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Sidney Mahlatsi,
Senior Engineering Technician: Mintek - Small Scale Mining Division
ABSTRACT;
Mintek has developed a process called iGoli Mercury-free Gold Extraction Process that can be
used to extract gold from 0.1 % gold concentrate to produce 99.90 percent gold product. The
process uses a mixture of pool acid (dilute hydrochloric acid), bleach (sodium hypochlorite) and
sodium metabisulphate to leach and recover gold.
Artisanal and small-scale miners concentrate their gold using sluice boxes followed by panning as
a final physical separating method. The gold produced in this manner is extracted from the
concentrate by a chlorine solution produced from a mixture of pool acid and bleach. The leach
liquor contains gold and other metals that are soluble in chlorine media such as base metals and
ferrous iron. During leaching excess gas that is produced is redirected to a separate vessel where
it is scrubbed using caustic soda to form water and sodium chloride (salt).
The slurry from the leaching process is filtered to separate the gold bearing leach liquor and the
solid residue. This gold pregnant solution is treated with sulphur dioxide, introduced in the form
of sodium metabisulphate, to reduce gold ions in solution to a metallic gold powder. The solid
waste produced from iGoli process is rich in silicate with effluent and is neutralized using lime/
limestone with an addition of apatite where necessary to destroy or precipitate all base metals and
ferrometals available.
The development of this process was mainly driven by the need to ensure reduction in mercury
use and subsequent alleviation on the entire biophysical environment. There is an array of
mitigating measures that could be used as treatment methods for the safe use of iGoli leaching
process.
The process wastes which are significantly less toxic are characterized as follows:
→ Waste solids
Feed → → Waste solution (effluent)
→ Waste heat
→ Waste gases
Any potentially hazardous gases released from the gold leaching process are monitored and
controlled by neutralization below the legislative requirements. The tailings produced have a high
percentage of silica and iron with low levels of base metals. The process is very important to
artisanal and small-scale miners as it lowers the risk of mercury poisoning on the miners
themselves and mercury pollution into the environment. The process also offers economic
benefits because of its high recoveries and product purity coupled with its simple way of waste
management. Lastly the process recovers refractory gold which is very difficult to recover using
other conventional ASM extraction methods.
1. INTRODUCTION
The environment is a very important part of our lives. It is the complex totality of circumstances
surrounding an organism or a group of organisms, especially the combination of external physical
conditions that affect and influence the growth, development, and survival of organisms.
The natural environment consists of all the conditions affecting the nature of an individual or
community, which we shall never completely understand until we see it as a living organism.
Most of our chemical and mining activities occurring in our every daily life have a significant
negative impact to our environment. In addition, new processes that are developed daily still
impact on the environment either positively or negatively, depending on the type of waste that is
produced by the process.
A process technology has been developed in Mintek for small-scale miners, which uses pool acid,
bleach and metabisulphate to dissolve and recover gold from a gold concentrate. During recovery
the process produces chlorine gas emissions, effluent and solid waste as a generated waste.
2. STUDY OBJECTIVE
A study was conducted in South Africa to derive measures, which could eliminate or minimise
the environmental impacts that might be caused by the implementation of the iGoli process. The
method developed focussed on making the iGoli process environmentally friendly so that the
process can be operated within existing South African legislative standards.
Table 1 and 2 depicts the South African impurity standards within the underground water and the
solid waste generated. The objective of the study was to develop a method, which can be used to
treat iGoli effluent for an effective waste disposal.
Table 1.Limits of the elements in underground water
pH Cl P F As Cd Cr Cu Fe Pb Mn Hg Se Zn B CN
ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm
5.5-9.5 0.25 10 1 0.02 0.05 0.05 0.01 0.3 0.01 0.1 0.005 0.02 0.1 1 0.02
3. PROCESS DESCRIPTION
Mintek’s Small Scale Mining Division (SSMD) developed a process which recovers gold from
gold concentrates without using mercury. The miners obtain this concentrate by panning or
simple gravity concentrating methods.
The gold in the solids concentrate is dissolved in a solution containing a mixture of pool acid (33
- 34 % HCℓ) and bleach (15 - 16 % NaOCℓ). The solution mixture produces chlorine gas in the
ratio 1:1 (HCℓ-NaOCℓ) of mixture to Cℓ2, which dissolves gold in the concentrate to form an
aqueous media of gold and other elements. The solid material fed into this process should be
concentrated to a grade of at least 1000 g/t (0.1% gold) for the process to be viable.
The combined mixture of pool acid (HCℓ) and bleach (NaOCℓ) produces chlorine gas, where
some of it is lost as excess chlorine to the surrounding environment. To avoid losses of gas to the
environment the excess chlorine gas (Cℓ2) from the reaction chamber is redirected into an
attached scrubber/vessel where neutralisation using NaOH solution is carried out as shown in
Figure 1.
The leaching of gold from the solid concentrate occurs between a gas fluid and a solid gold
surface in a chloride solution media, it is modeled by heterogeneous reaction equation.
During the reaction process gold that dissolves goes into solution to form an ionic gold and the
remaining solids are separated from the solution using a vacuum filtration unit to separate the
pregnant solution and the solids residue. The solution formed is subjected to a solution treatment
using sodium metabisulphate (as a source of SO2) to reduce gold ion in solution to a metallic
gold.
The solution, at a low pH and low electro potential difference, precipitates gold out in the form of
a gold powder. The effluent which results after recovering gold is treated to produce an
environmentally friendly waste that will have either no or less environmental impact.
3.1Mitigation measures
During treatment of the effluent stream three reagents were investigated under laboratory
conditions namely lime, calcium hydroxide and sodium hydroxide. These neutralising agents
were studied based on their reactions with the effluent solution and also on the economical
advantage.
The effluent solution was neutralised using the latter reagents at a pH>7. Calcium chloride is very
soluble in water i.e. the solubility of calcium chloride is about 39 g per 100 ml of water. The
existence of arsenic in some of the gold bearing material introduced arsenic in our effluent stream
when iGoli process was implemented. Phosphorus in an apatite mineral reacts with arsenic
forming a apatite complex. The complex compound precipitate out in pH higher than 7 as a stable
(Ca10(AsxPyO4)6(OH)2 ) arsenic apatite complex.
During the extraction of gold most of the minerals that are in different particle sizes and
quantities are also oxidized by chlorine to form chlorites of gold, silver, base metals, ferrometals
etc.
The recovery of gold also includes the recovery of ferro metals, base metals, etc., which when the
gold is selectively precipitated they all remain in the leach liquor as wastes or as a source of
valuable base metals etc. The unreacted mineral or inert solids are left and disposed as waste
solids, which are environmental friendly i.e. mostly silicate mineral.
The reactions governing the formation of wanted and unwanted products occur in a
heterogeneous mixture with the reaction equations written to show the reaction between the
minerals and chlorine gas being produced by a mixture of pool acid and bleach.:
1.15 Fe
1.10 As
1.05
1.00
0.95
0.90
0 2 4 6 8 10
Time (hours)
Figure 2. The behaviour of Arsenic, gold and iron predicted by the modeling equations.
The graph in Figure 2. was drawn using experimental conversion of As, Au and Fe kinetic data in
the reaction modeling equation, which shows that As is reaction rate controlled. The graph of
gold and Fe seems to be controlled by a combination of rate equations, where the mineral iron
seems to be controlled by diffusion and reaction rate, where gold is controlled by three model
equations which are ash, diffusion and reaction rate at the surface of the gold mineral particle.
4. EXPERIMENTAL PROCEDURES
4.1. NEUTRALISATION
Three representative solution produced from leaching gold in three different gold bearing material
were used to investigate the behavior against treatment.. The leach liquor was produced by
leaching different concentrates from Klipval (Mpumalanga Province), Ventersdorp (North West
Province) and Springs (Gauteng Province). The samples were known to have ore bodies, which
contained major impurities such as arsenic (Klipval and Mpumalanga), uranium (Witwatersrand -
Springs) and lead in (North West – Krugersdorp area). The effluent produced was divided into 3
sets of one liter effluent samples, each to be treated using the following procedure:
• All solutions produced were neutralized to at least a pH greater than 7 to determine elements
not precipitating that are harmful to the environment.
• The slurry formed was filtered to separate the solution from the solid cake, which was later to
be tested for washability of base metal etc.
• The total cake was dried and 200 g sampled and pulverized for traditional fire assay to
determine which elements are easily washed during rainy season..
Solution containing arsenic as chloride:
• The solution containing arsenic was co-precipitated using apatite of different stoichiometric
ration before being neutralised with hydrated lime (CaOH) or unhydrated lime (CaO).
• The slurry formed followed the same procedure as shown above.
The reaction is similar with other elements such as base metals etc., in the effluent or waste
solution.. Most of the elements form hydroxides and carbonates with different neutralizing agents
such as lime,caustic and limestone. In the reaction with sodium hydroxide, the consumption is
twice the amount in comparison to other neutralizing agent as shown in Table 7.
Table 5 shows a summary of the results for a processed effluent solution obtained when different
neutralizing agents was used.
Table 5. Final effluent impurity levels with ordinary neutralising agent
Soln P Cl Cr Mn Fe Co Ni Cu Zn As Mo Hg Pb
ppm g/l ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm ppm
NaOH 18.7 224 <2 <2 <2 <2 <2 <2 <2 <2 <2 <2 <2
CaOH <10 256 <2 3.3 <2 <2 4.1 3.5 <2 <2 <2 <2 <2
CaO <10 256 <2 <2 <2 <2 <2 3.2 <2 <2 <2 <2 <2
A neutralization testwork was carried out at pH higher than 7 to encourage elements in solution to
drop to levels below the required legislative standards. The level of chlorine in the filtrate
produced was high due to the formation of calcium and sodium chloride which are highly soluble
in water. It is known that calcium chloride and sodium chloride have a solubility constant of 390
g/l and 350 g/l in water respectively.
Table 6. Final average effluent impurity levels with apatite-neutralising agent
Soln P Cl Cr Mn Fe Co Ni Cu Zn As Mo Hg Pb
Ppm g/l ppm Ppm ppm Ppm ppm ppm ppm ppm ppm Ppm Ppm
NaOH 9.75 161 <2 <2 <2 <2 <2 10 25 <2 <2 <2 <2
CaOH 7.01 184 <2 <2 <2 <2 <2 12 29 3.7 <2 <2 <2
CaO 5.00 184 <2 <2 <2 <2 <2 15 34 <2 <2 <2 <2
The solubility constant of chlorine in solution is decreased by the addition of apatite because of
the formation of a complex arsenic and chlor-apatite. A relative addition of apatite seems to
reduce the solubility of chlorine by almost 50%.
Table 7. Summary of the results for different neutralization agent
Activity Neutralising agent Consumption (g/l) Cost (R/l) pH
Normal NaOH 179 11.46 8.8
Ca(OH)2 200 10.00 7.66
Netralisation
CaO 200 19.20 8
Normal NaOH 91 5.82 7.21
Ca(OH)2 114 5.70 9.32
Netralisation
CaO 65 6.24 7.48
Normal NaOH 89 5.70 7.43
Ca(OH)2 103 5.15 7.66
Netralisation
CaO 101 9.69 7.58
Apatite addition NaOH 150 9.6 9.2
Ca(OH)2 105 5.25 7.8
CaO 55 5.28 9
Table 6 and 7 indicate that to reduce the level of impurities in an effluent stream a pH greater than
7 must be achieved using any of the above neutralizing agents. Table 7 shows that when apatite
was used to complex with arsenic, consumption of a neutralising agents is reduced by almost 10
percent. The benefit of using apatite is relative to its advantage of complexing with arsenic,
decreasing solubility levels of other impurities such as chlorides etc. In all the testwork carried
out, calcium hydroxide had the lowest cost when used as a neutralising agent.
5.2. SOLUBILITY
Most of the elements precipitated during neutralisation process were tested to determine their
solubility during rainy seasons to indicate their washability into underground water. Water at
different temperatures was used to test distribution of elements with temperature. Hydrolysis of
elements controls their solubility into solution.
FeCl2 + H2O → Fe 2+ + 2Cl- + H+ + OH- → FeCl2.XH2O, …….……….25
In essence this equation could only be formed in an acidic medium where the cake formed was
also acidic. In our case most of the elements that could be washed will be elements that are
soluble at high pH such as group I and II elements which are not harmful to the environment.
6. CONCLUSIONS
• The waste produced can be made environmentally friendly by neutralising with
approximately 100g of either dehydrated lime (CaO) or hydrated lime (Ca(OH)2 ) per litre of
impurity concentrated iGoli effluent at a pH greater than 7.
• It was observed and understood from washability testwork that all the chemicals used to
precipitate impurities in the waste effluent were not harmful to the environment; instead they
produce a stable solid cake with most formed salts remaining in solution being from group I
or II elements of the periodic table.
• The consumption of both hydrated and dehydrated “lime” is reduced by 10 to 50 percent
when apatite mineral is used during neutralisation process, with an average neutralisation cost
of R10/l of effluent produced..
• Most of the elements formed or precipitated using apatite as an additive are more resistant to
water wash because of an arsenic apatite complex formation.
7. RECOMMENDATIONS
The following recommendation was established:
• A method must be derived to minimise or purify the formation of group I or II chlorides
during neutralisation of the iGoli effluent.
• Due to resistance posed by miners who refuses to use other processes for the extraction of
their gold mineral etc., it is advisable that the mercury retorts which they are using currently
be discouraged at the same time encouraging them to adapt to new processes that are safer
and more environmentally friendly.