This thesis presents the development and application of a dynamic model of gold adsorption onto activated carbon in gold processing. The primary aim of the model is to investigate different carbon management strategies of the Carbon in Pulp (CIP) process. This model is based on simple film-diffusion mass transfer and the Freundlich isotherm to describe the equilibrium between the gold in solution and gold adsorbed onto carbon. A major limitation in the development of a dynamic model is the availability of accurate plant data that tracks the dynamic behaviour of the plant. This limitation is overcome by using a pilot scale CIP gold processing plant to obtain such data. All operating parameters of this pilot plant can be manipulated and controlled to a greater degree than that of a full scale plant. This enables a greater amount of operating data to be obtained and utilised. Two independent experiments were performed to build the model. A series of equilibrium tests were performed to obtain parameter values for the Freundlich isotherm, and results from an experimental run of the CIP pilot plant were used to obtain other model parameter values. The model was then verified via another independent experiment. The results show that for a given set of operating conditions, the simulated predictions were in good agreement with the CIP pilot plant experimental data. The model was then used to optimise the operations of the pilot plant. The evaluation of the plant optimisation simulations was based on an objective function developed to quantitatively compare different simulated conditions. This objective function was derived from the revenue and costs of the CIP plant. The objective function costings developed for this work were compared with published data and were found to be within the published range. This objective function can be used to evaluate the performance of any CIP plant from a small scale laboratory plant to a full scale gold plant. The model, along with its objective function, was used to investigate different carbon management strategies and to determine the most cost effective approach. A total of 17 different carbon management strategies were investigated. An additional two experimental runs were performed on the CIP pilot plant to verify the simulation model and objective function developed. Finally an application of the simulation model is discussed. The model was used to generate plant data to develop an operational classification model of the CIP process using machine learning algorithms. This application can then be used as part of an online diagnosis tool.

Costs saving measures are important for South African gold producers due to increasing energy costs and decreasing production volumes. Demand Side Management (DSM) is an effective strategy to reduce electricity consumption and costs. DSM projects have been implemented widely on South African mining systems such as pumping, refrigeration, rock transport and compressed air. Implementations have, however, been limited on gold processing plants despite the significant amounts of energy that this section consumes. The main objective of gold processing plants is production orientated and energy management is not a primary focus. This rationale is re-evaluated owing to high electricity price inflation and availability of DSM incentives. This study investigated the cost saving potential of DSM interventions on gold plants. Electrical load management was identified as a key opportunity that can deliver substantial cost savings. These savings were shown to be feasible in respect of the required capital expenditure, effort of implementation and maintenance of operational targets. Investigation procedures were compiled to identify feasible load management opportunities. The most potential for electricity cost savings was identified on comminution equipment. Consequently, a methodology was developed to implement electrical load management on the identified sections. The methodology proposed simulation techniques that enabled load management and subsequent electricity cost optimisation through production planning. Two electrical load management case studies were successfully implemented on comminution equipment at two gold processing plants. Peak period load shift of 3.6 MW and 0.6 MW, respectively, was achieved on average for a period of three months. The annual cost savings of these applications could amount to R1.4-million and R 660 000. This results in specific electricity cost reductions of 3% and 7% for the two respective case studies. Results from the two case studies are an indication of potential for electrical load management on South African gold processing plants. If an average electricity cost saving of 5% is extrapolated across the South African gold processing industry, the potential cost savings amount to R 25-million per annum. Although the costs saving opportunities are feasible, it is influenced by the reliability of the equipment and the dynamics of ore supply. This insight plays a decisive role in determining the feasibility of DSM on gold processing plants. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Costs saving measures are important for South African gold producers due to increasing energy costs and decreasing production volumes. Demand Side Management (DSM) is an effective strategy to reduce electricity consumption and costs. DSM projects have been implemented widely on South African mining systems such as pumping, refrigeration, rock transport and compressed air. Implementations have, however, been limited on gold processing plants despite the significant amounts of energy that this section consumes. The main objective of gold processing plants is production orientated and energy management is not a primary focus. This rationale is re-evaluated owing to high electricity price inflation and availability of DSM incentives. This study investigated the cost saving potential of DSM interventions on gold plants. Electrical load management was identified as a key opportunity that can deliver substantial cost savings. These savings were shown to be feasible in respect of the required capital expenditure, effort of implementation and maintenance of operational targets. Investigation procedures were compiled to identify feasible load management opportunities. The most potential for electricity cost savings was identified on comminution equipment. Consequently, a methodology was developed to implement electrical load management on the identified sections. The methodology proposed simulation techniques that enabled load management and subsequent electricity cost optimisation through production planning. Two electrical load management case studies were successfully implemented on comminution equipment at two gold processing plants. Peak period load shift of 3.6 MW and 0.6 MW, respectively, was achieved on average for a period of three months. The annual cost savings of these applications could amount to R1.4-million and R 660 000. This results in specific electricity cost reductions of 3% and 7% for the two respective case studies. Results from the two case studies are an indication of potential for electrical load management on South African gold processing plants. If an average electricity cost saving of 5% is extrapolated across the South African gold processing industry, the potential cost savings amount to R 25-million per annum. Although the costs saving opportunities are feasible, it is influenced by the reliability of the equipment and the dynamics of ore supply. This insight plays a decisive role in determining the feasibility of DSM on gold processing plants. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2015

Although bacterial leaching of sulphidic minerals is a well-known phenomenon, it is only in the last ten years that full-scale bacterial leaching plants have been commissioned for gold processing. In order for bacterial leaching to compete successfully with other pretreatment processes for refractory ores, particularly with established technologies such as roasting and pressure leaching, it needs to be efficient. This requires the optimization of the parameters affecting the leaching reaction and the growth of bacteria. The entire biotreatment process is agitation leaching, carried out in stirred reactors or Pachuca type reactors. The bacterial oxidation is a complex reaction involving gaseous, liquid and solid phases. The interactions are highly complex, and analysis is complicated by the presence of solids in the leaching medium. Inspite of the amount of research that has been performed, kinetic and process models are underdeveloped. Since kinetic data varies widely with the type and source of concentrate, experimental data should be generated before doing the full-scale reactor design. In sizing reactors for a commercial scale process, it would be useful to have a mathematical model that one could use to predict the amount and rate of release of metal, as a function of the various operating parameters of the system. G.R.Halli arsenical gold sulphide concentrate obtained from Hutti Gold Mines Ltd., Karnataka, was chosen for our study, because of its high refractoriness. An indegenous strain of Thiobacillus ferrooxidans was used for biooxidation. The experiments were conducted in a well-agitated stirred tank reactor under controlled conditions. Sparged air was supplemented with carbon-dioxide for optimized growth. In this work, more than 90% gold and 95% silver could be recovered from the sulphidic gold concentrate when bioleaching was used ahead of cyanidation, compared to 40% and 50% by direct cyanidation. A generalized model, which accounts for both direct bacterial attack and indirect chemical leaching, has been proposed for the biooxidation of refractory gold concentrates. The bacterial balance, therefore, accounts for its growth both on solid substrate and in solution, and for the attachment to and detachment from the surface. The overall process is considered to consist of several sub-processes, each of which can be described in terms of a mechanism and related rate expressions. These sub-processes were studied seperately under kinetically controlled conditions. The key parameters appearing in the rate equations were evaluated using the experimental data. Since the refractory concentrate contains pyrite and arsenopyrite as the major leachable entities, leaching studies have been done on pure pyrite and arsenopyrite as test minerals and the key parameters in the rate equations are evaluated using this data. The model so developed is tested with the leaching kinetics of the concentrate. The growth of bacteria is dependent on the availability of the substrate, ferrous iron, and the dependence is modelled by the widely accepted Monod equation. The effect of carbon dioxide supplementation on the bacterial activity was studied and the optimal concentration for growth was found to be l%(v/v). Studies on indirect chemical leaching showed that the rate is sensitive to surface area of concentrate. Indirect rate constant of arsenopyrite was found to be greater than that of pyrite, since pyrite is more nobler than arsenopyrite. Conditions of direct leaching alone was obtained at high pulp density and using substrate adapted bacteria. The rate constant of arsenopyrite was found to be greater than that of pyrite. The parameters obtained were tested with the overall batch leaching data of the concentrate and favourable comparision was obtained. Thus, it has been possible to isolate the various simultaneous sub-processes occurring during the leaching and propose useful models to describe these processes in some detail. The model has been extended successfully to predict the continuous leaching behaviour using the parameters obtained from the batch data. Studies on the effect of residence time and pulp density on steady state behaviour showed that there is a critical residence time and pulp density below which washout conditions occur. The critical residence time at 10% pulp density was found to be 11 hrs. Operation at pulp densities lower than 5% and residence times lower than 72 hrs is not favourable for efficient leaching. Studies on the effect of initial ferric iron concentration showed that there exists an optimum concentration of ferric iron at which the time required to reach steady state is minimum.