Bureau of Mines Information Circular/l9?

Processing Gold Ores Using Heap Leach-Carbon Adsorption Methods

UNITED STATES DEPARTMENT OF THE INTERIOR

Information Circular 8770

Processing Gold Ores Using Heap Leach-Carbon Adsorption Methods

By H. J. Heinen, D. G. Peterson, and R. E. Lindstrom

UNITED STATES DEPARTMENT OF THE INTERIOR Cecil D. Andrus, Secretary

BUREAU OF MINES

This publication has been cataloged as follows:

Heinen, Harold J Processing gold ores using heap leachsarbon adsorption methods / by H. J. Heinen, D. G. Peterson, and R. E. Lindstrom. [Washington] : U.S. Dept. of the Interior. Bureau of Mines, 1978.
21 p. : ill. ; 27 cm. 8770) Bibliography: p. 19-21.
1. Gold Merallurgy. 2. Cyanide process. 3. Gold ores. I. Peterson, David G., joinr author. 11. Lindstrom, Roald E., joinr author. 111. United Srates. Bureau of Mines. 1 % .' Title. V . Series: Unired States. Bureau of Mines. Informarion circular Bureau of Mines ; 8770.

(Information circular

Bureau of Mines ;

TN23.U71

no. 8770

622.06173

U S . Depr. of the Inr. Library

CONTENTS

Abstract Introduction Chemistry of c y a n i d a t i o n ................................................. Mineralogy of gold o r e s .................................................. Amenability t e s t i n g ...................................................... Cyanide heap-leach o p e r a t i o n s ............................................ G o l d - s i l v e r recovery from p r o c e s s s o l u t i o n s ......................... Economics of heap-leach o p e r a t i o n s .................................. Cyanide handling and d i s p o s a l Recent i n n o v a t i o n s i n g o l d - s i l v e r r e c o v e r y from cyanide p r o c e s s s o l u t i o n s Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . References ...............................................................

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ILLUSTRATIONS Laboratory column l e a c h i n g u n i t ...................................... P i l o t - s c a l e heap leach ............................................... Heap-leach c y a n i d a t i o n Leaching o r e heaps by t h e pending method ............................. H y p o t h e t i c a l d i s t r i b u t i o n of gold i n a continuous carbonadsorption operation ............................................... Recovery of gold from a c t i v a t e d carbon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Proposed t r e a t m e n t of cyanide e f f l u e n t s high i n s i l v e r c o n t e n t . . . . . . . Proposed heap leach-carbon a d s o r p t i o n process f o r gold o r e s low i n silver .......................................................... T A B L E Estimated c o s t of a commercial heap-leach c y a n i d a t i o n o p e r a t i o n

...............................................

PROCESSING GOLD ORES USING HEAP LEACH-CARBON ADSORPTION hiETHODS

by
H. J. Heinen,'

D. G . Peterson,' and R. E. Lindstrom2

ABSTRACT This Bureau of Mines r e p o r t reviews t h e r e c e n t developments i n t h e heap l e a c h i n g of gold o r e s w i t h d i l u t e cyanide s o l u t i o n s and t h e recovery of gold and a s s o c i a t e d s i l v e r from t h e pregnant e f f l u e n t s by a carbon a d s o r p t i o n d e s o r p t i o n method. M i n e r a l o g i c a l c o n s i d e r a t i o n s , e x p e r i m e n t a l work, f i e l d s t u d i e s , and commercial o p e r a t i o n s a r e d e s c r i b e d . Also p r e s e n t e d a r e r e c e n t process advances developed by t h e Bureau, i n c l u d i n g t h e a p p l i c a t i o n of (1) a l c o h o l a d d i t i v e s t o t h e c o n v e n t i o n a l h o t a l k a l i n e cyanide s t r i p s o l u t i o n t o enhance gold d e s o r p t i o n from precious metal-laden a c t i v a t e d carbon, and ( 2 ) Na,S p r e c i p i t a t i o n of t h e s i l v e r from g o l d - s i l v e r cyanide s o l u t i o n s a s a means of reducing t h e i n v e n t o r y of carbon r e q u i r e d f o r p r e c i o u s - m e t a l a d s o r p t i o n from heap l e a c h e f f l u e n t s and f o r t h e p r o d u c t i o n of l o w - s i l v e r b u l l i o n from a c t i v a t e d carbon s t r i p p i n g s o l u t i o n s .

INTRODUCTION
Gold m i n e r a l i z a t i o n i s widespread i n t h e United S t a t e s . I n 1967 t h e Bureau of Mines conducted a n engineering a p p r a i s a l of more t h a n 1,300 lode and p l a c e r d e p o s i t s , r e p r e s e n t i n g a l m o s t a l l o f t h e N a t i o n ' s known gold r e s e r v e s , t o determine t h e i r gold product p o t e n t i a l ,(28).3 These d e p o s i t s were estimated t o c o n t a i n over 400 m i l l i o n ounces of g o l d ; however, only 2 pct of t h i s amount was found t o be e x p l o i t a b l e a t $35 p e r ounce. A 400-pct i n c r e a s e i n t h e p r i c e of gold w i t h i n a period of 1 o r 2 y e a r s caused a remarkable r e e v a l u a t i o n of t h e type of m a t e r i a l t h a t c o n s t i t u t e s o r e . Low-grade m a t e r i a l s c o n t a i n i n g a s l i t t l e a s 0.03 ounce of gold p e r ton, providing s u f f i c i e n t tonnage i s a v a i l a b l e , a r e now being f i e l d t e s t e d f o r precious-metal r e c o v e r y . The Bureau of Mines and s e v e r a l mining companies have conducted e x t e n s i v e h y d r o m e t a l l u r g i c a l s t u d i e s t o e x p l o i t low-grade o r e s and mine waste m a t e r i a l . The innovations developed i n c l u d e heap-leach c y a n i d a t i o n followed by precious-metal r e c o v e r y

lMetallurgist. "~u~erviso chemical r~ engineer. Authors a r e with t h e Reno Metallurgy Research Center, Bureau of Mines, Reno, Nev 3 ~ n d e r l i n e dnumbers i n parentheses r e f e r t o items i n t h e l i s t of r e f e r e n c e s a t t h e end of t h i s r e p o r t .

from t h e r e s u l t a n t s o l u t i o n s by carbon a d s o r p t i o n o r by p r e c i p i t a t i o n on zinc, and new procedures f o r more e f f i c i e n t s t r i p p i n g of gold from a c t i v a t e d carbon and s e p a r a t e recovery of gold and a s s o c i a t e d s i l v e r from enriched s t r i p s o l u t i o n s . The purpose of t h i s r e p o r t i s t o review t h e s t a t e - o f - t h e - a r t o f heapl e a c h processing of p r e c i o u s metal o r e s and t h e a p p l i c a t i o n of g r a n u l a r a c t i v a t e d c h a r c o a l f o r precious-metal recovery from cyanide s o l u t i o n s . Heap l e a c h i n g may be d e f i n e d a s t h e p e r c o l a t i o n leaching of p i l e s o f lowg r a d e o r e s o r mine waste t h a t have been stacked o r p i l e d on s p e c i a l l y prepared w a t e r t i g h t drainage pads f o r pregnant l i q u o r c o l l e c t i o n . This p r o c e s s i n g conc e p t d a t e s back t o about 1752 when t h e Spanish miners p e r c o l a t e d a c i d s o l u t i o n s through l a r g e heaps of oxide copper o r e on t h e banks of t h e Rio T i n t o R i v e r . Since t h e n , t h i s p r o c e s s has been used e x t e n s i v e l y throughout t h e world t o leach oxide copper v a l u e s from mine s t r i p m a t e r i a l from open p i t mini n g of porphyry copper d e p o s i t s . Uranium producers have a l s o used heap l e a c h i n g s i n c e t h e l a t e 1950's f o r e x t r a c t i n g uranium from sub-mill-grade o r e s and f o r e x p l o i t i n g r e l a t i v e l y s m a l l low-grade o r e d e p o s i t s . Heap-leach cyanidat i o n i s a comparatively r e c e n t development suggested by Bureau of Mines m e t a l l u r g i s t s i n 1967 a s a p o t e n t i a l l o w - c a p i t a l means f o r p r o c e s s i n g limestone and dolomite s i l t s t o n e - t y p e o r e s c o n t a i n i n g submicrometer p a r t i c l e s of gold i n a -* -a 19 22). porous h o s t r o c k (15 CHEMISTRY O F CYANIDATION The b a s i c p r i n c i p l e of t h e c y a n i d a t i o n process i s t h a t weak a l k a l i n e c y a n i d e s o l u t i o n s have a p r e f e r e n t i a l d i s s o l v i n g a c t i o n on t h e gold and s i l v e r c o n t a i n e d i n a n o r e . The r e a c t i o n ( E l s n e r ' s e q u a t i o n ) g e n e r a l l y accepted f o r s e v e r a l decades a s r e p r e s e n t i n g t h e d i s s o l u t i o n of gold by cyanide s o l u t i o n i s

Recent r e s e a r c h on t h e mechanism of c y a n i d a t i o n , however, i n d i c a t e s t h i s r e a c p . 305). Most of t h e gold d i s s o l v e s by t h e t i o n proceeds i n two s t a g e s r e a c t ion

(1,

and a s m a l l b u t s i g n i f i c a n t p r o p o r t i o n d i s s o l v e s v i a r e a c t i o n 1. The gold d i s s o l u t i o n r a t e i s dependent on t h e c o n c e n t r a t i o n of NaCN and t h e a l k a l i n i t y o f t h e s o l u t i o n , t h e optimum p H being 1 0 . 3 ( 3 ) . For e f f i c i e n t leaching, t h e g o l d should occur a s f r e e , f i n e - s i z e , c l e a n p a r t i c l e s i n an o r e t h a t c o n t a i n s no "cyanicides" o r i m p u r i t i e s t h a t might d e s t r o y cyanide o r otherwise i n h i b i t t h e d i s s o l u t i o n r e a c t i o n . An adequate supply of d i s s o l v e d oxygen must be p r e s e n t i n t h e cyanide s o l u t i o n throughout t h e r e a c t i o n p e r i o d . The chemistry involved i n t h e d i s s o l u t i o n of gold i n t h e heap-leach c y a n i d a t i o n treatment i s t h e same a s t h a t f o r t h e a g i t a t i o n - c y a n i d a t i o n p r o c e s s . I n heap leaching, t h e oxygen, e s s e n t i a l f o r t h e d i s s o l u t i o n of gold, i s i n t r o duced i n t o t h e cyanide s o l u t i o n a s i t i s being s p r i n k l e d upon t h e o r e heap. The adsorbed oxygen and carbon d i o x i d e from t h e a i r may a l s o cause chemical

l o s s e s of cyanide according t o t h e following r e a c t i o n s :

NaCN

CO,

H20

HCN

NaHCO,.

(4

I n heap l e a c h i n g h i g h l y oxidized o r e s , t h e decomposition of cyanide by carbon dioxide may be a s g r e a t a s t h a t caused by t h e a c i d c o n s t i t u e n t s of t h e o r e . The decomposition of cyanide by carbon d i o x i d e , a s w e l l a s by ground a c i d s , i s minimized by u s i n g s u f f i c i e n t a l k a l i such a s lime (CaO) o r c a u s t i c soda (NaOH) i n t h e l e a c h s o l u t i o n t o m a i n t a i n t h e a l k a l i n i t y a t a pH r a n g e of 9 t o 11. The m i n e r a l c o n s t i t u e n t s of t h e o r e and o t h e r f o r e i g n substances c a n i n f l u e n c e t h e c y a n i d a t i o n process i n a number of d i f f e r e n t ways pp. 284351; 1 2 ) . S i l v e r normally occurs w i t h g o l d e i t h e r a s a n i m p u r i t y i n t h e p a r t i c l e r o f n a t i v e gold o r a s s i l v e r - b e a r i n g m i n e r a l s . The occurrence o f s i l v e r i n gold o r e s may range from l e s s t h a n 1 ppm t o s e v e r a l hundred times t h e l e v e l of t h e gold p r e s e n t i n a n o r e . Generally, s i l v e r i s a l s o d i s s o l v e d by t h e cyanide s o l u t i o n and follows t h e gold through t h e p r o c e s s sequence. I r o n s u l f i d e m i n e r a l s , which a r e common c o n s t i t u e n t s o f gold o r e s , a r e o x i d i z e d t o some e x t e n t d u r i n g t h e cyanide leach, t h u s r e s u l t i n g i n t h e formation of a c i d . These a c i d s a r e n e u t r a l i z e d by t h e lime used i n t h e cyanide l e a c h sequence. Copper m i n e r a l s may be d i s s o l v e d by t h e cyanide leach s o l u t i o n and t h u s consume l a r g e q u a n t i t i e s of NaCN and oxygen. Arsenic-bearing m i n e r a l s may a l s o i n t e r f e r e w i t h c y a n i d a t i o n . Realgar (Asas,) and orpiment (As,S,) r e a c t r a p i d l y w i t h t h e cyanide s o l u t i o n and i n h i b i t t h e d i s s o l u t i o n o f g o l d . Arsenopyrite (FeAsS), however, g e n e r a l l y o x i d i z e s v e r y slowly i n a n a e r a t e d cyanide s o l u t i o n and has v e r y l i t t l e a d v e r s e e f f e c t on t h e l e a c h i n g of g o l d . S t i b n i t e (Sb2S,) s t r o n l y i n h i b i t s c y a n i d a t i o n . The presence of b a s e m e t a l ions such a s Fea+, Fe3 , ~ i " , cu2+, 2n2+, and ~ n i n ~ th + e cyanide l e a c h s o l u t i o n w i l l r e t a r d t h e c y a n i d a t i o n of g o l d . I n some c a s e s t h e n a t u r a l l y occurr i n g carbonaceous m a t e r i a l s i n sedimentary-type gold o r e s a c t a s a d s o r b e n t s f o r t h e gold d i s s o l v e d by cyanide s o l u t i o n s . Charred mine timbers have simil a r p r o p e r t i e s and cause premature p r e c i p i t a t i o n of g o l d . Organic substances such a s decayed wood, o i l , g r e a s e , and f l o t a t i o n r e a g e n t s slow down cyanidat i o n of gold by consuming t h e d i s s o l v e d oxygen i n t h e l e a c h s o l u t i o n and a l s o i n h i b i t s subsequent gold recovery from l e a c h s o l u t i o n by p r e c i p i t a t i o n of t h e gold on z i n c d u s t .

( 1 ,

I:

Generally, gold and s i l v e r a r e recovered from pregnant cyanide s o l u t i o n s e i t h e r by p r e c i p i t a t i o n on z i n c d u s t o r by a d s o r p t i o n on a c t i v a t e d carbon. For p r e c i p i t a t i o n of gold on z i n c , c l a r i f i c a t i o n of t h e pregnant s o l u t i o n i s required t o e l i m i n a t e t h e suspended c l a y e y c o n s t i t u e n t s t h a t can c o a t t h e zinc p a r t i c l e s and r e t a r d p r e c i p i t a t i o n of t h e p r e c i o u s m e t a l s . E l i m i n a t i o n of t h e dissolved oxygen from t h e pregnant s o l u t i o n i s e s s e n t i a l t o p r e v e n t t h e r e d i s s o l u t i o n of t h e p r e c i p i t a t e d gold v i a r e a c t i o n 1 o r 2, and e x c e s s i v e z i n c consumption through i t s i n t e r a c t i o n w i t h t h e oxygen remaining i n s o l u t i o n . The p r e c i p i t a t i o n of gold on z i n c i s g r e a t l y improved by adding s o l u b l e lead s a l t s , such a s l e a d a c e t a t e o r lead n i t r a t e , t o cyanide s o l u t i o n s t o form a zinc-lead couple o f g r e a t e r a c t i v i t y . The r e a c t i o n f o r p r e c i p i t a t i p n of gold

by z i n c may be r e p r e s e n t e d by t h e f o l l o w i n g e q u a t i o n :

Na2Zn(CN),

Au

1/2H,

+ NaOH.

(5)

Activated carbon has t h e c a p a b i l i t y of adsorbing t h e gold cyanide complex from c y a n i d a t i o n r e a c t i o n pulps and u n c l a r i f i e d cyanide e f f l u e n t s , t h e r e b y e l i m i n a t i n g t h e l i q u i d - s o l i d s s e p a r a t i o n , c l a r i f i c a t i o n , and d e a e r a t i o n p r o c e s s i n g s t e p s t h a t a r e employed i n a n a l l s l i m e c o u n t e r c u r r e n t d e c a n t a t i o n z i n c p r e c i p i t a t i o n p l a n t . Although a c t i v a t e d carbon has been used i n g o l d - s i l v e r r e c o v e r y from cyanide s o l u t i o n s f o r s e v e r a l decades, t h e mechanism of gold a d s o r p t i o n on a c t i v a t e d carbon i s s t i l l n o t f u l l y understood. One t h e o r y i s t h a t t h e gold i s adsorbed a s t h e gold cyanide complex AU(CN)~-and t h a t t h i s a d s o r p t i o n t a k e s p l a c e by i o n exchange (1,p. 341). Some f a c t s t h a t support t h i s t h e o r y a r e (1) CN- ions a r e a l s o adsorbed by t h e a c t i v a t e d c a r bon, (2) a d s o r p t i o n of AU(CN)~-i o n i s n o t accompanied by a d s o r p t i o n of a d e q u i v a l e n t q u a n t i t y of caa+ o r ~ a ions + from s o l u t i o n , and ( 3 ) t h e adsorbed g o l d can be desorbed o r d i s p l a c e d w i t h OH- i o n s provided by h o t a l k a l i n e s o l u t i o n s . A r e c e n t s t u d y (7) i n d i c a t e d t h a t t h e gold adsorbed o n t o a c t i v a t e d carbon i s e i t h e r i n t h e calcium aurocyanide or hydrogen aurocyanide form, depending on t h e p H of t h e cyanide s o l u t i o n and t h e c o n c e n t r a t i o n and c h a r a c t e r of t h e " s p e c t a t o r " c a t i o n s p r e s e n t . MINERALOGY O F G O L D ORES The manner o f gold occurrence and i t s a s s o c i a t i o n w i t h t h e gangue minera l s d i c t a t e whether o r n o t t h e o r e can be processed by t h e cyanide heap-leach method. From a m e t a l l u r g i c a l s t a n d p o i n t , gold o r e s may be roughly c l a s s i f i e d a s (1) simple o x i d e o r e s c o n t a i n i n g f i n e p a r t i c l e s of n a t i v e gold i n a q u a r t z o r limestone gangue, (2) simple s u l f i d e o r e s i n which t h e gold i s a s s o c i a t e d ~ i t minor h amounts of p y r i t e o r a r s e n o p y r i t e , (3) p l a c e r o r alluvium m a t e r i a l , ( 4 ) complex o r r e f r a c t o r y o r e s i n which t h e gold-bearing m i n e r a l s p e c i e s a r e n o t r e a d i l y s o l u b l e i n cyanide s o l u t i o n , (5) complex b a s e m e t a l o r e s i n which t h e precious m e t a l s a r e important economic c o n s t i t u e n t s , and (6) base m e t a l o r e s i n which t h e p r e c i o u s metals a r e of minor v a l u e and a r e byproducts o f t r e a t m e n t (27). Of t h e s e , only t h e simple oxide and s u l f i d e o r e s and c e r t a i n p l a c e r s a r e s u i t a b l e f o r heap l e a c h i n g . These m a t e r i a l s must p o s s e s s t h e f o l lowing c h a r a c t e r i s t i c s : (1) Gold and s i l v e r v a l u e s a r e l e a c h a b l e by cyanidat i o n , (2) s i z e of t h e gold p a r t i c l e s i s extremely s m a l l , ( 3 ) t h e h o s t r o c k i s porous t o cyanide s o l u t i o n , and remains permeable during t h e r e l a t i v e l y long l e a c h c y c l e , (4) gold p a r t i c l e s i n o r e s o f low p o r o s i t y a r e l i b e r a t e d o r exposed by f r a c t u r i n g and c r u s h i n g , (5) t h e o r e i s f r e e o f carbonaceous mater i a l which has t h e c a p a b i l i t y of adsorbing gold cyanide and c a u s e s premature p r e c i p i t a t i o n of t h e gold, (6) t h e o r e i s r e l a t i v e l y f r e e of "cyanicides" o r substances t h a t d e s t r o y cyanide o r i n t e r f e r e with t h e g o l d - c y a n i d a t i o n r e a c t i o n , such a s p a r t i a l l y oxidized s u l f i d e s of antimony, z i n c , i r o n , copper, and a r s e n i c c o n t a i n i n g m i n e r a l s , (7) t h e o r e does n o t c o n t a i n e x c e s s i v e amounts of "fines" o r c l a y e y c o n s t i t u e n t s t h a t w i l l impede s o l u t i o n p e r c o l a t i o n , and ( 8 ) t h e o r e i s r e l a t i v e l y f r e e of acid-forming c o n s t i t u e n t s t h a t cause high l i m e consumption.

Types of gold-bearing d e p o s i t s found amenable t o heap leaching a r e a s follows: (1) Limey s i l t s t o n e c o n t a i n i n g submicrometer-size gold p a r t i c l e s and minute amounts of p y r i t e , g a l e n a , c i n n a b a r , and s t i b n i t e , ( 2 ) s i l i c i f i e d s i l t s t o n e s c o n t a i n i n g micrometer-size p a r t i c l e s o f g o l d , o f t e n a s s o c i a t e d w i t h r e s i d u a l i r o n oxides, (3) sanded dolomite o r e i n which f i n e gold p a r t i c l e s occur on t h e i n t e r g r a n u l a r s u r f a c e s , ( 4 ) v e i n q u a r t z o r e i n which gold occurs i n l i m o n i t e - r i c h c a v i t i e s and f r a c t u r e s , ( 5 ) igneous h o s t m a t e r i a l c u t w i t h small q u a r t z v e i n s c o n t a i n i n g f r e e gold and minor amounts of p y r i t e , ( 6 ) a s c h i s t c o n t a i n i n g f r e e gold i n t h e l a m i n a t i o n of t h e r o c k s , and (7) s i l i c e o u s q u a r t z s i n t e r of h o t - s p r i n g o r i g i n . AMENABILITY TESTING Even though t h e minera l o g i c a l s t u d i e s may i n d i c a t e t h a t t h e gold mineralization i s associated w i t h h o s t rocks t h a t a r e s u i t a b l e f o r heap l e a c h i n g , it i s prudent t o conduct l a b o r a t o r y and p i l o t t e s t s f o r verification. The t e c h n o l ogy f o r determining whether o r n o t a gold o r e i s amena b l e t o p e r c o l a t i o n leaching w i t h weak cyanide s o l u t i o n s is well established. I n i t i a l l y , b o t t l e cyanidation t e s t s a r e conducted on 200t o 500-gram charges of ground o r e t o determine t h e degree o f gold e x t r a c t i o n and r e a g e n t consumption. I f t h e gold c o n t e n t of t h e o r e i s leachable a t a r e l a t i v e l y c o a r s e g r i n d , column p e r c o l a t i o n t e s t s a r e made on o r e crushed t o v a r i o u s s i z e s , ranging from minus 2- t o minus 1/4-inch f e e d . The t e s t apparatus i s shown i n f i g u r e 1. About 60 pounds of crushed o r e i s mixed with s u f f i c i e n t lime t o provide p r o t e c t i v e a l k a l i n i t y during c y a n i d a t i o n . This ore-lime mixture i s t r a n s f e r r e d t o a column about 6 inches i n diameter t o make a bed about ! , f e e t high. Twelve l i t e r s of s o l u t i o n c o n t a i n i n g 1 . 0

Pump
Barren cyanide solution
FIGURE 1. - Laboratory colunin leaching u n i t .

pound NaCN per t o n i s pumped t o t h e t o p of t h e column, and t h e flow r a t e i s c o n t r o l l e d so t h a t t h e s o l u t i o n t r i c k l e s slowly downward through t h e o r e . The pregnant e f f l u e n t from t h e column i s t h e n passed upward through t h r e e s m a l l columns c o n t a i n i n g g r a n u l a r a c t i v a t e d carbon and placed i n s e r i e s . The b a r r e n s o l u t i o n from t h e a d s o r p t i o n columns i s r e c y c l e d f o r a d d i t i o n a l l e a c h i n g a f t e r making any n e c e s s a r y adjustments i n t h e cyanide and lime c o n c e n t r a t i o n . Leachi n g i s continued u n t i l no f u r t h e r s i g n i f i c a n t amount of gold i s e x t r a c t e d from t h e o r e . P i l o t - s c a l e heap-leach t e s t s may be conducted on a tonnage s c a l e i f i t i s d e s i r a b l e t o confirm r e s u l t s obtained i n l a b o r a t o r y column-percolation The p e r c o l a t i o n t e s t s , or t o f u r t h e r q u a n t i f y r e a g e n t requirements ( f i g . 2 ) . r a t e of s o l u t i o n through t h e o r e can b e s t be measured by conducting tonnages c a l e experiments i n columns c o n t a i n i n g a bed of o r e 15 t o 20 f e e t high.

FIGURE 2.

Pilot-scale heap leach.

CYANIDE H E A P -LEACH OPERATIONS Cyanide heap l e a c h i n g i s a comparatively r e c e n t h y d r o m e t a l l u r g i c a l d e v e l opment f o r e x p l o i t i n g low-grade gold o r e s , mine waste m a t e r i a l , o r d e p o s i t s too s m a l l t o j u s t i f y c o n s t r u c t i o n of m i l l i n g f a c i l i t i e s . Although t h e process i s analogous t o heap l e a c h i n g of copper o r e s , i t i s s t i l l considered t o be i n t h e developmental s t a g e because many p r o c e s s v a r i a b l e s i n f l u e n c i n g s o l u t i o n p e r c o l a t i o n and d i s s o l u t i o n of t h e gold a r e n o t f u l l y understood. Each comm e r c i a l i n s t a l l a t i o n has developed an o p e r a t i n g technique f o r pad and heap p r e p a r a t i o n and leaching procedure t h a t meets t h e requirements of t h e o r e . The technique s e l e c t e d depends l a r g e l y on t h e manner of occurrence o f t h e gold, p h y s i c a l c h a r a c t e r i s t i c s and m i n e r a l composition of t h e o r e , and t h e s c a l e of o p e r a t i o n .

A l l commercial cyanide heap-leach o p e r a t i o n s a r e being conducted on mater i a l stacked on impermeable pads. W a t e r t i g h t pads o r bases a r e r e q u i r e d t o c o l l e c t t h e pregnant s o l u t i o n s and t o e l i m i n a t e t h e p o s s i b i l i t y of l o s i n g gold and s i l v e r cyanide s o l u t i o n s t o t h e ground and contaminating l o c a l streams and underground water r e s o u r c e s . The types o f m a t e r i a l s used f o r c o n s t r u c t i n g t h e impervious pads i n c l u d e (1) compacted t a i l i n g s mixed w i t h b e n t o n i t e , (2) a s p h a l t ( b l a c k t o p ) o r l i g n i n s u l f o n a t e mix placed on compacted g r a v e l and covered w i t h a n a s p h a l t s e a l e r , ( 3 ) r e i n f o r c e d c o n c r e t e p a d s , and (4) p l a s t i c or rubber s h e e t i n g l a i d on a smooth excavated a r e a and covered w i t h 2 t o 3 f e e t of washed sand and g r a v e l .
B a s i c a l l y , two methods of heap-leach c y a n i d a t i o n a r e used commercially: (1) s h o r t - t e r m l e a c h i n g of crushed o r e , and ( 2 ) long-term l e a c h i n g of r u n - o f mine m a t e r i a l .
\

I n p r a c t i c i n g s h o r t - t e r m , heap-leach c y a n i d a t i o n , t h e o r e i s crushed t o a small s i z e , s t a c k e d 4 t o 8 f e e t high on permanent pads, each w i t h a c a p a c i t y ranging from 1,000 t o 10,000 t o n s , and leached by s p r i n k l i n g t h e top of t h e heap w i t h d i l u t e cyanide s o l u t i o n ( f i g . 3 ) . Cyanide s o l u t i o n p e r c o l a t e s through t h e heap d i s s o l v i n g t h e gold and s i l v e r v a l u e s . I t i s subsequently c o l l e c t e d on t h e w a t e r t i g h t pad, which i s sloped t o permit t h e pregnant s o l u t i o n t o flow i n t o channels f o r t r a n s f e r t o a s t o r a g e pond o r tank. The feed m a t e r i a l i s crushed t o a s i z e t h a t w i l l g i v e good l i b e r a t i o n o r exposure of the gold m i n e r a l i z a t i o n t o cyanide s o l u t i o n and s t i l l o b t a i n r e a s o n a b l e percolation rates. I n t y p i c a l o p e r a t i o n s , o r e s a r e crushed t o minus t h r e e - f o u r t h s inch, and a s f i n e a s minus one-fourth i n c h i n t h e c a s e of a gold-quartz o r e . The leach c y c l e i s measured i n days, g e n e r a l l y from 7 t o 30. When t h e leach cycle i s completed, t h e waste i s removed from t h e pad and a new b a t c h of crushed o r e i s a p p l i e d . The C a r l i n Gold Mining Co. (21) s t a r t e d t h i s t y p e of leaching on mine c u t o f f m a t e r i a l crushed t o t h r e e - f o u r t h s inch i n 1971. The Smoky Valley Mining Co. has completed t h e i n s t a l l a t i o n of a 8,000-tonlday short-term heap leach-carbon a d s o r p t i o n - e l e c t r o w i n n i n g f a c i l i t y a t Round 29). Mountain t h a t went on-stream December 1976 ( Long-term l e a c h i n g i s used p r i m a r i l y t o e x t r a c t gold from uncrushed, porous, sub-mill-grade m a t e r i a l from open p i t o p e r a t i o n s . The o r e charges a r e run-of-mine m a t e r i a l generated by b l a s t i n g , and may c o n t a i n some l a r g e

Barren cyanide solution

Pregnant cyanide effluent

FIGURE 3.

- Heap-leach cyanidation.

boul:l..rs, b u t most of t h e feed i s minus 6 inches i n s i z e . The tonnage of t h e heaps under t r e a t m e n t u s u a l l y ranges from 10,000 t o 2,000,000 t o n s . Most l e a c h heaps a r e shaped t o resemble a t r u n c a t e d pyramid 20 t o 30 f e e t high, a s d e p i c t e d i n f i g u r e 3 . The h e i g h t i s governed by f a c t o r s such a s o r e permeab i l i t y and t h e maintenance of p r o t e c t i v e a l k a l i n i t y , cyanide s t r e n g t h , and s u f f i c i e n t d i s s o l v e d oxygen i n t h e l e a c h s o l u t i o n a s i t p e r c o l a t e s downward through t h e heap. The leach c y c l e i s measured i n months. These heaps a r e leached u n t i l i t i s no longer p r o f i t a b l e t o c o n t i n u e t h e o p e r a t i o n , which may be f o r y e a r s . Upon t e r m i n a t i o n of t h e l e a c h , t h e r e s i d u e i s l e f t on t h e pad. Cortez Gold Mines has completed heap l e a c h i n g approximately 2 m i l l i o n t o n s of Cortez operated t h e f i r s t run-of-mine c u t o f f m a t e r i a l (8-9; 20, pp. 40-42). known i n t e g r a t e d heap-leach cyanidation-carbon a d s o r p t i o n - e l e c t r o w i n n i n g p l a n t a t i t s Gold Acres p r o p e r t y , about 8 m i l e s from t h e main cyanide p l a n t . Generally, t h e cyanide l e a c h s o l u t i o n s a r e introduced o n t o t h e heaps by s p r a y i n g from p e r f o r a t e d p l a s t i c p i p e s , by s p r i n k l i n g u s i n g p l a s t i c s p r i n k l e r heads, o r by ponding. Ty i c a l r a t e s of a p p l i c a t i o n of t h e l e a c h s o l u t i o n s r a n g e from 5 t o 75 g a l / f t of s u r f a c e a r e a p e r day. Pond l e a c h i n g , a s i l l u s t r a t e d i n f i g u r e 4 , was a p p l i e d s u c c e s s f u l l y by t h e Idaho Mining Corp. (30) t o e x t r a c t t h e r e a d i l y l e a c h a b l e gold v a l u e s from a sanded dolomite o r e t h a t

n
Impervious pad

Barren cyanide solution

e x h i b i t s slow p e r c o l a t i o n c h a r a c t e r i s t i c s . one hundred and s i x t y thousand t o n s of o r e was stacked about 25 f e e t h i g h and l e v e l e d ; t h e f l a t s u r f a c e of t h e p i l e was d i v i d e d by s m a l l d i k e s i n t o n i n e ponds t o f a c i l i t a t e c o n t r o l of l e a c h i n g s o l u t i o n s . The heap was washed w i t h b a r r e n s o l u t i o n s from t h e carbon a d s o r p t i o n p l a n t .

In commercial a p p l i c a tion, solution strengths range from 0 . 5 t o 1 . 0 pound of sodium cyanide p e r t o n of s o l u t i o n , and t h e pH i s maintained a t about 10 w i t h t h e a p p l i c a t i o n of lime (CaO) o r c a u s t i c soda (NaOH)
Pregnant cyanide effluent Gold-Silver Recovery From Process S o l u t i o n s

Based on t h e a v a i l a b i l i t y of e x i s t i n g c o n v e n t i o n a l cvanide m i l l f a c i l i t i e s w i t h a z i n c p r e c i p i t a t i o n c i r c u i t , t h e gold and s i l v e r contained i n heap-leach pregnant s o l u t i o n s may be recovered from s o l u t i o n s by c o n v e n t i o n a l M e r r i l l Crowe p r e c i p i t a t i o n . I f m i l l f a c i l i t i e s a r e n o t a v a i l a b l e o r i f t h e concent r a t i o n of gold i n s o l u t i o n i s below a nominal 0.05-0z/t0n s o l u t i o n , t h e p r e f e r r e d method f o r r e c o v e r i n g t h e p r e c i o u s metal v a l u e s from heap-leach e f f l u e n t s i s by a d s o r p t i o n on a c t i v a t e d carbon. Not only i s t h e carbon a d s o r p t i o n process more e f f i c i e n t t h a n z i n c p r e c i p i t a t i o n f o r t r e a t i n g d i l u t e g o l d - s i l v e r cyanide s o l u t i o n s , b u t t h e method a l s o e n t a i l s lower c a p i t a l and 24). operating c o s t s (5-5,

FIGURE 4.

- Leaching ore heaps by the ponding method.

The carbon a d s o r p t i o n method became p r a c t i c a l on development of a u s a b l e method f o r s t r i p p i n g t h e p r e c i o u s metal v a l u e s from t h e a c t i v a t e d carbon s o it could be r e c y c l e d i n t h e system. Today, t h e u s e of a c t i v a t e d carbon i n conjunction w i t h heap l e a c h i n g i s a simple, economical p r o c e s s t h a t i s s u i t a b l e ... f o r e x p l o i t i n g l e a n r e s o u r c e s o r s m a l l o r e b o d i e s . The c a p i t a l investment f o r t h i s p r o c e s s i s e s t i m a t e d t o b e about 20 t o 25 p c t of t h e c o s t of a convent i o n a l c o u n t e r c u r r e n t d e c a n t a t i o n cyanide p l a n t , and o p e r a t i n g c o s t s a r e about 40 p c t (6-5, 24) of a c o n v e n t i o n a l cyanide p l a n t . I n t y p i c a l continuous carbon-adsorption o p e r a t i o n , t h e gold cyanide e f f l u e n t s from heap leaching a r e pumped upward through from t h r e e t o f i v e columns o r tanks i n s e r i e s which c o n t a i n g r a n u l a r a c t i v a t e d carbon. The harder carbons, manufactured from coconut s h e l l s , a r e p r e f e r r e d f o r u s e

because t h e r e i s l e s s tendency f o r breakage o r a b r a s i o n . The amount of gold and s i l v e r t h a t can be loaded on t h e carbon w i l l v a r y g r e a t l y , depending on t h e t y p e of o r e and t h e t e n o r of t h e cyanide l e a c h s o l u t i o n . Some f a c t o r s t h a t i n f l u e n c e t h e loading a r e ( 1 ) t h e c o n c e n t r a t i o n of gold and s i l v e r i n cyanide l e a c h s o l u t i o n s , ( 2 ) r a t i o of gold t o s i l v e r , ( 3 ) pH of leach s o l u t i o n , (4) c o n c e n t r a t i o n of i m p u r i t i e s , (5) flow r a t e , and ( 6 ) t y p e and p a r t i c l e s i z e of g r a n u l a r carbon employed. T y p i c a l loadings o b t a i n e d commercially range from 200 t o 800 ounces of gold, o r combination of gold and s i l v e r , per t o n of carbon. However, t h e a d s o r p t i o n phenomena i s n o t r e s t r i c t e d t o gold and s i l v e r cyanide complexes. A c t i v a t e d carbon i s c a p a b l e of adsorbing a l a r g e v a r i e t y of o r g a n i c s u b s t a n c e s , and i n o r g a n i c c o n s t i t u e n t s s u c h a s s i l i c i c a c i d , and m e t a l l i c i o n s such a s calcium, copper, n i c k e l , merc u r y , and i r o n , t h u s r e d u c i n g t h e number of s i t e s a v a i l a b l e f o r t h e p r e c i o u s m e t a l s . The p r e f e r r e d pH of t h e l e a c h s o l u t i o n t o o b t a i n e f f i c i e n t gold a d s o r p t i o n ranges from 9 t o 11. The c o n c e n t r a t i o n of f r e e cyanide i n t h e l e a c h s o l u t i o n should be maintained a t a v a l u e t h a t i s a s low a s p o s s i b l e and s t i l l be c o n s i s t e n t w i t h s a t i s f a c t o r y metal e x t r a c t i o n from t h e o r e . F i n e r s i z e carbon p a r t i c l e s adsorb g r e a t e r amounts of gold and a t a f a s t e r r a t e t h a n c o a r s e carbons; however, t h e mesh s i z e should n o t be so s m a l l t h a t it r e s u l t s i n p a r t i c u l a t e carbon l o s s e s t o t h e process s o l u t i o n s d u r i n g t h e a d s o r p t i o n s t e p . The a d s o r p t i v e c a p a c i t y o f a c t i v a t e d carbon manufactured from coconut s h e l l s f o r gold cyanide i s g e n e r a l l y g r e a t e r t h a n t h a t of carbons prepared from petroleum coke, wood, o r c o a l . Also, h i g h e r c o n c e n t r a t i o n s of gold i n pregnant cyanide s o l u t i o n s produces h i g h e r gold loading on t h e carbon. Simil a r l y , h i g h e r gold loading on a c t i v a t e d carbon and t h e p r o d u c t i o n of lower gold-bearing b a r r e n s a r e achieved by using lower flow r a t e s . There a r e two methods f o r loading a c t i v a t e d carbon. I n one method, t h e g o l d - b e a r i n g cyanide s o l u t i o n i s p e r c o l a t e d downward through a f i x e d bed of a c t i v a t e d carbon. I n t h e o t h e r , t h e pregnant cyanide s o l u t i o n i s pumped upward through t h e carbon a t a v e l o c i t y s u f f i c i e n t t o m a i n t a i n t h e bed o f c a r bon i n a f l u i d i z e d s t a t e o r suspended i n t h e s o l u t i o n stream without being c a r r i e d o u t of t h e system. The choice of loading technique depends on t h e amount of t u r b i d i t y or s l i m e s p r e s e n t i n t h e heap-leach e f f l u e n t s . The f i x e d beds o r gacked carbon columns a r e l i m i t e d t o a maxirnum s o l u t i o n flow of about 5 gpmlft of c r o s s - s e c t i o n a l a r e a . The feed s o l u t i o n s must be f r e e of p a r t i c u l a t e m a t t e r because t h e bed of carbon behaves a s a s a n d - f i l t e r and w i l l e v e n t u a l l y become plugged i f s l i m e s a r e p r e s e n t . The o n l y advantage of t h e fixed-bed carbon i s t h a t t h e amount of carbon r e q u i r e d i s l e s s t h a n t h a t r e q u i r e d f o r a f l u i d i z e d system processing t h e same amount of s o l u t i o n . The f l u i d i z e d - b e d a d s o r p t i o n system i s g e n e r a l l y used i n commercial p r a c t i c e f o r adsorbing gold cyanide v a l u e s from u n c l a r i f i e d l e a c h s o l u t i o n s c o n t a i n i n g minor amounts of s l i m e s . Four important process v a r i a b l e s t o be c o n s i d e r e d i n t h e d e s i g n of a f l u i d i z e d bed a c t i v a t e d carbon loading system a r e (1) flow r a t e of t h e feed s o l u t i o n , (2) average d a i l y production of p r e c i o u s metals, ( 3 ) maximum amount of gold t h a t can be loaded on t h e carbon, and (4) t h e p a r t i c l e s i z e of carbon employed. Item 1 i s based on t h e volume of pregnant s o l u t i o n generated d a i l y from t h e heap-leach o p e r a t i o n . Item 2 may be based on a weighed maximum gold c o n c e n t r a t i o n i n s o l u t i o n s obtained from s e v e r a l heaps placed i n o p e r a t i o n a t s t a g e d i n t e r v a l s . The inventory of

carbon r e q u i r e d i n t h e p l a n t and t h e s i z e of a d s o r p t i o n and s t r i p p i n g equipment can be minimized by u t i l i z i n g t h e a d s o r p t i v e c a p a c i t y of t h e carbon f o r gold t o t h e f u l l e s t e x t e n t t h a t i s p r a c t i c a l . A loading of 400 ounces of p r e c i o u s metals per t o n i s considered d e s i r a b l e by t h e i n d u s t r y . However, i f t h e incoming s o l u t i o n c o n t a i n s l e s s than 0.05 ounce of gold per ton, t h e l o a d i n g u s u a l l y w i l l n o t exceed 200 o z / t o n of carbon. The p a r t i c l e s i z e of carbon used c o m e r c i a l l y i n heap-leach c y a n i d a t i o n i s e i t h e r minus 6 p l u s 16 o r minus 12 p l u s 30 mesh. Generally, t h e s o l u t i o n flow r a t e r e q u i r e d t o m a i n t a i n f l u i d i z a t i o n i n a bed of carbon c o n t a i n i n g minus 6- p l u s 16-mesh p a r t i c l e s i s about 25 gpm/fta of c r o s s - s e c t i o n a l a r e a o f t h e column, whereas f o r t h e minus 12- p l u s 30-mesh carbon, t h e r e q u i r e d flow r a t e i s 15 gpm/f$. Under t h e s e c o n d i t i o n s , t h e carbon bed expands about 50 p c t . The depth of t h e bed of c a r bon a t r e s t should n o t be more t h a n t h r e e times t h e diameter o f t h e column. The h e i g h t of t h e column should be 2.5 t o 3 times t h e h e i g h t of t h e carbon a t r e s t t o allow f o r proper expansion of t h e bed and t o provide enough f r e e board t o a l l o w f o r s o l u t i o n s u r g e s . The amount of carbon r e q u i r e d f o r a f l u i d i z e d bed a d s o r p t i o n system employing minus 12- p l u s 30-mesh carbon p a r t i c l e s i s about 10 times t h e d a i l y amount of carbon s t r i p p e d . For t h e minus 6- p l u s 16mesh carbon, t h e carbon i n v e n t o r y should be about 15 times t h e d a i l y amount of carbon s t r i p p e d because of higher s o l u t i o n v e l o c i t y and s h o r t e r c o n t a c t time. I n d u s t r i a l experience has shown t h a t t h e carbon charge should be e q u a l l y d i s t r i b u t e d through f o u r o r f i v e columns o r tanks i n s e r i e s f o r a n e f f i c i e n t c a r bon a d s o r p t i o n system. During s t a r t u p o f a c o u n t e r c u r r e n t carbon a d s o r p t i o n system f o r p r o c e s s ing heap-leach cyanide e f f l u e n t s , t h e f i r s t o r lead column of carbon may adsorb a l l of t h e p r e c i o u s metal v a l u e s . A f t e r t h e carbon has been i n s e r v i c e for some time and c a r r i e s about 20 ounces o f gold p e r ton, a g r a d u a l b r e a k through of gold w i l l occur i n t h e e f f l u e n t from t h e f i r s t column and be adsorbed by t h e succeeding bed of carbon. As t h e carbon i n t h e f i r s t column becomes loaded w i t h more gold and i t s a d s o r p t i v e c a p a c i t y d e c r e a s e s , t h e gold content of t h e column e f f l u e n t s o l u t i o n g r a d u a l l y i n c r e a s e s . It i s obvious from monitoring t h e progress o f a d s o r p t i o n t h a t t o o b t a i n e f f i c i e n t u t i l i z a t i o n of t h e carbon g o l d , it i s advantageous t o use s e v e r a l charges o f carbon i n s e r i e s . E f f l u e n t samples should be c o l l e c t e d a t r e g u l a r i n t e r v a l s and analyzed, p r e f e r a b l y by t h e atomic a b s o r p t i o n technique t o o b t a i n r a p i d gold and s i l v e r a s s a y s a t t h e p l a n t s i t e . When t h e a n a l y s e s i n d i c a t e t h a t t h e l e a d charge of carbon has adsorbed t h e d e s i r e d amount of gold o r becomes s a t u r a t e d , a p o r t i o n of t h i s carbon charge ( r e p r e s e n t i n g t h e d a i l y production of loaded carbon) i s removed, and an e q u i v a l e n t amount from each of t h e o t h e r columns i s advanced one column. An e q u i v a l e n t amount o f f r e s h a c t i v a t e d carbon i s added t o t h e l a s t column t o i n s u r e t h e p r o d u c t i o n of b a r r e n s o l u t i o n s low i n gold content f o r r e c y c l i n g t o t h e heap. F i g u r e 5 i l l u s t r a t e s t h e h y p o t h e t i c a l d i s t r i b u t i o n of gold a t t a i n a b l e i n p r o c e s s i n g 5,000 tons of cyanide s o l u t i o n c o n t a i n i n g 0.10 ounce of gold per t o n and employing f o u r 1-ton beds of carbon in series. The p r e c i o u s metal v a l u e s p r e s e n t l y a r e recovered from loaded carbon by two r a d i c a l l y d i f f e r e n t t e c h n i q u e s . I n one p r a c t i c e , adopted by some s m a l l companies w i t h l i m i t e d c a p i t a l f o r investment i n t h e r e q u i r e d equipment, t h e loaded carbon i s shipped t o s m e l t e r s where t h e product i s burned t o recover a

dore' b u l l i o n by s m e l t i n g t h e ashed r e s i d u e . T y p i c a l s m e l t e r charges i n c l u d i n g t h e nonpayment f o r 7 . 5 p c t o f t h e t o t a l gold c o n t e n t Barren w i l l average about $3,500 Solution p e r d r y t o n of carbon cont a i n i n g 300 ounces o f gold per t o n . A d d i t i o n a l c o s t s t o be considered a r e t h e Pregnant solution purchase p r i c e of t h e a c t i 0.10 oz/fonPu NoCN CaO v a t e d carbon and haulage c h a r g e s . Thus, a r e a s o n a b l e c o s t f i g u r e f o r processing a t o n of loaded carbon by t h e s m e l t i n g technique i s u $5,500 t o $7,000. I n t h e Solution storage p r e f e r r e d method, gold ond makeup tank recovery from a c t i v a t e d c a r FIGURE 5. Hypothetical distribution of gold in a con. bon i s a c c o m ~ l i s h e dbv ~. desorbing t h e gold anb s i l tinuous carbon-adsorption operation. v e r v a l u e s from t h e carbon and e l e c t r o w i n n i n g t h e v a l u e s from t h e r e s u l t a n t s t r i p s o l u t i o n s . This p e r m i t s repeated r e u s e o f t h e carbon, which g r e a t l y enhances t h e economics of t h e carbon c y a n i d a t i o n p r o c e s s . The f i r s t p r a c t i c a l d e s o r p t i o n process was d e v e l oped by t h e Bureau o f Mines i n 1952 (26 -3 3 1 ) . The process (commonly r e f e r r e d t o a s t h e Zadra p r o c e s s ) employs a 1 . 0 p c t NaOH-0.1 p c t NaCN s t r i p s o l u t i o n a t 93" C and a t atmospheric p r e s s u r e t o desorb t h e gold and s i l v e r from t h e c a r bon. The g o l d - s i l v e r d e s o r p t i o n s t e p , which i s dependent upon t h e c o n c e n t r a t i o n of a l k a l i (NaOH) and t h e temperature o f t h e s t r i p s o l u t i o n , i s g r e a t l y enhanced by t h e a d d i t i o n of a n a l c o h o l such a s e t h a n o l o r methanol t o t h e d e s o r b e n t o r s t r i p p i n g s o l u t i o n . The p r e c i o u s metal v a l u e s contained i n t h e s t r i p s o l u t i o n a r e electrowon from t h e s o l u t i o n , and t h e b a r r e n s o l u t i o n r e c y c l e d f o r a d d i r i o n a l s t r i p p i n g . Current i n d u s t r i a l a p p l i c a t i o n of t h e - - i n d i c a t e s t h a t 50 t o 100 hours a r e r e q u i r e d Zadra d e s o r p t i o n process (10-11) t o s t r i p t h e carbon from a loading of 300 ounces of gold t o l e s s t h a n 5 ounces o f gold per t o n of carbon. The Bureau a t t h e S a l t Lake C i t y Metallurgy Research Center developed a p r e s s u r e s t r i p p i n g method t h a t g r e a t l y reduces 25). s t r i p p i n g time and r e a g e n t consumption (3,
00002 oz Au

Economics of Heap-Leach Operations P i z a r r o d e s c r i b e d i n d e t a i l t h e 10,000-ton-per-month heap-leaching operat i o n a t t h e C a r l i n Gold Mine, C a r l i n , Nev. (21). The heap-leach e f f l u e n t s j o i n t h e pregnant s o l u t i o n s from t h e C a r l i n mill f o r c l a r i f i c a t i o n followed by c o n v e n t i o n a l z i n c d u s t p r e c i p i t a t i o n f o r gold recovery. Reagent consumption was minimal, 0 . 1 pound NaCN and 1 . 0 pound CaO per t o n of o r e . P i z z a r o (21) and McQuiston (20, pp. 19-25) presented s e v e r a l e x c e l l e n t t a b l e s o f c a r l i n t s o p e r a t i n g costsBased on t h e s e d a t a , t h e c a l c u l a t e d heap-leaching o p e r a t i o n c o s t s a t C a r l i n were $0.96 per t o n of o r e i n 1973 and $ 1 . 2 1 per t o n i n 1974.

Mountain S t a t e s Research and Development, Tucson, A r i z . (4-5J, made a n economic e v a l u a t i o n on four p r o c e s s e s co-nly employed f o r r e c o v e r i n g gold from low-grade o r e s . The e x t r a c t i o n p r o c e s s e s e v a l u a t e d were (1) heap l e a c h ing w i t h carbon a d s o r p t i o n , ( 2 ) v a t leaching w i t h carbon a d s o r p t i o n , (3) conv e n t i o n a l c o u n t e r c u r r e n t d e c a n t a t i o n , and (4) carbon-in-pulp c y a n i d a t i o n . Bhappu (4) i n d i c a t e d t h a t t h e heap-leach process i s economically j u s t i f i e d i n t h e p r o c e s s i n g of l e a n o r e s averaging 0.04 ounce of r e c o v e r a b l e gold p e r t o n a t gold p r i c e s o f $80 per ounce f o r m u l t i m i l l i o n - t o n o r e b o d i e s . For t h e s m a l l e r o p e r a t i o n s , l a b o r c o s t s would be p r o p o r t i o n a t e l y much l a r g e r p e r t o n , and t h e c o s t s f o r equipment and f a c i l i t i e s would d i f f e r widely depending on t h e a c c e s s i b i l i t y of t h e mine. Chisholm ( 6 ) r e p o r t e d t h a t a s m a l l mining company i n New Mexico brought i n t o production-a 500-ton-per-day open p i t gold mine and heap-leach o p e r a t i o n a t a t o t a l c o s t of $150,000. A breakdown of t h e c o s t s f o r items of equipment purchased and f o r mine f a c i l i t i e s was p r e s e n t e d . A d d i t i o n a l c o s t f a c t o r s t h a t appear t o s u b s t a n t i a t e t h e foregoing c o s t s were developed a s a r e s u l t of information g a t h e r e ? from s e v e r a l s o u r c e s . Based on a 500,000-ton heap-leach o p e r a t i o n , t y p i c a l c o s t s f o r p r e p a r i n g an a s p h a l t pad, i n c l u d i n g p r e p a r a t i o n of s i t e , subbase, s e a l e r , and covering t h e a s p h a l t w i t h a l a y e r of g r a v e l a r e $0.50 per square f o o t . This i s e q u i v a l e n t t o $0.50 per t o n of o r e , assuming t h a t a t o n of o r e i s s t a c k e d p e r square f o o t of pad s u r f a c e . The s t a c k i n g of o r e on a pad r e p o r t e d l y c o s t s about $0.10 per ton. The l e a c h i n g c o s t s a r e dependent on r e a g e n t consumption and l e n g t h of period of t r e a t m e n t , and t h u s can v a r y a p p r e c i a b l y . A r e a s o n a b l e l e a c h i n g c o s t r e p o r t e d l y i s $0.50 per t o n o f o r e . Operation of t h e carbon d e s o r p t i o n u n i t c o s t s about $0.02 per t o n of o r e , assuming t h a t t h e o r e c o n t a i n s 0.05 ounce of r e c o v e r a b l e gold per t o n and t h a t t h e carbon i s loaded w i t h 400 ounces of gold per t o n . P r e v a i l i n g p r a c t i c e i s t o r e g e n e r a t e t h e leached c a r bon b e f o r e r e u s e by h e a t i n g t h e carbon i n a steam atmosphere a t -700" C i n a -Based on c o s t f i g u r e s s t a t e d i n a r e c e n t a r t i c l e on c a r r o t a r y k i l n (8-10). bon r e g e n e r a t i o n (161, t h e c o s t f o r r e a c t i v a t i n g t h e s t r i p p e d carbon i s e s t i mated t o be $0.02 t o n of o r e . A sunnnary of t h e c o s t e s t i m a t e s , excluding mining c o s t s , i s shown i n t a b l e 1.

per

TABLE 1.

Estimated c o s t of a commercial heapleach cyanidation operation Item

1 Cost

C o n s t r u c t i o n of pad . . . . . . . . . . . . . . . I Stacking o r e on pad ............... Heap leaching . . . . . . . . . . . . . . . . . . . . . Carbon d e s o r p t i o n . . . . . . . . . . . . . . . . . Carbon r e g e n e r a t i o n . . . . . . . . . . . . . . . r o t a 1. . . . . . . . . . . . . . . . . . . . . . . .

per t o n of o r e $0.50

.02 1.14

CYANIDE HANDLING AND DISPOSAL The p r e c i o u s - m e t a l s mining i n d u s t r y f o r many y e a r s h a s promoted t h e h e a l t h and s a f e t y o f i t s employees r e g a r d i n g t h e h a n d l i n g and u s e o f c y a n i d e . The i n d u s t r y h a s d e m o n s t r a t e d t h a t , w i t h p r o p e r t r a i n i n g and i n s t r u c t i o n s , cyanide c a n b e used r o u t i n e l y i n leaching g o l d - s i l v e r o r e s w i t h l i t t l e r i s k t o t h e w o r k e r . However, growing c o n c e r n a b o u t o c c u p a t i o n a l h a z a r d s and e n v i r o n m e n t a l p o l l u t i o n has r e s u l t e d i n t h e p r o m u l g a t i o n of r e g u l a t i o n s t h a t r e q u i r e i n d u s t r y t o comply w i t h s t a n d a r d s and g u i d e l i n e s e s t a b l i s h e d b y F e d e r a l , S t a t e , and c o u n t y r e g u l a t o r y b o d i e s . The O c c u p a t i o n a l S a f e t y and H e a l t h A d m i n i s t r a t i o n (OSHA) i n O c t o b e r 1976 p u b l i s h e d i t s recommendations d e s i g n e d t o p r o t e c t t h e h e a l t h o f employees working w i t h c y a n i d e s a l t s . The p u b l i c a t i o n , " C r i t e r i a f o r a Recommended S t a n d a r d - 4 c c u p a t i o n a l Exposure t o Hydrogen Cyanide and Cyanide S a l t s [ N ~ c N , KCN, and c ~ ( c N ) , ] " c a n be p u r c h a s e d f r o m t h e S u p e r i n t e n d e n t o f Documents, U.S. Government P r i n t i n g O f f i c e , Washington, D . C . 20402. Employees working a t a h e a p - l e a c h c y a n i d a t i o n i n s t a l l a t i o n may be exposed t o c y a n i d e i n t h e form o f d u s t and s o l u t i o n s , e s p e c i a l l y d u r i n g mixing o f c o n c e n t r a t e d s t o c k cyanide s o l u t i o n s . I n g e s t i o n o f a s l i t t l e a s 0.20 gram o f sodium c y a n i d e i s c o n s i d e r e d t o be l e t h a l f o r human b e i n g s ( 1 7 ) . The h e a p l e a c h o p e r a t i o n i t s e l f i s c o n s i d e r a b l y l e s s hazardous b e c a u s e t h e leach i s c o n d u c t e d i n a n open a r e a w i t h maximum v e n t i l a t i o n . By m a i n t a i n i n g t h e a l k a l i n i t y o f t h e l e a c h s o l u t i o n a t pH 1 0 t o 11, t h e p o s s i b i l i t y o f g e n e r a t i n g hydrogen c y a n i d e g a s (HCN) i s minimized, and o n l y t r a c e amounts of HCN c a n be r e l e a s e d by i n t e r a c t i o n of NaCN and COa i n t h e e n v i r o n m e n t . Measurements made b y Mining Enforcement and S a f e t y A d m i n i s t r a t i o n (MESA) i n s p e c t o r s (18) show t h a t t h e HCN c o n c e n t r a t i o n i n t h e a i r c l o s e t o a working heap i s c o n s i s t e n t l y 2) o n l y 2 t o 3 ppm. T h i s i s s i g n i f i c a n t l y l e s s t h a n t h e l i m i t o f 1 0 ppm ( e s t a b l i s h e d b y OSHA f o r s u s t a i n e d b r e a t h i n g o f g a s e o u s c y a n i d e . In a well-designed heap-leach i n s t a l l a t i o n , t h e pregnant cyanide s o l u t i o n s e t t l i n g pond, which c a t c h e s t h e d r a i n a g e from t h e heap, s h o u l d b e d e s i g n e d s o t h a t t h e c a p a c i t y of t h e pond i s s u f f i c i e n t t o accommodate t h e maximum r a i n f a l l and r u n o f f t h a t c a n b e e x p e c t e d f o r t h a t p a r t i c u l a r l o c a l i t y , t h u s p r e v e n t i n g t h e discharge of cyanide s o l u t i o n t o t h e watershed during o p e r a t i o n a n d a f t e r abandonment of t h e l e a c h e d o r e heap. The s e t t l i n g ponds a r e gene r a l l y earth f i l l structures t h a t a r e lined with watertight polyvinyl chloride o r p o l y e t h y l e n e s h e e t i n g . Ponds h o l d i n g c y a n i d e s o l u t i o n s s h o u l d b e a d e q u a t e l y p o s t e d and f e n c e d t o r e s t r i c t a c c e s s t o t h e a r e a . Because o f t h e a p p r e c i a b l e e v a p o r a t i o n l o s s e s t h a t o c c u r d u r i n g heap l e a c h i n g , most o p e r a t o r s a r e a b l e t o m a i n t a i n c o m p l e t e r e c y c l i n g o f t h e l e a c h and wash s o l u t i o n s . Thus t h e need t o d i s c h a r g e p o t e n t i a l l y h a z a r d o u s s o l u t i o n s t o maintain the water balance f o r the leach o p e r a t i o n i s circumvented. I f a b l e e d o f f s y s t e m i s r e q u i r e d , i n t h e e v e n t o f a n a b n o r m a l l y heavy r a i n f a l l , c y a n i d e removal t e c h n i q u e s must be c o n s i d e r e d . The most w i d e l y used method f o r r e d u c i n g f r e e c y a n i d e and h e a v y - m e t a l c y a n i d e c o n c e n t r a t i o n s i n w a s t e s t r e a m s i n v o l v e s c h e m i c a l t r e a t m e n t w i t h c h l o r i n e o r h y p o c h l o r i t e . The

r e a c t i o n mechanism i s b e l i e v e d t o be a s follows: NaCN

2NaOH

C1,

-. NaCNO

2NaC1

+ H,O,

(6)

The a v a i l a b l e c h l o r i n e may be f u r n i s h e d a s c h l o r i n e gas o r a h y p o c h l o r i t e s o l u t i o n . Approximately 1 pound of calcium h y p o c h l o r i t e , Ca(OCl),, w i l l o x i d i z e 1 pound of f r e e c y a n i d e . The term 'heavy m e t a l s " g e n e r a l l y denotes t h o s e metals t h a t a r e o f p a r t i c u l a r concern i n cyanide t r e a t m e n t such a s copper, s i l v e r , z i n c , cadmium, mercury, a r s e n i c , chromium, manganese, i r o n , and n i c k e l . The main method employed f o r removal of t h e heavy metals a f t e r t h e d e s t r u c t i o n of cyanide i s by a d d i t i o n of lime t o p r e c i p i t a t e t h e metals and t o promote f l o c c u l a t i o n of t h e p r e c i p i t a t e s . The heavy-metal p r e c i p i t a t e s would be f i l t e r e d and shipped t o a n approved t o x i c - s u b s t a n c e l a n d f i l l f o r d i s p o s a l . The U.S. Environmental P r o t e c t i o n Agency (EPA) r e g u l a t i o n s f o r l i m i t a t i o n s of cyanide d i s c h a r g e i n waste s o l u t i o n s i s 0.02 ppm C N .
It i s c l e a r l y advantageous from a n economic s t a n d p o i n t f o r t h e mine opera t o r t o lower t h e s o l u b l e gold l o s s e s i n t h e heap t o a minimum by thorough washing of t h e leached o r e w i t h f r e s h w a t e r . The washing s t e p r e s u l t s i n recovery of most o f t h e d i s s o l v e d gold and a l a r g e p o r t i o n of o t h e r cyanides remaining i n t h e heap a s f r e e cyanide o r complexed w i t h heavy m e t a l s . Heavymetal cyanide s a l t s a r e known t o p e r s i s t f o r s e v e r a l y e a r s , b u t r e s i d u a l f r e e cyanide i n abandoned heaps i s b e l i e v e d t o e x i s t no more t h a n 1 month, depending on c l i m a t i c c o n d i t i o n s ; however, s c i e n t i f i c d a t a t o s u p p o r t t h i s content i o n a r e l a c k i n g . The r e t e n t i o n and f a t e of r e s i d u a l cyanide i n heap leached r e s i d u e s i s being s c r u t i n i z e d t o an i n c r e a s i n g e x t e n t by r e g u l a t o r y a g e n c i e s .

Abandoned heaps a r e l e s s s u s c e p t i b l e t o wind and water e r o s i o n t h a n f i n e l y ground t a i l i n g s impounded behind a dam. I n t h e semiarid r e g i o n s of t h e Western United S t a t e s , where most of t h e heap l e a c h c y a n i d a t i o n i s being p r a c t i c e d , i n v a s i o n of t h e abandoned heaps by n a t i v e d e s e r t f l o r a has been observed t o occur w i t h i n 1 o r 2 y e a r s . Under p r o v i s i o n s of t h e F e d e r a l Metal and Nonmetallic Mine S a f e t y Act of 1966 ( P u b l i c Law 89-577), M E S A i s r e s p o n s i b l e f o r t h e enforcement of t h e h e a l t h and s a f e t y s t a n d a r d s p r e s c r i b e d t o p r o t e c t t h e workers a t a l l mine s i t e s , which i n c l u d e s heap-leach c y a n i d a t i o n o p e r a t i o n s . With t h e s i g n i n g of the F e d e r a l Mine S a f e t y and Health Act of 1977 ( P u b l i c Law 91-173), i t became the r e s p o n s i b i l i t y of t h e S e c r e t a r y of Health, Education, and Welfare and t h e S e c r e t a r y of Labor t o develop and promulgate improved h e a l t h and s a f e t y s t a n dards f o r persons working a t mining p r o p e r t i e s . New and/or r e v i s e d r e g u l a t i o n s w i l l be implemented by t h e Mining S a f e t y and Health ~ d m i n i d t r a t i o n (MSHA) under t h e Department of Labor. The e f f e c t i v e d a t e o f t h e s e r u l e s and r e g u l a t i o n s i s expected t o be March 9, 1978. Under p r o v i s i o n s of t h e Resource Conservation and Recovery Act of 1976 (Public Law 94-580), EPA i s r e s p o n s i b l e f o r t h e development of r e g u l a t i o n s and g u i d e l i n e s f o r d i s p o s a l and management of a l l s o l i d w a s t e s , i n c l u d i n g mining wastes. EPA c u r r e n t l y i s conducting a d e t a i l e d s t u d y on t h e adverse e f f e c t s

on t h e environment of s o l i d wastes from a c t i v e and abandoned s u r f a c e and underground mines. Guidelines f o r t h e d i s p o s a l of mining wastes a r e expected following t h e completion of t h e s t u d y i n June 1978. Meanwhile, S t a t e and/or county gwernmentswhere heap-leach c y a n i d a t i o n o p e r a t i o n s e x i s t r e g u l a t e t h e d i s p o s a l o r abandonment of cyanided o r e heaps. RECENT INNOVATIONS I N GOLD-SILVER RECOVERY F R O M CYANIDE PROCESS SOLUTIONS Recently, e f f o r t s have been d i r e c t e d toward t h e development of lower c o s t gold-processing procedures t h a t w i l l improve t h e economics of t r e a t i n g lower grade o r e s and d e p o s i t s t o o s m a l l t o warrant c o n s t r u c t i o n of c o n v e n t i o n a l m i l l facilities. The Bureau o f Mines (14) developed a more e f f i c i e n t p r o c e s s f o r r e c o v e r ing gold and s i l v e r from laden a c t i v a t e d carbon. F a c t o r s t h a t c a n a f f e c t t h e performance of t h e modified s t r i p s o l u t i o n i n c l u d e temperature, and c o n c e n t r a t i o n s of NaOH and e t h a n o l . The s t r i p s o l u t i o n , which i s w a t e r c o n t a i n i n g 1 wt-pct NaOH and 20 v o l - p c t e t h a n o l , i s heated t o 80" C and c i r c u l a t e d through a bed of loaded carbon t o desorb p r e c i o u s metals and cyanide i o n s . The precious metals a r e recovered by e l e c t r o l y s i s , and t h e d e p l e t e d e l e c t r o l y t e i s r e c y c l e d t o t h e carbon d e s o r p t i o n column. F i v e t o s i x hours of simultaneous s t r i p p i n g and e l e c t r o w i n n i n g w i l l desorb up t o 99 p c t of t h e precious metal values c a r r i e d by t h e a c t i v a t e d c a r bon. A flow diagram f o r t h e p r o c e s s i s shown i n f i g u r e 6 . Activated carbon, which had been used f o r c a r b o n - i n pulp c y a n i d a t i o n of g o l d ores f o r several years, is now p l a y i n g a n important r o l e i n t h e recovery of gold from heap-leach c y a n i d a t i o n e f f l u e n t s . However, a p p l i c a t i o n of t h i s technology t o t h e t r e a t m e n t of gold o r e s that are rich i n silver g r e a t l y i n c r e a s e s t h e amount of a c t i v a t e d carbon needed t o adsorb t h e e q u i v a l e n t d o l l a r v a l u e of s i l v e r from a n e q u a l volume of l e a c h solution. A processing sequence was developed t h a t circunwents t h e handling of l a r g e q u a n t i t i e s of a c t i v a t e d carbon ( 1 3 ) . It cons i s t s of r e c o v e r i n g t h e s i l v e r s e l e c t i v e l y a s a AgzS

"

le

FIGURE 6.

- Recovery of gold from activated carbon.

p r e c i p i t a t e u s i n g sodium s u l f i d e , and a f t e r f i l t r a t i o n , r e c o v e r i n g t h e gold from t h e f i l t r a t e by carbon a d s o r p t i o n . The key t o t h i s p r o c e s s i s t h e format i o n of r e a d i l y f i l t e r a b l e AgzS f l o c s by a g i t a t i n g t h e s l u r r y w i t h 0.5 pound of CaO p e r t o n of s o l u t i o n f o r about 1 hour. The p r o c e s s sequence i s shown i n f i g u r e 7 . The Ag,S p r e c i p i t a t i o n - c a r b o n a d s o r p t i o n processing method i s being evaluated a t a heap-leach c y a n i d a t i o n i n s t a l l a t i o n by Sand Springs Co., F a l l o n , Nev., f o r p r o c e s s i n g a s i l v e r o r e low i n gold c o n t e n t . The sodium s u l f i d e p r e c i p i t a t i o n procedure was a l s o shown t o be e f f e c t i v e f o r s e l e c t i v e l y p r e c i p i t a t i n g s i l v e r from h i g h l y c o n c e n t r a t e d g o l d - s i l v e r e f f l u e n t s obtained i n t h e i n i t i a l s t a g e s of s t r i p p i n g p r e c i o u s metal-laden a c t i v a t e d carbon. The method provides a means f o r t h e subsequent production of a low-silver gold b u l l i o n . S i l v e r i s p r e c i p i t a t e d s e l e c t i v e l y from s t r i p s o l u t i o n by t h e same procedure used p r e v i o u s l y f o r s i l v e r p r e c i p i t a t i o n from pregnant cyanide l e a c h s o l u t i o n s . F i l t r a t e s c o n t a i n i n g l e s s than 1 ppm Ag and UD t o 800 m m Au were o b t a i n e d . The ~ r e c i ~ i t a t e s which , c o n t a i n diatomaceous e a r t h , lime, s l i m e s , e t c . , a s w e l l a s Ag,S, a s s a y 3,000 t o 6,000 ounces of s i l v e r p e r t o n and r e p r e s e n t 99-pct s i l v e r r e c o v e r y . The e n t r a i n e d gold amounts t o l e s s t h a n 0 . 1 p c t of t h e t o t a l p r e c i o u s m e t a l c o n t e n t . The
L .

NaAg(CNI2 soluticIn from heap leach

Gold recovery

I
precipitotion Retention

.....

Corbon adsorption Loaded carbon

I

I
Corbon stripping

IL,

u
Filtration Silver product Gold product

wren solution

FIGURE 7.

Proposed treatment of cyanide effluents high in silver content.

Corbon columns

l Loaded

Stripped carbon L---------------------

mrbon

II

17
Strip roluliOn tank

s i l v e r - f r e e f i l t r a t e can t h e n be e l e c t r o l y z e d t o win t h e gold by d e p o s i t i o n on s t e e l wool cathodes. Barren e l e c t r o l y t e recycled t o t h e d e s o r p t i o n u n i t can be used t o desorb more v a l u e s from t h e carbon. F i n a l l y , t h e gold-laden s t e e l wool c a t h odes when mixed w i t h proper f l u x e s c a n be r e f i n e d i n t o gold b u l l i o n low i n s i l v e r . Figure 8 shows a conceptual flow diagram d e p i c t i n g t h e heap leach-carbon a d s o r p t i o n d e s o r p t i o n system and t h e precious m e t a l s s e p a r a t i o n and recovery c y c l e .

Desorplion unit

SUMMARY

The r i s i n g free-market gold p r i c e has given a new . Au cyonida solution l e a s e on l i f e t o t h e gold -+-+-...-+ mining i n d u s t r y . The heap Filtration IH y leach c y a n i d a t i o n - c a r b o n E 1 e c l r o l ~ t i c Recycled r l r i p soIution adsorption-electrowinning SilvFr product Gold product process developed by t h e F e d e r a l Bureau of Mines has FIGURE 8. Proposed heap leach-carbon adsorption ?roved t o b e a n economical process for gold ores low in silver. method f o r e x p l o i t i n g lowgrade gold o r e s and s m a l l i s o l a t e d d e p o s i t s n o t s u i t a b l e f o r t r e a t m e n t by conv e n t i o n a l c y a n i d a t i o n procedures. Heap l e a c h i n g may be t h e most p r o f i t a b l e method f o r p r o c e s s i n g s e l e c t e d gold and s i l v e r o r e s t h a t do not r e q u i r e f i n e g r i n d i n g and a r e r e a d i l y amenable t o c y a n i d a t i o n .
Digestion

precipitation

-%
-

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Homestake Uses Carbon-in-Pulp To Recover Gold From Slimes. Min., v . 27, No. 12, 1974, pp. 44-49.

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Hedley, N . , and T. Howard. Chemistry of Cyanidation. Co., Wayne, N . J . , 1968, 54 pp.

American Cyanamid

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