Bulawayo Mining Company

METALLON GOLD ZIMBABWE

HOW MINE

KUBVORUNO PRIDE TAFADZWA| MINING | August 1, 2017 PLANT OPERATIONS

REPORT

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TABLE OF CONTENTS

Title page .. 1

Table of contents ...2

Executive Summary .. 3

Definition of terms 4

General Overview of the Reduction Process

Crushing 5

Process flow of ore during crushing . 6

Milling 8

Process flow of ore during milling ... 9

Carbon In Pulp ..11

Process flow of pulp at the Carbon In Pulp section 12

Elution .. 14

Process flow of carbon and pregnant solution ....14

Elution Plant Operations ..16

Tailings Disposal 17

Tailings Dam 5 ..18

Observations and Challenges 19

Recommendations .... 20

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EXECUTIVE SUMMARY

"As-mined" or "run-of-mine" ore consists of valuable minerals and gangue. Mineral processing,
sometimes called ore dressing, mineral dressing follows mining and prepares the ore for extraction
of the valuable metal from metallic ores to produces a commercial end product GOLD. Apart from
regulating the size of the ore, it is a process of physically separating the grains of valuable minerals
from the gangue minerals, to produce an enriched portion, or concentrate, containing most of the
valuable minerals, and a discard, or tailing, containing predominantly the gangue minerals. The
gold ore reduction process involves

Crushing
Milling
Carbon In Pulp
Elution and Electro winning
Smelting
Tailings Disposal

DEFINITION OF TERMS

1. Rough Ore Bin (R.O.B) facility for storing ore from underground.
2. Fine Ore Bin (F.O.B) facility for storing crushed ore prior to milling
3. Stock Pile temporary storage of ore on the which is used when the rough ore bin is full
4. Dust - Particulate matter in the air with potential of causing harm to the environment and its
occupants.
5. Milling Plant A entity that utilises ball mills and other related equipment to effect ore size
reduction
6. Ball mill - The equipment used for grinding ore from a coarse to a fine size using steel balls
as grinding media
7. Mill start up - The process of starting up a mill
8. Mill run down - The process of grinding out ore in the milling circuit after feed conveyors
have been stopped
9. Mill shut down - The process of stopping the mill
10. Grind Particle size distribution
11. Concentrates - Free gold recovered gravity process
12. Concentrating - Process of running the machine
13. Gravity concentrators-Equipment that recovers free gold through high speed rotation and
difference in densities of ore particles
14. Intensive Cyanidation-process of gold dissolution by use of high strength cyanide solution.

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15. LOTO - Lock Out Tag Out

16. Pregnant solution - Solution containing high gold values.
17. Tails - solution containing low gold values
18. Wire wool - steel that conduct electricity and used for depositing gold.
19. Leaching/Cyanidation - dissolution of gold particles into solution by use of cyanide.
20. Titrations - Method used to determine the strength of cyanide and alkalinity of pulp.
21. Pulp - Mixture of solids (ore) and water.
22. Solid Cyanide White pellets of sodium cyanide (98%)
23. Antidote - Chemicals used to neutralize the effect of cyanide in case of inhalation or
intoxication (e.g. sodium thio-sulphate, amyl nitrite and sodium nitrite).
24. Housekeeping - The act of cleaning up a work station of any spillages, rejects, off-cuts or trash
resulting from work activity.
25. Lime - Inorganic material containing calcium oxide used for pH conditioning
26. Banks- a series of pumps
27. Piezo-meter An instrument used to measure water pressure in the dam.
28. Free board - vertical distance between the water line and the upper most water tight deck of
the dam.
29. TSF-Tailings Storage Facility

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General Overview of the Reduction Process

Jaw crusher
Crushing Gyratory crusher
Barmac crusher

Ball mills
Milling Hydrocyclones
Knelson Concentrators

Carbon
Cyanide
Carbon In Pulp
Hydrogen Peroxide
Oxygen

Hydrochloric Acid Wash

Elution Caustic-Cyanide Soak
Electro winning

Tailings Super Flow Tank

Disposal Pumps and Delivery Lines
Dam wall Cycloning and
Paddock systems

CRUSHING

Crushing is the first mechanical stage in the process of comminution in which the main objective
is the liberation of the valuable minerals from the gangue. It is generally a dry operation and is
performed in three stages which are

i. Primary crushing ( Jaw crusher)

ii. Secondary crushing (Gyratory crusher)
iii. Tertiary crushing (Barmac crusher)

Vibrating screens are placed in line with the crushers to remove undersize material, or scalp the
feed, and thereby increase the capacity of the crushing plant. Undersize material tends to pack the
voids between the large particles in the crushing chamber, and can choke the crusher, causing
damage, because the packed mass of rock is unable to swell in volume as it is broken.
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Crushing may be in open or closed circuit depending on product size. In open-circuit crushing,
undersize material from the screen is combined with the crusher product and is then routed to the
next operation. Open circuit crushing is used in intermediate crushing stages. Since the tertiary
crusher produces ball-mill feed, closed-circuit crushing is employed in which the undersize from
the screen is the finished product. The crusher product is returned to the screen so that any over-
size material will be re-circulated.

Process Risks/hazards

EMS OHS QMS

Dust Noise Ore size (feed, product)
Poor housekeeping Dust Poor housekeeping
House keeping Crushing rate
Working inside the crusher Moisture content
Conveyor in motion
Uncontrolled and unexpected
excessive discharge
Flying rock
Personal Protective Equipment

i. Overalls,
ii. Safety shoes,
iii. Hard hat,
iv. Clear goggles with side shields,
v. Dust respirator,
vi. Gloves and
vii. Ear plugs.

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Process flow of ore in the Crushing Plant

Rough Ore Bin

Capacity - 578 tonnes
Ore size +150mm
Grizzly bars above 3 ore passes

Vibratory Feeders / Vibro chutes 1,2&3

Fitted with adjustable gate iron bars supported on
chains, to control feedrate onto conyeyor belt Ore size -150mm

Conveyor Belt 1
Fitted with a Tramp metal detector for detection of Ore size -150mm
metal objects on the conveyor

Vibrator 1
Screen size : 2.5m * 1.25m Undersize : - 50 mm
Aperture Size : 50 mm Oversize : + 50mm

Jaw Crusher 1&2

Size : 14 * 24 Inch Ore Size reduction : 150mm to -50mm

Conveyor Belt 2
Fitted with magnet to trap metal objects that could
Ore size : -50mm
have escaped the tramp metal detector

Vibrating screen 2
Size : 2m * 1m Undersize : -25mm
Aperture size : 25mm Oversize : + 25mm

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Gyratory Crusher
Size : 36 Inch Diameter
Ore Size Reduction : 50mm to - 25mm
Gap : 25mm

Conveyor Belt 3
Ore Size : -25mm

Conveyor Belt 4
Ore Size : -25mm

Conveyor Belt 6
Ore size : -25mm

Barmac Crusher
Ore Size : - 15mm
Main Vibrator 3
Conveyor Belt 5
Size : 5.2 * 2.15 m
Ore Size : +20mm
Poly Screens
Oversize : + 20mm
Undersize : -20mm

Fine Ore Bin 2

Conveyor Belt 8 Conyeyor Belt 7
Capacity : 800 tonnes
2 Discharge Chutes Ore Size : - 20mm Ore size : -20mm
Ore Size : -20mm

Fine Ore Bin 1

400 tonnes

-
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MILLING: Summary Process flow of ore in the Milling Plant

Volumetric Conveyor 1 Inclined Conveyor 2

Jumper Conveyor 3 Conveyor belt 4
Adjustable speed Positioned with an
electronic belt Ore size : - 20mm Ore size : - 20mm
Controlled feed rate
Fine Ore Bins cutter and
FOB 1 : 400 t weightometer
FOB 2 : 800 t
Ore Size : -
20mm

VD 9 Screen
O/F Fitted with 10 *
10mm poly screens
Undersize : - 10mm
Oversize : + 10mm
Primary Ball Mill
Primary Mill Pump Knelson Gravity
Concentrator Mill size : 12 ft * 12 ft
Receiving Sump O/F
Size : 48 Inch Diameter Grinding media : 100mm
Addition of dilution
Steel ball
water Pressure : 12 - 15 KPa
Liners : Steel
Ore size : - 10mm
Feed rate : + 40 t/h
Discharge densities : 65-
U/F 75% solids
Acacia Plant

Primary Mill Hydrocyclone

O/F
Feed densities : 45 - 50% solids
Underflow : 70 - 75% solids
Overflow : 26 - 30% solids

Delkor Screen

Splitter box

Secondary Mill 1

Secondary Mill 2 9
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Splitter box

O/F

Secondary Mill 1
Knelson Concentrator Re-Grind 1
Size : 7 * 11 ft Hydrocyclone
Feed rate : 20t/h Size : 20 Inch
Diameter Feed : 40 - 45%
Feed : 70-75% solids
Pressure : 8-20 KPa solids
Grinding media :
Overflow : 26-30%
60mm steel balls
solids
Discharge density:
Underflow : 70-75%
45-50% solids
solids
U/F

O/F

Secondary Mill 2
Knelson Concentrator Re-Grind 2
Size : 6.5 * 20 ft Hydrocyclone
Feed rate : 20t/h Size : 30 Inch
Diameter Feed : 40 - 45%
Feed : 70-75% solids
Pressure : 8-20 KPa solids
Grinding media :
Overflow : 26-30%
60mm steel balls
solids
Discharge density:
Underflow : 70-75%
45-5o% solids U/F solids

O/F
Delkor Screen
Removal of trash
Secondary Mill 3 material
Re-Grind 3
Size : 7 * 11 ft Hydrocyclone
Feed rate : 20t/h
Feed : 40 - 45% solids
Feed : 70-75% solids
Overflow : 26-30% Discharge box directing to CIP
Grinding media : solids
60mm steel balls
Underflow : 70-75% Target Overall Grind : 75%
Discharge density: solids
45-50% solids passing 75m
Pulp density : 26 - 30% solids
U/F

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2.0 Milling Circuits

There are two milling circuits in the milling circuit, the primary circuit being the first stage of
grinding and the secondary circuit which is mainly the re-grind circuit.

2.1 Primary Milling Circuit

2.1.1 Process Flow

Figure 1 Primary mill circuit

2.1.2 Description
Ore from the fine ore bin is fed onto Conveyor belt 1 through volumetric chutes and is
discharged onto conveyor 2 (incline conveyor). Conveyor 2 feeds Conveyor 3 (jump conveyor)
which in turn feeds conveyor 4. Ore on Conveyor 4 goes into the banana chute together with mill
feed water and oversize from the vibratory screen. 100mm steel balls are manually fed onto
conveyor 2 and are conveyed together with the ore until they go into the mill.steel ball addition is
done on morning shift and 2 tonnes are added daily.

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Primary mill discharge is diluted and pumped to the vibratory screen. Oversize from the screen
goes back into the mill while underflow becomes Knelson Concentrator feed. Knelson
concentrator concentrates are deposited into a concentrates box and are later further processed in
the Acacia Plant. Knelson Concentrator tailings form Primary Mill Cyclone Feed. The Primary
mill cyclone overflow is discharged in the Regrind 1 and 2 mill discharge sumps while the
underflow becomes regrind 1, 2 and 3 feed.

2.2 Secondary Milling Circuit

2.2.1 Process Flow

Figure 2 Secondary Milling Circuit

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2.2.2 Description
Primary mill cyclone underflow is split into three forming feed for the three regrind mills. A
tonne of 60mm steel balls are added to each regrind mill a day. Regrind mill 1 and 2 have similar
circuits where the mill discharge goes to the Knelson concentrator and tailings from there
become the cyclone feed. Underflow from each respective cyclone is fed back into the mill and
the overflow goes to the Delko Screen for trash removal. The underflow becomes the final
product that goes to downstream processes.

Major Equipment
The major equipment used in the milling section are:

- ball mills

- knelson concentrators

- acacia plant

- vibrating screens

- linear screen

- cyclones

- centrifugal pumps

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3.1 Ball Mills

Figure 3 mill diagram

3.1.1 Operating principle of a ball mill

The ball mill is lined to protect the shell from the grinding media, At How Mine, the feed size of
the ball mills is generally fines, therefore interaction of the feed itself does not result in
comminution. Steel balls are fed into the ball mill as grinding media and comminution occurs
due to the interaction between the charge and the steel balls.

Figure 4 Comminution in a ball mill

Comminution is mainly by abrasion, as grinding media is dragged against the shell and impact as
grinding media falls to the toe of the mill.

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3.2 Knelson concentrator

There are three Knelson concentrators in the plant, KC 48, KC 20 and KC 30. The numbers
denote the size of the diameter in inches

3.2.1 Operating principle

The Knelson concentrator is a high-speed centrifuge that sets a centrifugal force to the particles
in the slurry against a fluidization water flow. The conical shape of the concentrating cone
incorporates a series of rings, increasing in diameter from bottom to top. Around the
circumference of each ring, holes allow the injection of fluidization water into the concentrating
cone. Positioning the concentrating cone inside the rotor housing creates a water cavity.
Fluidization water flows into the cavity through the rotor shaft. Once the cavity fills to capacity,
pressure forces water through the fluidization holes and into the concentrating ring. During
operation, the entire rotor assembly spins at a pre-determined speed according to the size and
model of the unit. This rotational speed creates a centrifugal acceleration.

Concentrating cone

Water cavity

Water inlet

Figure 5 Cross section of Knelson Concentrator

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Feed slurry enters the unit through a stationary feed tube. It flows down into the concentrating
cone, where centrifugal force drives it outward to the cone wall. As the solids reach the wall,
they fill each ring starting from the bottom. Once every ring reaches capacity, a concentrating
bed is established. Water injected from the water cavity fluidizes this bed. Optimum fluidization
occurs when inward flow of water through the bed balances with outward forces of solids. This
enables fine grained target heavy mineral particles to sink into the bed through interstitial
trickling. Provided that the flow of fluidization water is maintained, the selection and
concentration of high specific gravity particles and rejection of low specific gravity particles will
continue.

When the concentrating cycle ends, the flush cycle is initiated and the rotor power is shut off.
When the rotor comes to a complete stop, the fluidization water flow valve is opened for several
seconds. Opening the valve while the rotor is stationary allows water flow into each ring to wash
out the concentrates. Concentrates flush out through the bottom of the concentrating cone and
into the concentrate launder. R

3.3 ACACIA Plant

All the concentrates collected from the concentrate boxes of the three Knelson concentrators are
processed in the acacia plant.

3.3.1 Working Principle

Figure 6 ACACIA Plant layout

1. Transfer of Concentrate to the reactor.

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Knelson Concentrator gravity concentrate generated over a 24-hour period held in the
concentrate boxes is transferred to the ConSep ACACIA Reactor in bags which are
emptied into the Reaction vessel.
2. Pre-washing of the gold concentrate to remove ultra-fine solids (slimes)
To ensure the leach overflow solution does not carry suspended solids that interfere with
the subsequent gold electrowinning, and that water and subsequently pregnant solution
can be recovered by drainage, the concentrate solids are fluidized until overflow runs
clear.
Reaction vessel overflow solution containing fine solids is discharge back to the milling
section into the primary mill discharge sump
3. Mixing of the Leach Reagents
The leach solution is made up in the mixing tank
Reagents Added:
Potable water (2.8 m3)
3.5 buckets of Cyanide 53kg
13kg caustic soda
2kg leach aid
4. Leaching of the Concentrate
The leach solution is pumped from the mixing tank to the reaction vessel at a rate
sufficient only to fluidize the concentrate. This ensures that no fine are carried over to in
the pregnant overflow.
The leach solution is circulated through the reaction vessel for about 24 hours.
5. Recovery of Pregnant Solution
At termination of leaching, the reaction vessel overflow is sampled for assay, the flow is
stopped and drainage of the solution through the distributor to the reaction vessel feed
tank is commenced.
6. Transfer of Solution to Electrowinning
The gold bearing solution, which is now all located in the solution tank, is transferred to
direct electrowinning feed tank
7. Discharge of the Leach Residue
The leached residue is fluidized and then discharged to the milling section.
8. Electrowinning
The pregnant solution is pumped to the electrowinning cell feed tank where it is sampled.
The solution in the electrowinning cell feed tank is pumped to the EW cell at controlled
flow rate. Solution is circulated on the cell for a specific period of time determined by the
cell tail assay.
9. Disposal of Electrowinning Tail

The EW tail is transferred in total to the CIL circuit

3.4 Hydro-cyclone
Hydro-cyclones are used for different purposes which include de-chipping, de-watering and
classification, at How Mine however, they are mainly used for classification.

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Figure 6 hydro-cyclone

Feed is introduced under pressure through the tangential inlet generating a vortex with a low
pressure zone along the vertical axis. The particles in the feed are subjected to two opposing forces,
an outward centrifugal force and inward dragging force. The centrifugal force accelerates the
settling rate of the particles thereby separating them according to size and density. Heavier and
fast settling particles move to the wall where velocity is lowest and migrate to the apex or spigot
as underflow. The drag force pushes slower settling particles to the zone of low pressure along the
vertical axis where they are forced upwards through the vortex finder and report to the overflow.

The internal of the hydro-cyclone is lined in order to protect the shell and to increase its life span.
Spigots wear out due to the abrasion forces as the coarse material exits. As a result they should be
measured regularly and replaced when worn out.

The How mine milling section has 4 cyclones, one for each mill and their main function is
classification.

3.5 Screens
Screening is the mechanical separation of particles on the basis of size by passing the particles of
various shape and sizes through holes or slots on the screen surface.

The milling section has two types of screens, the vibrating screen and the linear screen. The Delko
Linear screen is a non-vibrating linear screen.

3.5.1 Vibrating Screens

The screens are mounted with two vibrating motors running in parallel resulting in the whole
screen vibrating linearly at the support of absorbers. The vibrating screen is composed of the

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screening box, vibrating motors and an absorber system. Also on the screen are spray water nozzles
to aid in de-sliming the oversize material as it moves along the screen.

3.5.2 Linear Screen

The linear screen is used to remove trash from the regring cyclones overflow. The screen has a
perforated feed box positioned above the wear resistant polyester cloth with an aperture size of
1000m. The screen cloth is driven by a pulley system powered by a motor .The oversize material
(trash) is retained on the screen and is washed off the screen by water sprays into the discharge
chute.

Figure 7 linear screen

CARBON IN PULP

After the final communition stage (milling) the pulp is normally dilute and thickening is performed
to increase pulp density to about 50% solids by mass. This reduces the size of the leaching plant
that would be required as-well as reduces the amount of leaching reagents required. The leaching
of gold can be conveniently be represented by the Elsener equation,

4Au + 8NaCN + 2 H2O 4 Na Au (CN)2 + 4 NaOH

With optimum Cyanide concentration , clean gold particles dissolve forming a gold aurocyanide
complex in the aqueous phase which is readily adsorbed onto the activated carbon. In addition,
oxygen is a crucial reagent for leaching. Pulp may contain organic and inorganic components

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that consume oxygen, reducing the overall level of dissolved oxygen in the pulp and thus
reducing the leach kinetics.

Advantages of lime addition include

i. decomposition of Bicarbonates in mill water,

ii. improvement in settling rate in thickeners and
iii. improvement in extraction rates

Pulp densities which are too high, as-well as those which are to low can affect gold leaching
performance. Densities should be maintained at 48 50% solids.

Other parameters which affect adsorption include

i. the concentration of free ions such as calcium, sodium and potassium, oxygen
concentration and pH
ii. mineralogy of the material,
iii. particle size of the feed and finely divided material is preferred.

Carbon Adsorption

The technique involves contacting the leached pulp with granular carbon in series of gently
agitating tanks 1 - 18 with a sufficient retention time. The loaded charcoal is then separated from
the pulp on a vibrating trommel screen, coarse enough to retain the carbon but fine enough to allow
the pulp to pass through . The carbon is next sent to the stripping column for deposition and
regeneration. In the final tank 18, 2 tonnes of fresh or barren carbon is put in contact with low
grade or tailing solution. As it moves up the train, the carbon loads to higher and higher
concentration of gold, as it comes in contact with high grade solution.

Tank volume Leach tanks Carbon tanks

1 6 : 140 cubic metres 1;3;4;5;6 2 and 7

7 17 : 80 cubic metres 8;9;11;12;13 10 and 14

18 : 180 cubic metres - 18

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Process flow of ore at the CIP section

Water Storage
concrete tank
Clear water from
CIP

High Rate Thickener Tank 1 High Rate Thickener Tank 2

Flocculent : 1.5kg/hr Overflow from Tank 1
Liquid cyanide : 0.042 litres/sec Clear water
Hydrogen Peroxide : 5litres/hr

Leach Tank 1 Carbon Tank 2 Leach Tank 3 Leach Tank 4 Leach Tank 5
Addition of Production Tank Positioned Compressed Compressed
oxygen Pump agitation Sieve Bend air agitation air agitation
Compressed Round blowers Compressed
air agitation around carbon air agitation
retention screen

Carbon Tank 10 Leach Tank 9 Leach Tank 8 Carbon Tank 7

Leach Tank 6
Pump agitation Compressed Compressed Pump agitation
air agitation Compressed
Round blowers air agitation Round blowers air agitation
around carbon around carbon
retention screens retention screen
Positioned carbon Positioned carbon
transfer pump transfer pump

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Leach Tank 11 Leach Tank 12 Leach Tank 13

Carbon Tank 14
Compressed air Compressed air Compressed air
agitation agitation Pump agitation
agitation
Round blowers around
carbon retention screens
Positioned carbon
transfer pump

Leach Tank 17 Leach Tank 16 Leach Tank 15

Carbon Tank 18
Compressed air Compressed air Compressed air
Pump agitation agitation
agitation agitation
Round blowers around
carbon retention screens
Positioned carbon
transfer pump
Positioned sieve bend

Carbon movement

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Tank 18
Tank 2
2 tonnes
barren carbon Production
Tank 14 Tank 10 Tank 7 tank
from elution
Loaded carbon
2 hours
receiving time

ELUTION

The final loaded carbon is removed by pumping out of the production tank 2, via a sieve bend on
tank 3 and trommel screen on tank 11, and transferred to the elution section where it pours into the
receiving hopper up to a marked 2 tonne level for 2 hours. It is soaked in Hydrochloric Acid before
undergoing elution or deposition of gold cyanide at high temperatures and pH. The elution of
loaded carbon is obtained by using a pressure elution of 2 bars at 1200C in 6-8 hours. The rich
eluate solution that emerges from the elution process is passed through electro winning cells where
gold and other metals are precipitated onto the cathodes.

Process flow of carbon and elute solution at the Elution section

Carbon Receiving Acid wash column Elution Column

Hopper 2.8m3 of the 3 % acid solution Carbon transfer into column : 25
Acid pump into column : 10 mins
2 tonne level marked mins
in red Cold cycle at 2 bars: 15 min
Acid soak : 1hr Hot cycle to 120 : 1hr 30mins
2 hours receiving
time Acid drain : 5min Caustic - Cyanide pump : 30
Caustic soda pump : 10min mins
Caustic - Cyanide soak : 1 hr

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High Grade Tank 2B High Grade Tank 1A

High Grade Tank 3C
Low grade solution Solution samples of eluant
Filled with barren are obtained from discharge
Takes 3 hrs to fill
solution after every 30 mins untill tank is
electrowinning tank 2B Continuation of obtaining elution solution
samples every 30 mins full.
Barren solution is later Takes 3 hrs to fill
on used to wash the 4 Repeat solution samples are obtained
during the cold cycle after elution Solution samples of
next elution
Continuation of obtaining electrowinning electrowinning are
solution samples every 2 hrs obtained every 2 hrs after
tank is full
HGC 2B solution sample is taken when
closing electrowinning

Elution Plant Operations

Reagents prepared are 3% hydro chloric acid, caustic soda solution and high cyanide strength
solution.
Two tonnes of Carbon is transferred from the carbon receiving hopper to the acid wash tank
by pumping using water.
2.8m3 of the 3 % acid solution is pumped from the bottom of the acid wash tank through the
carbon bed and over flows into a recovery sump. Carbon is soaked in acid for 1 hour to remove
in-organic foulants.
Spent acid is drained from the bottom of the acid wash tank and caustic soda solution is pumped
from the bottom of the acid wash tank to neutralize residual acid remaining after the acid wash
cycle.
Treated 2 tonnes of carbon is transferred to the elution column by pumping using water.
The elution column loaded with carbon is pressured using cold water 2 bars and pre heating
using boiler steam is done to elevate temperatures to 120C.
2.8 m3 of Caustic cyanide solution is pumped from the bottom of the Elution column through
the bed of carbon. The overflow from the elution column as a result of pumping the caustic
cyanide solution is transferred to high grade tank 1A.
After transferring all the caustic cyanide solution into the elution column, carbon is soaked for
one and half hours at a temperature of 120C and a pressure of 2 bars.
Low grade strength recycled water (from HGC 3B) is pumped from the bottom of the elution
column to strip high grade mineral value from carbon. Carbon is fluidized and suspended in
solution by maintaining a solution flow rate of 2 bed volumes and the resultant overflow is
transferred into high grade tanks HGC1A and HGC2B.

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High grade solution is immediately pumped to the electro-winning circuit when the stripping
process commences. After filling the two high grade tanks, a third tank is also filled in
preparation for the next elution (low grade strength solution). 30 minutes before end of the
elution cycle, the steam is switched off and a cold cycle strip is done (that is, striping using
cold water for 30 minutes).
The elution and electro wining process is carried out ensuring critical operating parameters are
within range, that is, a working pressure of 2 bars, working temperatures of 1200 C and flow
rates of 2 bed volumes for the elution process and flow rates of 20m3/h, a working voltage in
the range of 4-6 V and current in the range of 350-500 A for electro winning process.
Hazards associated with elution and electro winning include:
i. Chemical spills
ii. Pressure vessels-explosions
iii. Ground flooding
iv. Air pollution
v. Suffocation, Respiratory effects and Fatalities due to (caustic-cyanide fumes)
vi. Steam &Heat stress (boiler steam)
vii. Electrocution

TAILINGS DISPOSAL

Pulp from the last tank 18 gravitates to the tailings thickener were it is dosed with ferrous
sulphate at a rate of 0.4kg/t to neutralise residual cyanide in the pulp.
The tailings attendant checks the high pressure pump and tailings bank pumps whether they
are in good operational condition. There are 2 banks B and C running consisting of 4 pumps
per bank and 1 spare bank A used in case of emergencies, however currently bank A is not
functional as some pumps are not available.
The tailings attendant also checks the quality of water used for running the high pressure pump
in terms of clarity and open the water supply valves to the high pressure pump.
The tailings attendant starts the high pressure pump and the operating pressure for the Curo
pump should be in the range of 1500-1700 kpa before starting the banks.
After the required pressure for the high pump is achieved, the tailings attendant starts up the
banks. On starting the bank, the tailings attendant start by starting the first pump (pump number
1) which is connected to the thickener discharge pipe followed by the preceding pump up-to
the last which is the fourth pump. The fourth pump is connected to the tailings dam delivery
line.
A plug is then inserted on the suction of the pumps which is before pump number 1 (drain
plug) and feed valve (thickener discharge valve) is opened to allow flow of pulp into the
pumps.
The tailings attendants hourly checks and records the amperage for the running banks and Curo
pump pressure. The operating amperages for the running bank(s) pumps should be in the range

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of 30-35 Amps. If one the pumps operating amperage falls below the standard operating
amperage then the bank is immediately stopped and the pump is inspected. If all the pumps
operating amperage falls below the standard operating amperage then the bank is immediately
stopped and the delivery line to tailings dam is inspected. A stand by bank is left running and
if the running bank is not coping up with the pulp inflow resulting in the thickener filling up
,the plant is immediately stopped to prevent spilling of pulp from the thickener. Corrective
action is taken to correct the anomaly.
When shutting down the tailings plant, the tailings attendant stops the first pump and all the
pumps would stop immediately as they are interlocked. Pulp would back flow back into the
thickener and the pumps would be stationery after all the pulp in the delivery line has been
cleared through back flow. The attendant would then close the feed valve and removes the
drain plug.
Finally the high pressure pump is stopped and all water valves supplying water to the high
pressure pump are closed.
In case of emergence the tailings attendant allows the pulp to back flow into the thickener
before closing the feed valve and removing the drain plug. The CIP supervisor ensures that the
emergency pump near the emergence ponds is operating well and the drainages feeding the
emergence pond are clear or not blocked.

Tailings Dam 5

Pulp with densities between 20-25 % solids are pumped from the tailings plant by a series of
pumps on banks A and B ,via a conveyance of HDPE pipes.
Cyclones are mounted at the discharge ends of the pipes from B- Bank. Cyclone performance
is influenced by the feed slurry density. The underflow solids are used to construct the outer
embankment (dam wall) and the cyclone overflow gravitates along the beach towards the
return water pool. The cyclone underflow is mainly coarse material with an average percentage
solid of 80% and overflow contains average percentage solids of 20%.
Water from the cyclone overflow is temporarily contained in the pool which is centralised in
the dam and is pumped back to the plant for recycle/re-use. A free board of 9m is maintained
and a slope of 33 on the dam wall is maintained.
Pulp from C-Bank is discharged during paddock construction or bypassed to discharge in the
beach.
Under-drains were installed during initial bench constructions and they contains clear water
which is collected at the seepage pond. Water from the seepage pond is recycled back to the
dam for irrigation and suppression of dust on the dam wall. An automated pump is used to
pump seepage water.
The under-drains flow-rate are measured on a daily basis and the results logged.

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The tailings facility has storm water drains around so as to contain and prevent all the storm
water from entering the dam.
Duties of the TSF supervisor include
1. Ensuring that all wall building, repairs of rat holes, erosion and gullies is done.
2. Measuring and logging the progress length on the dam wall
3. Ensuring that the catwalks are stable and are not damaged. Catwalks are constructed by filling
in empty lime bags with sand.
4. Inspection to ensure that the berm is maintained at 7m and the wall slope is maintained at 33.
The dam wall is constructed until the vertical height is 9m and next wall has to be constructed
with the same parameters.
5. To inspect and check for any leaks along the delivery line and comments on the status of the
lines at the end of the shift and any deviations are corrected immediately.

Crest marker poles/ Datum poles are installed at the dam wall berms to measure elevation, total
free board and vertical free board. Currently there are 17 crest marker poles around the dam
wall approximately 40m apart, 10 basin marker poles in the beach and a center marker pole in
the pool/pond.
Dam 5 is 39Ha big and managed by the Fraser Alexander company based in South Africa
which has got great expertise in tailings management.
The cycloned dam wall is currently on bench 5. Cyclones A and B are used and connected to
the B-Bank delivery line.
5 under drain pipes were installed and discharge into the seepage pond
Phreatic levels are measured by a piezometer/ dip meter from the installed piezo pipes on a
monthly basis and weekly or daily in the rainy season.
Rehabilitation is in progress and it involves planting trees to avoid soil erosion.

PADDOCK SYSTEM

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Paddocking is another way of dam wall construction which is currently in progress at the
western side of the dam opposite the cyclone dam wall. It involves mostly manual work
compared to cycloning and raises the dam wall at a much slower rate than the cycloning
systems. Two rectangle paddocks A and B are under construction, with A being 55m by 13m
and B is 50m*13m .

1. The 1st stage is packing. This involves construction of boundary mounds of 30cm height,
33 slopes and a crest width of 50cm to form a rectangle of length 50m and width 13.
Butter boards are used to maintain angle of slope.
2. The 2nd stage is tipping. Pulp is discharged into the packed paddock pool from C-Bank
delivery lines. The off take valve with a connected armored hose is opened and the main
line valve is closed. Close monitoring of tipping pulp is observed to avoid packing failure
and pulp spillage.
3. The 3rd stage is decanting. Decant pipes are installed at the beach side crest of the packed
mound strongly secured by burying one end into the packing and leaving the other end to
discharge into the beach. As slime level rises in the packed pool, water is removed/
decanted into the beach and flows to the pond.
4. The last stage involves leaving the slime now level with the packing to dry off whilst
repeating the above stages in construction of the adjoining paddock. High consolidation
pulp is preferred as it dries faster. When the paddock ground has stabilized, the paddock is
raised by packing, tipping, decanting and drying to the next level.

Hazards associated with tailings disposal at Dam 5 include:

i. Dust
ii. Uneven ground
iii. Working at heights/ steep slopes
iv. Pipe bursts
v. Pulp splashes
vi. High temperatures
vii. Effluent water
viii. Snakes, bees, wild animals
ix. Lightning
x. Seepage/ Dam failure

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OBSERVATIONS

There are a number of tests done at the plant in trying to maintain the flow of the process
smoothly.

These include;

1. Percentage grind of the meal

2. Percentage moisture in the ore (taken after ore comes from the fine ore bins)
This is whereby a sample is taken at conveyor number two at the mills and tests are
done to show percentage of moisture in sample.
Sample taken is weighed then a reading is taken.
Sample is then taken to the furnace and all moisture is removed.
Sample is brought back to scale where it is weighed again.
The formulae to get the percentage moisture is then;

100

Per hour the percentage of ore ranges from 0.6 1.8% ore which calculate to 0.27
0.81 tones per hour using the 45tph grinding quantity.
Per 8 hour shift this came to a total of 2.16 - 6.84 tonnes of water per shift.
The question is where does this tonnage of water comes from?
There is a strong belief that this tonnage of water recorded comes from underground,
meaning the ore from underground will be comprised of 2.16 6.84 tonnes grind per
shift.
While on attachment at reduction, the student had discoveries which pose questions in
his head.
These are;
a) There is a lot of dust at the crushers.
b) During crushing water is added to suppress dust produced.
c) There is only one weightometer which is installed at conveyor belt number 2
at milling.
d) Sample for evaluation of moisture content is also taken from belt 2 at the
mills.

Therefore questions come;

i) If it is believed that ore from underground is so wet, where then does the
dust come from during crushing.
ii) What quantity of water is added at crushing per shift.
iii) Why is not that they take also a sample to evaluate moisture at conveyor 1
at the crushers.
iv) Where does the moisture content measured at conveyor 2 at mills comes
from.

Students belief;

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- Though the ore from underground comes wet, I strongly disagree that the tonnage of
moisture measured is the one from underground only.
- The student discovered a larger amount comes from the water added at crushing
rather than from underground.
3. Carbon content in carbon tanks
4. Silt levels
5. pH

PROBLEMS

1. Ore shortages during the hours from 0900 upto 1400 most the times
2. Low effective performance of gyratory crusher and barmac to an extent of replacing with
better old ones.
3. Vibrator number 2 had worn out screen.
4. A lot of dust at the crushersMixing of ore from fine ore bins and crushing plant
housekeeping distorted the feed ore size to the primary mill resulting in poor milling
efficiencies and poor overall grind.
5. Poor grind from the ball mills affects cyclone efficiency and particle classification ,
consequently densities are increased and carbon adsorption is reduced.
6. Breakdown of primary grinding mill, hence secondary mills were doing the primary
grinding
7. Reduction in tonnage per hour of ore grind per hour.
8. Percentage grind was reduced due to absence of primary mill, the 75 wasnt achieved to
an expected percentage.
9. Shortage of steel balls.
10. Silver nitrate sometime ran out for a period or about a week.
11. Tailings dam construction was also affected due to the poor grind from the milling plant
and currently cyclones are not in use since they require finely ground slimes for efficient
classification.
12. Flactuating milling rates affect cyanide dosing for the leaching process as it is supposed to
be according to the milling rate, for example 0.042 litres/ sec of cyanide for 48tonnes/hr
milling. Lack of communication between milling and high rate attendants on the current
milling rates results in higher or lower cyanide levels in pulp and poor carbon adsorption.
13. Lack of functional pump agitators on leach tanks 1;3;4;5;6;8;9;11;12;13;15;16 and 17,
results in slime settling at the bottom of the tank reducing the useful tank volume, also
settled slime may trap carbon and carbon tonnage is reduced.
14. The acid wash pump was not functional and acid reagent mixing and soaking was being
done in the receiving hopper which is sub-standard and hazardous.
15. Some pipes at the elution section have deteriorated and contain leakages, such that water
and chemical solutions leak to the floor causing flooding of grounds, air and land pollution.
16. The flocculent pump at the high rate thickener was not functional; the flocculent mixing
tank is in bad shape, flocculent solution spills to the ground as it is transferred to the DTV
pump which pumps it into the thickener. The ground is slippery and hazardous to the

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attendants. More time is spent attempting to clean the ground with pressurized water,
however it becomes tedious since the flocculent spill is continuous.
17. The super flow tank at the tailings section has no functional agitator, slimes were
continuously settling in the tank and now the tank volume has been greatly reduced, if pulp
too dense is to be sent to the disposal facility, cyclones will be affected and delivery pipes
will be choked, which in turn will lead to the whole plant shutting down

RECOMMENDATIONS

- A sample to be taken also from conveyor 1 at the crushers for testing of percentage
moisture in ore, this will tell the actual moisture tonnage in ore from underground.
- Production operations underground should be increased to produce enough ore to store
at the stock pile and feed the crushing section, this will in turn mean ore will be excess
enough to store in the fine ore bins and any kind of break down at the crushing section
will not stop the milling plant, ore processing will continue up until the break down has
been resolved.
- When primary mill is not functioning, reduce tonnage per hour from 45 to around 15 to
achieve the percentage grind expected.
- Ore obtained from housekeeping operations at the crushing plant should not be sent to
the milling plant but instead be re-introduced into the crushing circuit for efficient size
reduction. Also ore obtained from housekeeping operations at the milling plant should
be re-introduced into the primary mill.
- Procurement of functional agitators is vital to avoid slimes from settling below the
tanks. At one point each tank at a time should be emptied and checked for settled slime
and cleaned so as to maintain the tank volume and improve leaching and carbon
adsorption.
- A telephone should be installed at the high rate thickener bay to enable quick and easy
communication with the milling crew, to avoid overdosing or under dosing cyanide into
the pulp.
- Procurement of functional flocculent pump and re-installing flocculent mixing tank to
enable a good flow of flocculent into the high rate thickener tank and to avoid spillages
and flocculent wastage.
- Procurement of a functional acid pump is vital again to promote standard operations
and control hazards associated with Hydrochloric acid use.
- Leaking pipes at the elution section should be removed and replaced with new efficient
ones to avoid chemical spills, air and ground pollution.
- The settled slime in the tailings super flow tank should be washed in with lots of
pressurized water bit by bit until all of it is removed, careful enough not to introduce
chunks of mud into the delivery lines as this will choke the lines. During the cleaning
out process dilution water should be introduced at the inlet to the discharge line.
- Bank A pumps should be repaired and replaced to keep them available for the spare
line in cases of emergency.

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