRUM

Normal Confined Space Entry Permits and associated procedures

MUST be followed before entering the drum

• The drum internals should be inspected for wear regularly, typically

every 3 months. This is done by opening the inspection hatches in the
side of the drum.
• There is a likelihood of elevated HCN gas levels in the ILR Drum – flush
drum with water prior to opening inspection doors.
• The covers should be marked and removed. Note silicone sealant is
used for sealing.
• When the covers are removed check the HCN gas level before
inspecting.
• Avoid placing your head inside the drum.
• To replace the hatches clean the faces then use silicone sealant on the
faces AND in the bolt holes.
INSPECTING ILR DRUM

Normal Confined Space Entry Permits and associated procedures

MUST be followed before entering the drum

• Drum lifters: Thickness = 10 mm

• Drum lifters: Width = 75 mm
• Bisaloy spiral: Thickness = 5 mm
ILR SUMP PUMP – WARMAN

• Pump seal uses a high flow expeller and grease packed gland.
• Gland must be greased regularly – daily.
• Gland must be checked and adjusted at least weekly.
• Bearings should be lightly greased weekly (outer grease nipples only).
MECHANICAL MAINTENANCE
ITEMS
• ILR slurry pump – Seal, bearings, wear.
• ILR Drum – tyres, rollers, bearings, alignment, feed seal, internal.
• ILR Drum Drive – chain, gearbox, sprockets.
• Valves – butterfly, knifegate, ball.
• Peroxide pump (or oxygen sparger).
• Flocculant pump.
E & I MAINTENANCE ITEMS

• pH probe and transmitter – clean daily & calibrate weekly

• Air filters – clean twice weekly
• Level sensor
• Variable Speed Drives (pump and drum)
• Solenoid valves
• General Switchgear – relays, circuit breakers, switches, etc
• Pressure switch
• Electrical and Control Cabinets
• Pneumatics Cabinet
SITE VISIT – Dec 2019

• Met accounting discrepancies

• Cleaning of tanks
• Calibration of load cells
• Drum inspection and maintenance
• Feed manifold top seal
• Orifice plate
• ILR operations
• Drum drive and castor wheels
• General
Met Accounting – ILR

ILR Solution Volume per Preg Soln Tank Volume per

batch batch
6 – 7 m3 4 – 5 m3

Difference ~ 2 m3 of solution at ~ 200 ppm Au grade

~ 13 oz Au every batch

• Au assays almost comparable

• Calibrated solution cone load cell
• Noted smaller discrepancy since temporary pipe used for
solution transfer from ILR to Preg Tank
• Suspect leakage on Wash to CIL line during transfers
Cleaning of Tanks (Cones)

Feed Cone Solution Cone

Load Cell Calibrations

Tank ZERO SPAN

-15 kg 3,010 kg
Feed Cone
0 kg 2,500 kg
-180 kg 4,303 kg
Solution Cone
0 kg 4,300 kg
Drum Internal Inspection

Lifters:
75 mm width
10 mm thick

Diffuser OK
Feed Manifold and Top Seal

• Leaking water during Step 7

• 3 mm seal replaced with 6 mm Linatex

• Opening to be offset as downcomer

pipe is offset
Orifice Plate

• Orifice offset too low

• Causing wear on manifold flange

• Opening = 16 X 44 mm
Orifice Plate (cont’d)

Recommend:
• Replace orifice with standard unit (25 X 43 mm)

• Order new feed manifold as spare and replace on failure (or as

monitored)

Function:
• Regulate flow of solution recirculating
from solution cone back into the drum
• High flow – disrupt pump PID & faster
passing of fines through drum
• Low flow - blockages
ILR Operations

• Caustic addition – in manual mode

– Step 2 (Add Reagents)
– Step 5 (Transfer)

• Drain valve (pipe) blockage – monitor and observe

during Step 4
ILR Operations (cont’d)

pH probe test and clean (Safety)

• Test between batches with water - response
• Clean sensor and re-test (use sulphamic acid if
necessary)
• E&I Team to calibrate as required (1 or 2 weeks)
Drum Drive and Castor Wheels

• Chain slack – need to adjust or remove 1 or 2 links

• Remove excess grease from castor wheels – to

visually note wear patterns
– 8 mm walls; and some 12 mm
Other Considerations

• Safety shower inside ILR cage

• Corrosion protection – structure, tanks (legs), guards

• Access platform for solution cone

• Blank off line to Cyanide Mixing Tank (after XV-5330)

• Flowmeter on ILR Pregnant Solution pipe

– FIT and load cell comparison
– FIT and tank level comparison
Industry Trusts ILR Technology
Over 160 ILRs installed worldwide