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Beyuo, M. and Abaka-Wood, G.B. (2016). ―ZADRA Elution Circuit Optimisation and Operational Experience
at the CIL Plant of Gold Fields Ghana Limited‖, 4th UMaT Biennial International Mining and Mineral
Conference, pp. MR 161-167.
Abstract
The ZADRA system is another elution process where gold that is adsorbed on to activated carbon is desorbed from the
carbon by a reversal of the adsorption kinetics. The ZADRA elution circuit at Gold Fields Ghana Limited was designed as a
pressure system with an operational pressure set point of 350 kPa. It consists of circulating 3% sodium hydroxide water
based solution up flow through a stationary bed of loaded activated carbon at a flow rate of 64m3/h at a temperature of 125
°C. The process was designed to take about 16 hours to complete 30 elutions per month. The ZADRA process is
characterised by simplicity of system design and operation, with low desorption rates. Manual control is the standard devoid
of the necessity for automated controls and expected low chemical consumption. However, fluctuations in flow and
temperatures recorded during commissioning and operational stages, reduced stripping efficiencies with its concomitant
effect as an extension of the required stripping cycle time. Consequent on the extension of the required stripping cycle time
and high chemical consumption, the ZADRA elution process hardly completed one batch of elution per day. A review on the
basis of the process design as to whether it is a pressure or atmospheric ZADRA was carried out necessitating in the
reduction of the pressure set point to 120 kPa culminating in a complete turnaround in the system‘s performance. Other
changes followed resulting in a reduction of the stripping cycle time to 13 hours completing two batches of elution per day.
Keywords: Elution, ZADRA elution, activated carbon, eluate, electrowinning, heat exchangers
of high temperature and pressure, treatment of gold
1 Introduction loaded AC with concentrated cyanide or caustic
solution followed by elution with potable water,
The CIL Plant of Gold Fields Ghana Limited (GGL) aurocyanide complex is desorbed from the gold
Tarkwa Mine, currently exploits the tabular loaded activated carbon. Temperature is a key
auriferous conglomerates from seven active open variable in the elution process and temperatures of
pits Pepe, Awonaben, Teberebie, Akontansi Central, 100-120°C are necessary to achieve optimum
Akontansi Ridge, Underlap and Kottraverchy. The elution performance (Anon, 2016). A successful
CIL plant capacity was increased from 12.3 Mtpa to desorption process requires proper selection of
13.5 Mtpa in 2014. Further expansions being eluants, which strongly depends on the mechanism
considered have the potential to increase the of desorption. Selected eluant should be: cost-
capacity to 15.5Mtpa (Mineral resources report, effective, eco-friendly and efficient.
2014). The leaching circuit of the plant is made up
of 17 tanks in which sodium cyanide is used as the The most common commercial techniques for
lixiviant whiles activated carbon is introduced to elution of gold cyanide from activated carbon are
adsorb the leached gold. The plant employs both the the ZADRA and AARL procedure. In the ZADRA
Anglo American Research Laboratory (AARL) and elution process, hot solutions of 1% weight/volume
ZADRA methods to strip loaded carbon (1000 -1500 (w/v) sodium hydroxide (NaOH) and 0.2% w/v
g/t Au). The scope of this paper is aimed at sodium cyanide (NaCN) are recycled through a gold
reviewing the performance of the ZADRA elution cyanide-loaded AC bed for up to 72 h at 95–100 oC
circuit from its commissioning year to the end of and atmospheric pressure to desorb Au(CN)2. More
2015. recently a modified Zadra procedure operating at
140 oC in a pressurized system has reduced elution
time to 10–12 h (Robles, 2001).
1.1 Review on Gold Elution
Soleimani & Kaghazchi (2008) sought to investigate
A variety of techniques are found in literature on the for a rapid, safe, ambient temperature method for
recovery of gold from various solution. (Aylmore gold stripping from loaded activated carbon. Gold
and Muir, 2001; Grosse et al., 2003; Syed, 2012; loaded AC was contacted with a strong base
Van Deventer and Van der Merwe, 1995; Wan et al., followed by elution with an aqueous solution
1993; Yalcin and Arol, 2002). The adsorption of containing an organic solvent to investigate an
gold complexes onto activated carbon (AC) is the improved process for recovering gold from activated
basis of modern techniques for gold recovery and it carbon other than ZADRA or AARL methods. Gold
is proceded by the desorption of adsorbed gold from desorption from loaded activated carbon was carried
activated carbon with an efficient eluant. By means
1
out using acetonitrile, acetone, methanol, carbon at a flow rate of about 64m3/h at about
isopropanol and ethanol. Gold recovery for these 125°C. Pregnant eluate from the elution column is
solvents was in the order: acetone > acetonitrile > cooled to below boiling point and passed through
methanol > ethanol > isopropanol. It was concluded the electro winning cells where gold is deposited on
that organic solvents could be used to strip gold the cathodes. On leaving the electrowinning cell, the
from activated carbon which compared well with now gold depleted eluate is re-heated before it is
both ZADRA and AARL methods (Soleimani and circulated back into the elution column. Achieving
Kaghazchi, 2008). the design electro winning single pass extraction in a
ZADRA elution circuit is critical. Unlike the AARL
van Deventer and van der Merwe (1994) studied the elution system, poor single pass extraction in a
functional relationship between the effect of pH, ZADRA process has a direct impact on the overall
temperature, concentrations of cyanide and cations elution efficiency. The process was designed to last
on the gold cyanide equilibrium during elution from for about 14 to 16 hours. An elution column
activated carbon in columns and in batch reactors. temperature of 125 °C is maintained until the
They identified that the resistance to the mass process is over. Elution and electrowinning as
transfer were less intense under robust elution indicated occurs simultaneously, and solution
conditions. It was identified that the elution of circulation and transfer from one stage to the other is
aurocyanide was inhibited by the action of cations made possible by automated valves. Electrowinning
through the formation of Mn+(Au(CN)2−) on cells are operated within 750-800 A and 3.8-4.0 V.
activated carbon. Gold desorption conditions namely The first ZADRA elution process started at the CIL
high temperatures and intense cyanide pre- plant on 21st January 2009 and has since been
treatment, decreased the sensitivity of gold elution running to date.
to flow rate and the radial distribution of the gold
through the carbon particles. (van Deventer and van 3 ZADRA Elution Circuit Performance
der Merwe, 1994). Review
Boshoff (1994) suggested that the elution efficiency The scope of the performance review of the ZADRA
is independent of the amount of gold present on the elution circuit, covers from the commissioning year
activated carbon. It was proved that cyanide-free (2009) to the end of 2015. Selected operational
elutions of carbons containing < 1 200 g/t copper, parameters and experiences in the running of the
are indeed possible and that under these conditions circuit are presented in this section. Two sections of
acid wash conditions typically acid concentration performance review are presented; elution start-up
could be reduced without a detrimental effect on (February, 2009 to December 2012) and
gold elution efficiency (Boshoff, 1994). interventions (January, 2013 to December, 2015).
The start-up period mainly discusses the
ZADRA and AARL processes are known to be performance of the circuit from its commissioning to
effective in stripping of gold from activated carbon, the end of 2012. The intervention section, on the
but both processes suffer from high-energy other discusses the circuit performance whiles
consumption, high capital costs for pressurized various changes in operational parameters as a result
operations, long elution times and the use of of challenges encountered during the start-up period.
concentrations of environmentally obnoxious For the periods under review, ZADRA elution
sodium cyanide (Liebenberg and Deventer, 1997; circuit performance data have been analyzed and
Soleimani and Kaghazchi, 2008; van Deventer and presented. Operational parameters considered
van der Merwe, 1994). include gold loaded activated carbon concentration,
eluate flow, caustic concentration, elution duration,
2 Overview of CIL Plant (GGL) and stripping and electrowinning efficiencies.
ZADRA design parameters
3.1 Elution Start-up Performance
The ZADRA elution circuit at the CIL Plant
constitute various stages including carbon recovery, In the commissioning year, 2009, a total of 270
acid washing, carbon transfer, column fill, eluant elutions were performed, over 11 months,
recirculation, elution and electrowinning, carbon representing approximately 24.5 elutions/month as
cooling and discharge with no cyanide addition. The against the design of 30 elutions/month. The number
eluant is continuously circulated through the elution of elutions increased steadily from the month of
column and the electrowinning cell in series. commissioning to the end of the year. The least
number of elutions, 19 was performed in February
The process begins with recovery of loaded carbon and the highest, 32 was in December. On the other
into the acid wash vessel, where inorganic foulants hand, the strip cycle duration was observed to
are removed using hydrochloric acid. The process decrease towards the end of the year. In December,
consists of circulating about 3% NaOH solution up where the highest number of elutions was
flow through a stationary bed of loaded activated
2
performed, an average of about 16 hours of strip Table 1 Month Average AC Grade, Stripping
cycle was recorded. The longer the strip cycle the and Electrowinning Efficiency Data
less the number of elutions performed. The NaOH (2009).
concentration for the year was generally good,
recording an average of 3.01% with the least MONTH LC grade EC grade SE EE
monthly average concentration of 2.78% obtained in Feb-09 1331.32 164.45 76.96 64.54
February (see Table 2). A general improvement in Mar-09 1363.78 94.36 86.81 72.53
the stripping and electrowinning efficiency as the
Apr-09 1366.82 98.70 86.44 72.87
year progressed was achieved. It is a common
practice to experience fairly low stripping and May-09 1199.39 71.17 91.54 76.77
electrowinning efficiency during start-up of circuits, Jun-09 1181.10 46.83 90.03 78.44
as it takes some time to obtain optimum operating
Jul-09 1392.51 79.13 95.70 83.53
levels. Much stable efficiencies were observed
towards the end of the year. Gold loaded AC Aug-09 1502.75 70.04 89.56 83.25
stripped over the period (2009) averaged about 1372 Sep-09 1482.44 74.62 89.64 83.08
ppm. Month average gold loaded AC grade of 1168 Oct-09 1480.19 98.94 92.55 88.07
ppm was obtained in December, hence the increased
number of elutions (32), and the shorter strip cycle Nov-09 1420.71 78.60 95.03 91.05
period (16.63 hrs.) to compensate
2D Graph 1 for the relatively Dec-09 1168.36 79.80 93.26 84.97
poor gold loading on the AC. Average 1353.58 86.97 89.78 79.92
30
Number of Elutions
28 After commissioning, the ZADRA circuit faced
26 some challenges, which included excessive metal
build-up in eluate, rampant scaling in heat
24
exchangers, blockage of bottom strainers in elution
22 column, excessive pressure build-up, high
20 electrowinning cell feed temperature and poor
18
deposited gold texture and high burn-off.
16
Table 2 Month Average Elution Circuit
14 Parameters (2009).
12 Month NaOH Flowrate, Duration, N
Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec conc., ppm m3/h h
Month, (in 2009)
Feb-09 2.78 28.82 18.21 19
Mar-09 3.07 35.66 16.78 23
Apr-09 3.08 37.37 18.36 22
Figure 1 Elution Duration and Number of May-09 2.89 38.35 20.80 26
Elutions Data in 2009 Jun-09 2.87 36.22 21.00 24
The circuit‘s performance has been summarized in Jul-09 3.21 33.05 22.43 23
Table 1. It is shown that both stripping and Aug-09 3.14 33.72 24.18 25
electrowinning efficiencies generally improved Sep-09 3.27 33.37 17.64 22
across the year (2009). The stripping efficiency
Oct-09 3.11 40.65 20.20 27
showed a much linear trend than electrowinning
efficiency, having an R2 value of 0.8631, as against Nov-09 3.28 37.12 19.33 27
0.5554 for electrowinning efficiency. The data Dec-09 2.83 25.62 16.63 32
indicates that stripping efficiency increased steadily Average 3.05 34.54 19.60 25
between February to July, plateaued between July *N – Number of elutions
and September, and increased in November, and
thereafter decreased marginally. The excessive metal build-up in the eluate may be
responsible for the poor electrowinning efficiencies
encountered over the period under review. These
metals, predominantly copper (Cu) and nickel (Ni)
are competitively deposited on the cathodes of the
electrowinning cells, affecting the electrowinning
efficiency. The year average of electrowinning
efficiency increased from 79.41% to 89.02%
3
between 2009 and 2010, and reduced by 2.03% reported in June. The low concentrations
approximately 9 % in 2011 (Fig. 3). The effect of were mainly as a results of reduction in purity of
metal deposition on the cathode of the NaOH supplied. Low caustic (NaOH)
electrowinning cell was pronounced in 2011. concentrations may also haveCustic
negative impact on the
Electrowinning samples were analysed and the stripping efficiency.
results showed significant amount of Cu and Ni
4.5
were present in the samples (Table 3). The high
2009
concentration of these metal species were attributed 2010
to co-leaching due to high NaCN concentration used 4.0 2011
in the CIL circuit. Design
Caustic concentration, %
Table 3 Metal Distribution in Electrowinning 3.5
4
significantly from 2012 to 2014 and decreased generally above 60 (up to 64) m3/h in accordance
marginally in 2015. The year average flow rates with design. The year average flow rate in 2014 was
recorded were 39.54, 53.52, 61.18 and 54.92 m3/h approximately 61 m3/h. The least month average in
for 2012, 2013, 2014 and 2015, respectively. The 2014 was approximately 58 m3/h in August. It is
increase in the flow rates also resulted in increase in important to note that the shorter elution duration,
the number of elution cycles conducted, as the resulted in generally lower gold loading on activated
increased flow rate reduced the elution duration. carbon, as the residence time of carbon in the CIL
With the exception of 2013, between 2012 and circuit was shortened to keep elution cycle running.
2015, the number of elutions conducted were more The trends in Fig. 4 indicate that the gold loadings
than 30 per month. An average of 40 elutions/month on activated carbon decreased significantly after the
were conducted in 2014, whiles 43 elutions/month period when the changes were implemented (that is
was achieved in 2015. The least year average within 2012). The average year gold loading on the AC for
this period was 28 elution/month in 2013 (due stripping was 1558.68 g/t in 2012, which reduced to
industrial action for 2D2 Graphmonths),
1 whilst 30 1327.67 g/t in 2013, 1159.32 g/t in 2014 and
elution/month was conducted in 2012. 1145.64 g/t in 2015. Stripping efficiency was
70 22 affected especially in 2015, where it reduced by
Number of elutions per month / Elution flow rate
92 LC Grade
Year
5
electrowinning samples analysed were lower assurance on reagents used must also be ensured.
compared to that presented in Table 3. Adherence to the cleaning regimes as instituted
should be ensured to minimize the production of
scales, especially in heat exchangers.
Authors