NAMIBIA

Process Department

STANDARD OPERATING PROCEDURE

Electrowinning Start Up and Shutdown

SOP-PPL-510-002
 CONTENTS PAGE

1. Purpose ..................................................................................................................................3
2. Scope .....................................................................................................................................3
3. Glossary of Terms...................................................................................................................3
4. Responsibilities .......................................................................................................................3
5. Hazards ..................................................................................................................................4
6. Resources...............................................................................................................................4
7. Reference ...............................................................................................................................4
8. Documents..............................................................................................................................4
9. PPE ........................................................................................................................................5
10. Procedure ...............................................................................................................................5
11. Housekeeping .........................................................................................................................8
12. Record Keeping ......................................................................................................................8
13. Communication of Outcome ....................................................................................................8
14. REVISION LOG: .....................................................................................................................8

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 PLANT DEPARTMENT
STANDARDS OPERATING PROCEDURES
SOP-PPL-510-002

1. Purpose
The purpose of this document is to highlight the procedure for electrowinning process start - up.
The electrowinning process purpose is recovery the gold in solution both from the carbon stripping
process and the pregnant solution from the Intensive Cyanidation Reactor (ICR). This is the
process whereby metals, such as gold, are recovered from concentrated solutions by applying a
voltage across electrodes immersed in the concentrated solutions.

2. Scope
The electrowinning circuit consists of four electrowinning cells situated in the gold room. Two are
dedicated to the eluate electrowinning circuit, 510-EC-639 and 510-EC-640, one is dedicated to
the ICR electrowinning circuit, 510-EC-632, with one electrowinning cell in standby, 510-EC-1227.

3. Glossary of Terms
TERM Definition
Electrowinning Process used to remove metal ions from
liquid solutions. Most often used to
recover precious metals, it relies on an
electronic current to plate the metal ions
onto a cathode the solution can also be
recycled.
HCN Hydrogen Cyanide Gas
NaOH Sodium Hydroxide (caustic soda)

4. Responsibilities
Gold Room Supervisor/ Plant Operator: To be familiar with this procedure. It is the responsibility of
the Gold Room Supervisor, comply with all area requirements and take action as needed.
Process Superintendent: Ensure the compliance with this procedure.
Metallurgical Manager: Ensure and review the performance of this procedure

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 PLANT DEPARTMENT
STANDARDS OPERATING PROCEDURES
SOP-PPL-510-002

5. Hazards
Departure from laid down standards for this task could lead to personal injuries and/or damage to
machinery/equipment.
Electrical equipment - Gravitational - Working at height - Mechanical equipment Chemical -
Thermal
People at risk
Gold Room Supervisor / Operators
Equipment at risk
Electrowinning cells, pumps, extraction fan
Environment risk
Solution containing cyanide and caustic, HCN gases and fumes from electrowinning cell

6. Resources
People
Gold Room Supervisor and operators
Equipment
Gold room equipment
Consumables
Nil

7. Reference
Refinery Operator Manual
Plant control Manual
Electrowinning IOM manual
DWG: 500-PI-023/024
8. Documents
Log Sheet and book information
Check List for Gold Room Circuit

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 PLANT DEPARTMENT
STANDARDS OPERATING PROCEDURES
SOP-PPL-510-002

9. PPE
Hardhat
Earplugs
Gloves (leather and nitrile)
Safety Shoes
Safety Glasses
Half Mask Respirator with proper cartridge filter
Portable HCN monitor

10. Procedure
The ICR and Eluate electrowinning cells will be started from an operator interface terminal (OIT)
the local control station (LCS) or the local control station (LCS).
ICR and elution electrowinning circuit will be operated in a closed circuit. After multiple passes of
the elution solution through the electrowinning cells over a period of time, the barren solution will
have a gold grade of less than 10g Au/t.

Note: Obtain a sample of the pregnant solution for electrowinning and measure the alkalinity of
the solution. The solution pH should be greater than pH 12
If pH is below 12, additional caustic is to be added into the pregnant solution.
Under no circumstances should the voltage be adjusted to exceed 8 volts to avoid risk of
electrocution.

10.1. ICR and Elution Electrowinning Cell Cold start

The operator selects the duty pregnant solution pump, electrowinning cell and the pregnant
solution tank on the OIT for both circuits.
Ensure relevant interlocks are present for the corresponding duty pregnant solution pump
and electrowinning cell.
Check if electrowinning cells sludge drain valve is closed.
Check if the duty pregnant solution tank discharge valves are in the right positions.
Start the electrowinning cell extraction fan
One pregnant solution pump for each circuit is started

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 PLANT DEPARTMENT
STANDARDS OPERATING PROCEDURES
SOP-PPL-510-002

Check the flow rate of the solution through the electrowinning cell. The recommended flow
rate is 24m3/h.
Ensure the solution does not overflow the cell body.
Fill the cell with pregnant solution until the solution overflows the discharge weir.
Turn the rectifier Power Switch to the ON position. Adjust the voltage control knob to
approximately 4 volts and then adjust the amperage to read 250 amps on the analog
display.
Check the entire length of all bus bars for hot spots. If a bus bar is hot to touch, indicate
poor electrical connection and must be corrected immediately, otherwise serious damage
could result to the cell.
Set the voltage on the rectifier to 3 - 4 volts.
Slowly increase the amperage setting of the rectifier to the desired amperage value. This
should be no more than 60 amps per cathode.
Close and secure the cell lid. The cell lid must be closed to allow proper ventilation cooling
of the bus bars and the electrodes should be pressed against the bus bars by the lid for
good electrical performance.

10.2. Warm Start

For a warm start-up, it is assumed that the refinery operator have paused the sequence or
after a sequence fault, the fault has been rectified and the circuit is now ready for a restart.
The operator inspects the valves position prior to proceeding to step (5) and onwards of
the COLD start-up procedure for electrowinning.

10.3. After Emergency shutdown/power failure

In the eventuality of a power failure, the following valves will fail to the last position they are in:

ICR pregnant solution tank #1 electrowinning return valve

ICR pregnant solution tank # 2 electrowinning return valve
Pregnant solution tank #1 electrowinning return valve
Pregnant solution tank #2 electrowinning return valve

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 PLANT DEPARTMENT
STANDARDS OPERATING PROCEDURES
SOP-PPL-510-002

Pregnant solution tanks discharge valve are all fail to close. Prior to start-up, valve
positions must be check in the same way for a normal start-up sequence. After valve
inspection, proceed to step (5) of the electrowinning start-up procedures.

Note: Operators should be cautious of potential escape of harmful gases within the area of the
cells during the time the power is off.
Details for both

10.4. Short duration shutdown

At any point in the electrowinning, the refinery operator can stop the cycle. The following
procedure is to be followed:

Stop the flow of the pregnant solution into the electrowinning cells by stopping the pregnant
solution pumps.
Shut-off the rectifiers. If work is to be done on the electrowinning cells, ensure that the
rectifiers are isolated and tagged out. Inform the elution operator that the electrowinning
circuit is down.

10.5. Long duration shutdown

The following procedure needs to be followed when shutting down an electrowinning cell for long
duration:
Stop the flow of the solution through the cell by shutting down the solution feed pump and
closing the feed valve.
Power down the rectifier and completely turn the power off. Have the rectifier locked and
tagged out.
Shut off the draft from the EW extraction fan.
Drain the solution from the electrowinning cell.
Wash off any sludge in the bottom of the cell and on the electrodes into the sludge hopper.

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 PLANT DEPARTMENT
STANDARDS OPERATING PROCEDURES
SOP-PPL-510-002

11. Housekeeping
Check up everything is in order and clean

12. Record Keeping

Record any changes in the Gold Room communication book

13. Communication of Outcome

Gold Room Supervisor inform if any changes was made
The problems should be explained immediately during activities.
If there is an emergency or technical problem, notify the Shift Supervisor/ Process Superintendent
immediately

14. REVISION LOG:

Rev. no. Date Description Affected areas

Rev-0 15-06-2014 New Procedure EW-Gold Room
Rev-1 10-09-2015 Operational review EW- Gold Room

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