Documente Academic
Documente Profesional
Documente Cultură
Client Approval:
Date:
Rev.
1475-CP-001-E
AUTHOR
APPROVED
REV.
DATE
25-01-05
TH
28-04-05
GENERAL UPDATE
TH
31-08-05
TH
05-12-05
GENERAL UPDATE
TH
MD
10-02-06
GENERAL UPDATE
TH
IJM
257422914.doc
DESCRIPTION
Document No.
TABLE OF CONTENTS
1
INTRODUCTION
PROCESS DESCRIPTION
GENERAL
6
257422914.doc
3.1
Control System
3.2
Drives
3.3
Alarms
3.4
Common Functions
Crushing
4.2
4.3
Flotation
4.4
4.5
Services
4.6
4.7
4.8
Carbon Stripping
4.9
Electrowinning
4.10
Cyanide Detoxification
General
5.2
Crushing
5.3
5.4
Flotation
5.5
5.6
5.7
Carbon Stripping
5.8
Electrowinning
5.9
Cyanide Detoxification
6.1
Crushing
6.2
6.3
Flotation
6.4
6.5
6.6
Carbon Stripping
6.7
Electrowinning
6.8
Cyanide Detoxification
Crushing
7.2
7.3
Flotation
7.4
7.5
7.6
Elution Procedures
257422914.doc
Contents Page 2
INTRODUCTION
The Bendigo Gold Project is located at Bendigo in central Victoria, Australia. Ore is sourced
from extensions and developments to underground workings. The plant is designed to process
600,000 tonnes per year of ROM ore. The plant recovers gold from the ore by a combination of
gravity concentration, flotation and intensive cyanidation of concentrates.
This document describes the process plant and the control philosophy.
2
PROCESS DESCRIPTION
Crushing
Flotation
The plant design relies on the recovery of gold using gravity recovery methods (gold trap, jigs,
and centrifugal concentrators). It is expected that up to 70 % of the gold in the ore is recovered
this way and the recoverable remainder collected by froth flotation. Gravity recovery and froth
flotation techniques produce concentrates. Gravity concentrates are upgraded using a jig and
shaking tables. Shaking table tails are intensively leached using cyanidation and gold
electrowon from the leach solution. Flotation concentrates are treated using the CIL process.
Gold is eluted from loaded carbon and electrowon from the eluate solution.
Ore is delivered by truck from the underground mining operation to a run of mine (ROM) storage
pad. A front-end loader transfers ore from the ROM pad stockpile to the two stage crushing
plant. A conveyor delivers crushed ore to the fine ore bin. Crushed ore reclaimed from the fine
ore bin is fed to the high pressure grinding rolls crusher (HPGR) operating in closed circuit with
the ball mill screen. Coarse gravity gold is recovered in the ball mill screen gold trap in the
screen feed box. The screen undersize is pumped to the primary jigs. Jig tails gravitate to the
centrifugal concentrator. Spinners upgrade jig concentrates.
Tails from the centrifugal concentrator are pumped to the mill cyclone cluster. The cyclone
underflow gravitates to the ball mill feed chute. Ground ore slurry discharging from the ball mill
combines with mill screen undersize in the mill pump hopper. The slurry is pumped back to the
gravity gold recovery circuit. The cyclone overflow slurry gravitates to the float feed thickener to
remove excess water. Thickener underflow is pumped to the conditioning tank where dilution
water, activator, collector and frother are added.
Gold concentrate from the gold trap discharges into a kibble in the goldroom. Spinner and
centrifugal concentrator concentrates are periodically flushed to the gravity concentrate surge
tank and pumped to the gravity concentrate tank in the goldroom.
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Page 1
Coarse concentrates from the gold trap are sorted to recover coarse gold nuggets. After sorting,
coarse concentrates are crushed using the concentrate roll crusher and fed to the goldroom
gravity spinner. Goldroom gravity spinner tails, with accumulated spinner and centrifugal
concentrator concentrates, are fed to the goldroom fine screen. Oversize concentrates are recrushed and fed to the Concentrate Roll Crusher and fed back to the goldroom gravity spinner.
Fine concentrates are fed to the concentrate jig. Jig concentrates are upgraded using two
shaking tables and the concentrate calcined for direct smelting. Jig and table tails (middlings)
are leached in a proprietary system (Intensive Leach Reactor or ILR) where gold dissolves under
aggressive reaction conditions in an enclosed rotating drum. Cyanide and sodium hydroxide
solutions are added to the ILR. Solution containing solubilised gold (electrolyte) is circulated
through an electrowinning cell and recycled to the ILR.
The overflow of the conditioning tank feeds the flotation cells. Flotation concentrate slurry is
pumped to the concentrate thickener. Tails slurry is pumped to the sand cyclone. Fines are
removed in the cyclone overflow. The cyclone underflow (sands) slurry is diluted and pumped to
a section of the tailings storage facility. The cyclone overflow slurry gravitates to the flotation tail
thickener to remove excess water. Thickener underflow is pumped to the flotation tailings
storage facility. Supernatant water is decanted from settled solids and pumped back to the
process water tank.
The flotation concentrate slurry is thickened to remove excess water and combined with tails
slurry from the ILR. The combined slurry, screened to remove trash, is mixed with lime slurry
and pumped to the CIL circuit. Sodium cyanide is added to the slurry before is enters the
agitated CIL tanks. Dissolved gold is adsorbed onto activated carbon granules. After acid
treatment of the loaded carbon, gold is stripped (eluted) from the activated carbon into a gold
bearing solution (eluate). The eluate is circulated through a separate dedicated electrowinning
cell. Barren activated carbon is processed through a kiln to restore the gold adsorption capacity
and added back to the agitated leach tanks.
The leached slurry discharged from the agitated CIL tanks is treated in a cyanide detoxification
system to reduce the cyanide concentration to below permitted limits and pumped to a separate
tailings storage facility.
Goldroom activities include upgrading of the gravity concentrates and monitoring of
electrowinning from the electrolytes from the ILR and elution systems. Gold in the electrolytes
plated onto cathodes is periodically removed by washing cathodes with a high-pressure water
spray. Washings are filtered and dried in an oven with the shaking table concentrates and
smelted with fluxes into dor bullion.
The reagent area includes facilities for the offloading, mixing, storage and distribution of flotation
collector, activator, frother, flocculant, hydrated lime, sodium hydroxide, sodium cyanide, sodium
metabisulphite and hydrochloric acid. The actual reagents used will vary from time to time
depending on cost, performance and availability.
3
GENERAL
3.1
Control System
The control philosophy implemented for the Bendigo Gold Project is a typical system employed
in Australian mineral processing operations. Field instrumentation provides a number of inputs
to a set of programmable logic controllers (PLCs). The PLCs also collect status information on
all process drives and process states as well as providing drive control and process interlocking.
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Page 2
Standard personal computers (PC) are located in the Main Control Room (MCR) and the
Crusher Control Room (CCR), and networked to the PLCs. The computers operate a
Supervisory Control and Data Acquisition (SCADA) program for control and monitoring of the
relevant sections of the plant. The SCADA is configured to provide outputs to alarms, control the
function of selected process equipment, and provide logging and trending facilities to assist in
analysis of the operating plant.
The CCR and MCR are purpose built structures, located in the crushing and mill buildings
respectively. The CCR houses one control room operator station and the MCR houses one
control room operator station, one engineering station and a printer. The control room operator
station provides the following functions:
Graphic (mimic) displays of all plant areas, showing equipment status (ready, notready or running) and analogue values for critical process variables
Alarm display and logs, showing the alarm tag number, title, date and time
Trend displays with flexible time and process variable axes for any analogue process
variable
Loop displays showing controller settings and trending of process variable, set-point
and output
The control room operator stations are supplied from an uninterruptible power supply (UPS) unit
with twenty minutes standby capability.
Drives that form part of a vendor package shall be controlled from the vendors control panel. As
a minimum, Run and Fault signals from each vendor control panel are made available to the
SCADA system via the PLC.
The PLCs perform the control of the plant with the SCADA system providing an interface to the
PLCs which:
Access to various controls and set-points within the SCADA system are protected by a password
system. All users have view level access to all areas. The following user accounts are used,
with the corresponding access level:
USER
ACCESS LEVEL
Operator
Supervisor
Engineer
As per Supervisor, plus PID control loop tuning parameters and hardware
settings
The SCADA system contains several graphics replicating the process flow sheets. The screens
have dynamic displays of drive status, process status and indication for process quantities.
All drives are shown in graphical format. The colour of the symbol represents the state of the
drive as follows:
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Page 3
COLOUR
DENOTATION
YELLOW
ORANGE
RED
GREEN
Running
All controlled valves are shown in graphical format. The colour of the symbol represents the
state of the valve as follows:
COLOUR
257422914.doc
DENOTATION
RED
Valve closed
GREEN
Valve open
YELLOW
Fault
BLUE
Valve travelling
Page 4
The control loops described can be found on the Piping and Instrumentation Diagrams (P&IDs)
attached in Appendix 1.
3.2
Drives
Certain equipment is started by PLC controlled group sequences wherever possible, e.g. the
crushing section. Using the sequences allows the control room operator to start or shut down
sections of the plant faster, without risk associated with distractions.
Equipment drives have three modes of operation: namely AUTO, MANUAL and
MAINTENANCE.
3.2.1
Auto Mode
In AUTO mode, the drive is automatically started and stopped by the PLC program for drives
that belong to a particular group sequence control. A group sequence cannot be initiated if any
equipment in that sequence is not in Auto mode. The group sequences include an ALL TO
AUTO pushbutton, which sets all drives related to that sequence into AUTO mode.
Certain drives that are not necessarily associated to a group sequence may need to be set to
AUTO mode such as sump pumps, so that they will automatically start and stop based on the
activation of a level switch or other such field device.
Drives that do not require AUTO mode will have the AUTO mode selection disabled in the PLC
code. These drives will not have the AUTO mode pushbutton shown on the Citect SCADA motor
faceplate.
AUTO mode cannot be selected on the drive faceplate when the drive is faulted.
In AUTO mode, all process interlocks must be satisfied for the drive to run.
In AUTO mode, the operator may initiate a start and stop the drive from the Citect SCADA
system. The drive will run, provided that the process interlocks are satisfied. The drive will be
switched from AUTO to MANUAL mode if the Citect stop pushbutton is initiated, as well as
stopping the drive.
In AUTO mode, the operator may also start and stop the drive from the Local Control Station
(LCS). The drive will run provided that the process interlocks are satisfied.
Switching of the drive mode from AUTO to MANUAL will keep the drive at its current state (i.e.
drive will stay running).
Switching of the drive mode from AUTO to MAINTENANCE will stop the drive.
3.2.2
Manual Mode
In MANUAL mode, the individual drive is requested to start and stop from the Citect SCADA
system and the drive is under the control of the PLC program. In Manual mode, all process
interlocks must be satisfied for the drive to run.
In MANUAL mode, the operator may also start and stop the drive from the Local Control Station
(LCS). The drive will run provided that the process interlocks are satisfied.
Switching of the drive mode from MANUAL to AUTO will keep the drive at its current state (i.e.
drive will stay running).
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Page 5
Switching of the drive mode from MANUAL to MAINTENANCE will stop the drive.
3.2.3
Maintenance Mode
In MAINTENANCE mode, the operator only starts and stops the drive from a field stop/start
station located adjacent to the drive.
In this mode, all process interlocks are bypassed and not effective. It is assumed that in
MAINTENANCE mode the field operator will be in full control and supervising the drive.
When switching a drive into MAINTENANCE mode the drive will be stopped.
Switching of the drive mode from MAINTENANCE to MANUAL mode or MAINTENANCE to
AUTO mode will keep the drive at its current state.
In MAINTENANCE mode a spanner symbol appears adjacent to the drive shown on the mimic
display.
3.2.4
General Features
Modes are displayed on the Citect mimic pages by the colour of the equipment tag name box.
The equipment tag name box identifies the equipment name using a black text on a coloured or
clear background box. The background box colours are:
The selection of either mode is made via three separate push buttons on the equipment motor
control faceplates. A coloured border appears around the selected mode push button to denote
that it is selected.
The drives depicted on the mimic pages change colour to denote:
The Local Control Station stop button is always functional regardless of mode selected.
Safety interlocks such as conveyor pull wires, which must remain operational at all times, are
hardwired. All other interlocks are implemented in the PLC.
3.2.5
The motor drive faceplates include a tick box for interlocks. Ticking this box displays all of the
interlocks programmed for the drive within the PLC. SCADA users with Supervisor or Engineer
level access only may bypass interlocks on any item via a right click on the interlocks display
then selecting bypass on the equipment motor control faceplate if required. SCADA users with
Operator level access will find the check box on the equipment motor control faceplate disabled.
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Page 6
3.2.6
Symbols
Symbols appear adjacent to the drives as well as other control equipment to denote an abnormal
control condition.
These symbols are shown and described on the SYMBOLS LEGEND page.
3.3
Alarms
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Page 7
These are warning and notification type alarms. The alarm advises the operator that certain
conditions have changed on his plant and may require action or intervention. In some instances
an EVENT type alarms could lead to a PROCESS alarm if the alarm remains unattended.
A schedule of alarms and their category is presented in Appendix 1.
3.4
Common Functions
A number of common control functions are provided throughout the plant. These are listed here
to avoid repetition throughout detailed descriptions.
3.4.1
Conveyors
Conveyors are fitted with speed sensors to detect low speed or belt slip, limit switches to detect
belt drift, pull-wire switches to stop the conveyor in an emergency and start-up sirens and
flashing light beacons to advise of an imminent start.
3.4.2
Chutes
Where applicable, chutes are fitted with a laser (or suitable alternative) level switch or transmitter
to alarm on blockage at high level and stop equipment feeding the chute.
3.4.3
A number of the pump hoppers are fitted with level control. This generally includes an ultrasonic
level probe mounted over the hopper providing input to a level control loop. The level set-point
that is entered by the operator is maintained by the loop output adjusting the speed of the
associated pump. Level monitoring includes various alarms including high and low level.
3.4.4
Samplers
Sampler Type
Location
Airlift
Conditioning tank
Concentrate
thickener
underflow pump delivery
Airlift
CIL tank 7
Airlift
Detox tank
Poppet valve
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Page 8
The airlift sample consists of an airlift with a timer controlled solenoid valve that opens the air
supply on a controlled preset frequency and delivers sample into a suitably located container.
Sample frequency can be adjusted by changing the solenoid valve timer settings via the
SCADA.
The double stage cross cut sampler consists off an electrical motor driven sample cutter that
travels through the process stream. Primary sample is delivered into a surge launder to smooth
out the flow. The primary sample is passed through a Vezin type secondary sampler. The
sample is collected in a sample collection bucket. The reject primary sample from the secondary
sampler is fed to the flotation tailings concentrator. Sample frequency can be adjusted by
changing the sampler timer settings via the SCADA.
The single stage cross-cut sampler consists of a flexible pipe section normally discharging into a
funnel. The pipe is fixed to a pneumatically actuated ram that periodically moves the mouth of
the hose over a static sample collection slot in the funnel. The sample is collected via the slot
and gravitates into a sample collection bucket. Sample frequency can be adjusted by changing
the sampler timer setting at the field mounted sampler control panel.
The final CIL tail sampler consist of an actuated poppet type sampling valve on the CIL tails
pump delivery pipeline with a timer controlled solenoid valve that opens the air supply on a
controlled preset frequency and delivers sample into a suitably located container. Sample
frequency can be adjusted by changing the solenoid valve timer settings via the SCADA.
All samplers are interlocked so they do not operate without process flow.
Manually operated valves are provided as sample points on the ILR and CIL electrowinning cell
feed and tail pipelines.
3.4.5
Dust Collectors
The reverse air pulse to clean the filter media in the crusher dust collector and HPGR &
secondary screen dust collector is controlled on a timer supplied by the vendor.
3.4.6
Operation of spillage sump pumps is automatic. The sump is fitted with a switch, which
activates at a high level in the sump. The high level signal starts the pump. The pump runs for a
preset time after the high level signal is cleared. If the switch indicates the sump remains at a
high level after a preset delay, even though the pump has started, an alarm registers at the
SCADA.
3.4.7
All positive displacement e.g. helical rotor, diaphragm or peristaltic pumps have pressure relief
valves on the pump delivery pipeline located prior to any discharge isolation valves.
3.4.8
On gland-sealed pumps, seal water delivery valves are actuated. The valves are opened and
closed as part of the pump start up sequence.
Flow confirmation is provided as a start permissive and low gland water flow alarms when the
pump is running but does not trip a running pump. A gland water pressure gauge is installed at
each set of pumps. The individual pump gland water lines are equipped with Maric type flow
regulation valves.
3.4.9
Safety Showers
The safety showers are activated by a hand operated valve with a pull chain and equipped with
an eye bath activated by a handle and foot pedal.
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Primary crusher
Secondary crusher
HPGR
Ball mill
Mill pump
Cyclone pump
Several pressure and temperature transmitters are installed to provide data and equipment
protection. Many of these instruments are included in vendor packages that provide general
alarm conditions to the relevant vendor PLC system.
Also shown are the status of drives (ready, not-ready, running) and advisory alarms on selected
drives when shut-down.
3.4.11 Mass Flow Measurement
For control and tonnage accounting purposes at various points in the process, mass flow
measurement is provided.
For dry material on conveyors, this is achieved by belt weightometers. All belt weightometers
are single strain gauge load cell, dual idler type with span calibration by mass attached to the
frame. Weigh class idlers are installed three idlers before and three idlers after the
weightometer. The belt weightometers have a local display of instantaneous belt loading and
integrated dry tonnage flowrate, as well as totalised dry tons. The dry tonnage flowrate and
totalised dry tons are calculated by the PLC and displayed on the SCADA system.
For slurry flows, magnetic flow meters and a nuclear density meters are installed on the relevant
pipeline. Instantaneous slurry density and volumetric flow are displayed locally and on the
SCADA system. The dry tonnage flowrate and totalised dry tons are calculated by the PLC and
displayed on the SCADA system. The instruments are typically installed on a vertical section of
pipe at least 10 pipe diameters after and five pipe diameters before any constriction, valve, bend
or feature in the pipe that may cause a disturbance in the slurry flow.
3.4.12 Thickeners
Nuclear density meters are installed on the thickener underflow pump delivery pipelines. The
density meter can control the thickener underflow pump variable speed, i.e. slowing the pump if
the density drops and speeding up the pump if the density rises.
If the density of underflow slurry drops below the minimum acceptable, e.g. if the thickener feed
is interrupted due to a stoppage in the upstream process, the PLC alarms. The SCADA advises
the control room operator to close the remotely controlled actuated underflow pump delivery
valve feeding the downstream process and open the remotely controlled actuated recycle valve
diverting slurry back to the thickener feed. The PLC detects if the thickener is in this
recirculation mode for longer than a period of 15 minutes an alarm pops up at the SCADA
screen to ensure the control room operator stops flocculant solution addition.
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A magnetic flow meter on the delivery line from the underflow pump to the downstream process,
is installed after the valves used for diverting underflow slurry back to the thickener feed column.
The volumetric flow and nuclear slurry density measurement are integrated in the PLC to provide
indication and totalisation of the dry tonnage flowrate to the downstream process.
The thickeners are equipped with mud-level cone type interface detectors that warn the control
room operator via the SCADA if the bed level is rising so that corrective action can be taken
before a sliming condition occurs. Thickener rake torque measurement is displayed and logged
for trending on the SCADA system. An increase in solids loading raises the high and high-high
torque alarms that activate at the SCADA.
3.4.13 Cranes and Hoists
All powered hoisting equipment, including both travelling cranes and monorail type hoists, are
controlled by either hand held cable pendant with two speeds available for both hoisting and
travelling or hand held radio frequency remote control keypad (crusher, mill flotation and gold
room concentrate hoists).
4
4.1
Crushing
Page 11
The primary jaw crusher has an automated pneumatic grease lubrication system running on a
timer. The secondary cone crusher has a low-pressure air seal system to protect the eccentric
and drive from dust. The crusher is equipped with a vendor supplied hydraulic positioning
system for raising and lowering the main shaft to adjust the crusher gap setting and for tramp
relief. An air-cooled lubrication system circulates and cleans oil for the crusher drive.
The dust collection system on the outlet of the primary and secondary crushers and fine ore bin
feed conveyor head pulley and the system at the secondary screen and HPGR are started and
stopped automatically as part of the crushing sequence.
The fine ore bin feed weightometer installed on the fine ore bin feed conveyor measures and
totalises the flowrate of crushed ore from the crushing plant fed to the fine ore bin. The
indication can be used by the control room or crusher operator as a guide to adjust the primary
jaw crusher feeder speed to control the feed to the crushing plant. A level element is installed in
the fine ore bin feed conveyor head chute which stops the conveyor in the event of a high level
in the fine ore bin.
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The crusher spillage pump delivers to the stormwater collection pond and the stormwater
collection pump delivers decanted water underground for disposal. High level switches in the
crusher building and at the stormwater collection pond provide an alarm to warn of flooding.
Ventilation in the crusher building is provided by the crusher area fan. At the entrance for
personnel to the building, a green light illuminates while the fan is running and a warning red
light illuminates if the fan is stopped.
4.2
Refer to P&IDs 1475-P052 Fine Ore Bin & HPGR, 1475-P053 Grinding Gravity Circuit Sheet 1 of
3, 1475-P054 Grinding Gravity Circuit Sheet 2 of 3, 1475-P055 Grinding and 1475-P079 Gravity
Circuit Sheet 3 of 3.
4.2.1
The HPGR feed rate is controlled automatically using the variable speed drive of the fine ore bin
belt feeder. The fine ore bin reclaim weightometer on the HPGR feed conveyor measures the
flowrate of crushed ore from the bin and is used to control the feeder variable speed.
The feed to the fine ore bin will be stopped by interlock at low bin level to prevent material
impacting directly on the fine ore bin belt feeder causing damage. The fine ore bin maybe
emptied during maintenance. If the bin is re-filled from empty to full without the fine ore bin belt
feeder being started bridging may occur. In this case, when the empty bins low level alarm
condition is removed as filling commences, a timer is initiated. If the fine ore bin belt feeder is
not started before expiry of the timer, the feed to the fine ore bin will be stopped by an interlock
to the fine ore bin feed conveyor.
An electromagnet (HPGR magnet) is installed on a gantry at the discharge of the fine ore bin
belt feeder onto HPGR feed conveyor. The magnet is normally left energised (i.e. switched on).
If switched off it must be energised before initiating the HPGR start up sequence. To clean the
magnet, the fine ore bin reclaim feeder is stopped and the HPGR magnet hoist is used to move
the magnet along the gantry frame to a position adjacent to the conveyor and the magnet power
switched off, dropping accumulated metal into a skip for removal. The hoist is used to move the
magnet back along the gantry frame to the correct position and the HPGR feed restarted.
Metal detectors are installed on the HPGR feed and mill screen oversize conveyors. If the
HPGR magnet fails to remove tramp metal or non-magnetic metal is present, either HPGR metal
detector 1 or 2 activates the HPGR diverter gate in the HPGR feed bin, forcing material to
bypass the bin to the HPGR bypass bunker for a period long enough to ensure any metal
detected bypasses the bin. If the position switch on the HPGR diverter gate does not register
the gate has moved to the divert position in time, the HPGR feed and mill screen oversize
conveyors trip.
The HPGR is equipped with variable speed electric motors for the rolls. The roll speed is
controlled by the level in the HPGR feed bin measured by an ultrasonic level indicator. If the bin
fills up, the rolls speed up and vice versa to maintain a constant level in the bin. The HPGR
operates under a choke fed condition at all times and the roll speed is kept to the minimum
required to satisfy the throughout required while running as slowly as practical to maximise tyre
life.
The mill screen oversize weightometer installed on the mill screen oversize conveyor is used to
account for mill screen oversize returned to the HPGR feed The sum of the two weightometers
is the total HPGR feed rate and can be used to calculate the circulating load. An increase in
circulating load indicates poor screening efficiency at the ball mill screen, likely to be due to a
blinded screen deck. The mill operator should then investigate and rectify the situation as
required. A high level alarm in the HPGR feed bin overrides the normal fine ore bin reclaim
weightometer control of the fine ore bin reclaim feeder and reduces the feeder speed to a
minimum.
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The HPGR is equipped with a dedicated PLC for management of key alarms, trip settings,
interlocks, start up, and shut down sequencing for the main and auxiliary drives. All alarms from
the vendor PLC control panel are repeated at the SCADA system via the relevant plant PLC.
The power, torque, current and speed of the two motors are displayed at the SCADA system.
A level switch is installed in the ball mill screen feed box which stops the mill feed conveyor in
the event of a high level caused by a blockage in the ball mill screen feed box.
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4.2.2
The ball mill screen underflow and ball mill discharge, via the trommel, flow to the mill pump
hopper. There is one operating mill pump, with an installed standby. The mill pump delivers via
the jig feed distributor to the three primary jigs operating in parallel. Each pump has actuated
valves for isolation of suction, discharge and gland water. The hopper level is measured and is
controlled automatically by adjusting the pump variable speed.
Water addition to the grinding and gravity section is sourced from the process water tank via the
process water pump.
A flow meter is installed on the water supply to the ball mill screen gold trap and ball mill screen
sprays. The desired flowrate is entered manually into the controller at the SCADA and the
flowrate controlled by an actuated valve.
A flow meter is also installed on the water supply to the ball mill feed chute. The desired flowrate
to provide the required mill discharge slurry density is entered manually into the controller at the
SCADA and the flowrate controlled by an actuated valve.
The mill feed chute seal and mill trommel spray water flows are controlled by manually adjusted
valves. A master actuated valve on the pipeline supplying mill feed dilution, mill feed chute seal
and mill trommel spray water is interlocked to the ball mill drive such that the mill cannot be
started unless the valve is open first and the water supply will be closed when the mill is
stopped.
Jig hutch water is set during commissioning using the vendor supplied magnetic flow meter at
the jig and manually adjusting a water flow control valve at the jig also supplied by the vendor.
Hutch water flow can be optimised thereafter by adjusting the valve position. Hutch water
flowrate is indicated at the SCADA. The jigs are equipped with their own panel mounted
controller to adjust the stroke and frequency of the pulsation.
Mill pump hopper dilution water is controlled by an actuated control valve. The valve position is
controlled by the output of the nuclear density meter installed on the mill pump delivery pipeline
feeding the jig feed distributor to give a consistent cyclone feed slurry density. Operators check
the density of jig feed, mill cyclone overflow, underflow and mill discharge every hour using a
Marcy density scale.
Concentrates accumulating in the ball mill screen gold trap are flushed out periodically to a
Concentrate Kibble in the goldroom by opening remotely actuated purge valves. The fail close
valves are set to open for a short pre-set period and can be opened on a set frequency basis
controlled by a timer or on an ad-hoc basis by the operator. The gold trap should be routinely
purged prior to a planned plant shutdown.
Concentrates from the jigs are discharged into the spinner feed distributor. Spinner tails are
returned to the spinner tails pump hopper. A slurry of coarse solids gravitates from the spinner
tails pump hopper to the mill pump hopper. Provision is made to divert the coarse solids slurry
to the cyclone pump hopper if required. Fine solids and water overflow the hopper into an
overflow compartment and are pumped using the spinner tails pump to the mill screen gold trap
to increase feed dilution. A high level overflow on the hopper overflows to the mill pump hopper.
Four spinners are installed in two parallel pairs of spinners in series. Normally the two spinners
in each pair operate as a primary and secondary stage device with the first units tail feeding the
second unit. The feed valve to the first stage is actuated and closes when the first stage unit is
flushing; diverting slurry from the spinner feed distributor directly to the second stage unit until
flushing is complete. When the second stage unit is flushing, the actuated intermediate valve
closes and diverts the first stage unit tails directly to the mill pump hopper. Spinners are
equipped with their own panel mounted controller to allow setting of cycle times and the
sequential opening and closing of feed and flushing water valves.
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The centrifugal concentrator is located in the mill area. The centrifugal concentrator is controlled
by a Falcon AutoPAC" control system. This is a stand-alone unit mounted near to the
centrifugal concentrator and allows setting of key operational parameters such as cycle time.
Manipulation of process variables is only possible at the AutoPAC system user interface. The
SCADA only displays whether the centrifugal concentrator system is healthy and the unit is
concentrating, flushing or running in flush inhibit mode.
An actuated knife gate valve is provided on the centrifugal concentrator feed line from the gravity
screen underpan. During the normal concentrating cycle, the valve feeding the concentrator is
open. For bypass during the concentrate flush cycle the valve is closed and the slurry level
backs up in the screen underpan until it reaches the level of the overflow pipe that diverts slurry
directly to the centrifugal concentrator tail pipe feeding the cyclone pump hopper. Should the
concentrator trip, the valve fails closed in order to bypass it until it can be restarted.
There is one operating cyclone pump, with an installed standby. The pump delivers to the mill
cyclone cluster. A duty and a standby cyclone are installed. Each pump has actuated valves for
isolation of suction, discharge and gland water.
The cyclone pump hopper level is measured and is controlled automatically by adjusting the
pump variable speed. A diaphragm-protected gauge on the cyclone feed distributor measures
the cyclone pressure. The cyclone isolation valves are manually opened and closed. A low level
alarm in the hopper opens an actuated valve adding process water to the hopper to assist in
start up of the circuit and prevent the pump from choking.
A flow meter is also installed on the water supply to the centrifugal concentrator, gravity screen
sprays and cyclone pump hopper. The flow meter is not used for control of water addition but is
provided for monitoring purposes.
Though the cyclone feed slurry density is ultimately controlled by the water addition to the jig
feed slurry at the mill pump hopper, the cyclone feed density is monitored by the control room
operator. A nuclear density meter is installed on the cyclone pump delivery pipe line and the
measured density is indicated at the SCADA.
A level measurement device is installed in the cyclone underflow launder to warn of a choked
mill feed chute. A high level alarm will override the level control on the mill and cyclone pump
hoppers and will trip the mill feed conveyor.
Concentrates flushed from the spinners and centrifugal concentrator are delivered to the gravity
concentrate surge tank. The tank is equipped with a level measurement device. The level
measurement prevents any of the spinners or centrifugal concentrator from flushing
concentrates if the tank level is too high. Concentrates are pumped from the tank to the gravity
concentrate tank in the goldroom by the gravity concentrate transfer pump. There is one
operating pump, with an installed standby. The pump suction and delivery arrangement is a
single flexible hose. To change over pumps, a security cleared operator will enter the security
cage and change over the suction and delivery lines.
As the flushing of concentrates to the surge tank is an intermittent process, the delivery of the
gravity concentrate transfer pump is normally set to recycle to the tank to maintain the
concentrate solids in suspension when the tank level is low. After any of the spinners or the
centrifugal concentrator flushes a batch of concentrate to the tank and the level in the tank rises,
the position of actuated valves on the pump delivery is reset to transfer concentrate slurry to the
gravity concentrate tank in the goldroom until the level drops. The PLC inhibits flushing of any of
the spinners or the centrifugal concentrator if the gravity concentrate surge tank is at a high
level.
Balls are added to the mill every shift by the mill operator. The ball addition rate is manually
controlled by the operator to ensure the correct mill power draw is achieved.
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Balls are delivered in drums and immediate usage requirements stored near the mill. The drums
are emptied manually into the ball kibble and this hoisted to the mill feed chute floor and emptied
into the mill feed chute.
Spillage from the grinding and gravity bunded area is pumped to the mill pump hopper by mill
spillage pump 1 or 2. The mill hoist is a travelling overhead gantry crane that services the
grinding facilities.
4.3
Flotation
4.3.1
Flotation
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Spillage from the flotation bunded area is hosed to the flotation spillage pump and pumped to
the conditioning tank.
4.3.3
Concentrate Thickener
Flotation Tailings
Refer to P&ID 1475-P059 Flotation Tailings Sheet 1 and 1475-P060 Flotation Tailings Sheet 2.
If the sand cyclone is offline, flotation tails slurry is pumped directly to the flotation tail thickener
feed box and is mixed with dilute flocculant. If the sand cyclone is online, flotation tails slurry is
pumped to the sand cyclone. Fines are removed in the cyclone overflow and coarse sand
discharges from the cyclone underflow to the sand pump hopper and is pumped to the flotation
tailings storage facility. Sand cyclone overflow gravitates to the flotation tail thickener feed box
and is mixed with dilute flocculant.
Thickener feed gravitates into the thickener feed well. Thickener overflow reports to the process
water tank. Underflow from the flotation tail thickener is pumped by the flotation tail thickener
underflow pump to either the east flotation tailings storage facility. A duty and a standby
underflow pump are installed. Each underflow pump has actuated valves for isolation of suction,
discharge and gland water.
Sand cyclone underflow slurry is diluted with process water in the sand pump hopper. Diluted
sand slurry is pumped to a dedicated sector of the east flotation tailings storage facility. A duty
and a standby pump set are installed. Each sand pump set has actuated valves for isolation of
suction, discharge and gland water. The hopper level is measured and is controlled
automatically by adjusting the second stage pump variable speed. Hopper dilution water is
controlled by an actuated control valve. The valve position is controlled by the output of the
nuclear density meter installed on the sand pump delivery pipeline. The valve position control is
overridden at low pump hopper level to ensure the delivery pipeline flushes clear.
Three options are available for alternate operation of the flotation tailings disposal system.
Option 1 is the normal design case with the sand plant and flotation tails thickener online. The
single duty flotation tailings thickener underflow pump and one tailings pipeline are used as well
as the single duty 2 stage sand pump installation and one sand pipeline are used .
Under Option 2, if the sand plant is offline and the thickener online, the sand cyclone feed valve
(XV4040) is closed and the bypass valve (XV4041) opened in. The flotation tailings thickener is
sized to accept the higher feed rate as the unclassified flotation tailings have higher settling rate.
In order to process the increased underflow slurry volume through the thickener, a parallel
tailings thickener underflow pumping system is used. Both of the flotation tail thickener
underflow pumps are operated in parallel delivering separately via both tailings pipelines.
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Under Option 3, if both the sand plant and thickener are offline, due to the volume of dilute slurry
from the flotation tailings pumps the installed tails thickener underflow pumps will have
insufficient capacity for the unthickened flotation tailings slurry at the design plant feed rate. The
sand cyclone feed valve (XV4040) is closed and the bypass valve (XV4041) opened. To achieve
the thickener bypass, a tee section will be added into the thickener feed pipe prior to the
thickener feed box. This will feed the tailings thickener underflow pump suctions. A parallel
tailings thickener underflow pumping system is used with both of the flotation tail thickener
underflow pumps operating in parallel delivering separately via both tailings pipelines. A
reduced plant feedrate of 44 t/h is adopted to reduce the slurry volume pumped.
Water is reclaimed from the flotation tailings storage facility by a flotation tail decant pump.
Decant water is returned to the process water tank. A thermal flow switch is installed on the
decant pump delivery. If a no flow situation is detected by the switch, due to the process water
tank being full and the outlet float valve being closed, or the TSF being dry, the switch stops the
decant pump. The switch is linked to a timer and the pump will restart after a 20 minute delay.
Seepage water from the flotation tails storage facilities is collected in trenches. A pump is
located at the facility and seepage water pumped back onto the flotation tailings storage facility
by a seepage pump. The pumps are started and stopped automatically by a level switch in the
seepage trench.
Spillage from the flotation tails thickener bunded area is hosed to the flotation tail thickener
spillage pump and pumped back to the flotation tail thickener feed box. If the flotation tail
thickener is to be bypassed in the event of a breakdown, the delivery of the flotation tail pump
can be connected temporarily to the suction of the flotation tail thickener underflow pump.
4.3.5
Goldroom
The goldroom is manned during dayshifts only and all equipment is started and stopped locally.
4.3.6
Shaking Tables
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Goldroom fine screen oversize gravitates to the oversize concentrate bin and undersize to the
concentrate jig. Jig tails are discharged to the gravity middlings pump. Jig concentrates are fed
onto shaking table 1. Shaking table 1 middlings are fed to shaking table 2. Concentrates from
both tables are collected in buckets, excess water decanted and placed in trays in the calcine
oven for drying. Tailings from both shaking tables are combined with jig tails at the gravity
middlings pump and pumped to the ILR feed cone. The concentrate jig is equipped with a 1 mm
screen. Any coarse (i.e. +1 mm) concentrate accumulating in the jig is removed, collected in a
kibble and emptied into the oversize concentrate bin to be crushed and returned to the circuit.
Water is supplied to the jig and shaking tables from the goldroom water tank. The level of water
in the tank is controlled by a float valve to give a constant steady head of water. Water is
supplied to the gold room gold room spinner wetting box directly from the raw water supply.
The gravity concentrate tabling area is bunded to prevent escape of spilt high-grade
concentrates. The goldroom spillage pump is installed to return spilt high grade concentrates to
the gravity concentrate tank.
4.3.7
Goldroom - Smelting
Reagent makeup is performed by operators on day shift and the design of these systems is
based on this philosophy.
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4.4.1
Copper Sulphate
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Page 21
4.4.3
Flocculant
Sodium Cyanide
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The main section of the tank is partially filled with raw water via an actuated valve and briquettes
are loaded into a cage located in the main compartment of the tank. The tank is topped up with
raw water. The cyanide agitator is started to dissolve the briquettes to make up a 20% solution.
On completion of mixing, the agitator is stopped. The suction manifold valve from the main
section of the tank is reopened to balance the level in the main section and now partially empty
reserve compartment. The valve from the reserve compartment is then closed.
Sodium cyanide solution is pumped through a ring main by the cyanide pumps (one operating,
one standby) to the CIL, elution tank and ILR and returned to the cyanide tank. Line pressure is
maintained by a manually operated diaphragm valve. The ring main return discharges into the
reserve compartment of the tank to ensure it is always full.
Cyanide solution is dosed to CIL tank 1 from an actuated flow control valve on the ringmain
pipeline. The position of the control valve is set by a cascade loop from the concentrate
thickener underflow mass flow system to the CIL cyanide addition flowmeter located upstream of
the flow control valve.
If cyanide is required at the elution tank, it is added by opening via remotely controlled actuated
valve from the cyanide ringmain. The required volume of cyanide solution flowing to the tank is
totalised by a flow meter and the remotely controlled actuated valve closed. Cyanide addition to
the ILR from the ringmain is controlled by the ILR PLC.
The cyanide tank is equipped with level measurement devices indicating at the SCADA in both
compartments. A high level alarm in the main compartment is interlocked to the water addition
valve and a low level alarms at the SCADA screen. A low-low level in the main compartment or
low level in the reserve compartment will trip the cyanide pump.
A duplex strainer is installed on the suction of the cyanide pumps.
Spillage from the cyanide make up tank bunded area is pumped to CIL tank 1 by reagents
spillage pump 2. Reagent hoist 2 services the cyanide make up facilities.
4.4.5
Sodium Hydroxide
Hydrochloric Acid
Page 23
Hydrochloric acid is received in a bulk-a-box at 33% w/w strength. The bulk-a-box functions as a
storage tank and is connected to a stand pipe. The stand pipe provides a reserve while an
empty bulk-a-box is changed. A low level switch is installed in the stand pipe to indicate if the
bulk-a-box is empty and alarms at the SCADA screen if the level is low.
The hydrochloric acid offload pump is a fixed speed pump and delivers to the acid wash tank.
The pump is normally left in Maintenance mode and started and stopped in the field. The start
button initiates a timer so that if the pump is not stopped manually before the timer expires the
pump will stop to prevent accidental overdosing.
Acid spillage from the laydown area is hosed to a spillage sump. A pneumatically operated
diaphragm pump (supplied by BML) will be installed to dispose of spillage.
4.4.7
SMBS
Lime
Page 24
Lime slurry is dosed to the CIL at the trash screen underflow and at the detox tank from actuated
pulsing control valves on the ringmain main pipeline.
The lime tank is equipped with an ultrasonic level measurement element. The level of the tank
will drop as lime slurry is dosed to the CIL and detox tank. At a low level set-point, the actuated
water addition valve is opened to refill the lime tank and the lime silo vibrated fluidiser and lime
feeder is started. At a high level set-point, the actuated water addition valve is closed and the
fluidiser and feeder stopped.
A general fault alarm notifies the operator to check the lime system.
Spillage from the lime make up area is pumped to the detox tank by reagents spillage pump 1.
4.5
Services
4.5.1
Gland water pressure is monitored locally with a pressure gauge and pressure transducer
indicating at the SCADA. A low pressure will alarm at the SCADA and a low-low pressure will
trip the HPGR feed conveyor. A relief valve is provided to avoid over-pressuring the gland water
main, returning to the tank.
4.5.2
Process Water
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The process water tank is supplied with water recycled from the overflows of the flotation feed
thickener, concentrate thickener and flotation tail thickeners, return decant water from the
Flotation Tails Storage facilities and make-up water from the mine water supply (underground
pumping). The addition of decant and make-up water from the mine water supply is controlled
by float valves in the tank. Water sources entering the tank are delivered into the connecting
process water stand pipe to minimise sanding of the tank from suspended solids in the thickener
overflow streams.
The process water tank is equipped with a hydrostatic level measurement device. A low level
alarms at the SCADA and a low-low level will then trip the HPGR feed conveyor.
The CIL water tank is supplied with return decant water from the CIL tails storage facility, and
make-up water from the mine water supply. The water in the CIL water tank is used as spray
and dilution water at the trash screen, loaded carbon screen and CIL tail screen.
The addition of decant and make-up water from the mine water supply is controlled by float
valves in the tank. The CIL water tank is equipped with a hydrostatic level measurement device.
A low level in the tank alarms at the SCADA.
The transfer water pump is started and stopped by the operator as required. The level in the
transfer water tank is topped up as required by opening a manual valve on the Bendigo water
supply line.
If contaminated transfer water is to be disposed of the operator closes the delivery line valve to
elution area and opens the recycle valve on the delivery back into the transfer water tank and a
bleed valve feeding a small amount of contaminated water to the carbon safety screen feed box
and starts the pump. The flow of contaminated water to disposal at the carbon safety screen
feed box is controlled manually using the bleed valve.
4.5.3
Air
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Oxygen is delivered in liquid form by road tanker and off-loaded into a bulk liquid storage vessel
equipped with a vaporising system. The bulk oxygen supply system feeds a plant reticulation
system that supplies oxygen to the CIL and detox tanks. The oxygen system includes a tank
pressure and discharge pressure control system and tank level and pressure indicators.
4.5.4
Other
Uncontaminated plant site run-off is collected in the stormwater collection pond. Collected runoff water can be pumped either to the process water tank or to underground using the
stormwater collection pump.
4.6
Page 27
Flocculant solution is added to the ILR pump hopper and ILR thickener from a dosing tank
supplied by Gekko located at the ILR. The dosing tank is filled by the operator daily from the
flotation feed thickener dilute flocculant solution pipeline.
Concentrate thickener underflow slurry is pumped via flotation concentrate sampler to the trash
screen feed box. At the trash screen, material such as grit, woodchips, fibres, wire and plastic,
that would otherwise choke CIL interstage screens and contaminate loaded carbon recovered
from the CIL tanks, is removed. The trash screen underflow is pumped into CIL tank 1. The
screen spray water is manually controlled to achieve the required CIL slurry density.
Trash screen oversize reports to the trash basket. The basket is equipped with wedge wire
mesh panels to allow excess water to drain away, retaining the trash. The basket can be
removed with a forklift or hoisted with a crane and emptied. The empty basket can then be
replaced.
Lime slurry is added to the trash screen underpan by a pulsing valve on the lime ringmain pipe.
A pH meter is installed in CIL tank 1. The output of the pH meter is used to control the valve
pulse frequency.
The ILR may not operate when the trash screen or trash screen underflow pump is stopped as
ILR tails would blind the screen or overflow the trash screen underflow hopper.
4.7
Page 28
Slurry discharged from the final stage CIL tank gravitates to the cyanide detoxification tank.
A detector is provided on the CIL tank top floor level for monitoring of hydrogen cyanide gas with
local buzzer or horn alarms and SCADA alarms in case of high levels.
A laboratory is provided for CIL operators to check slurry densities, pH, and dissolved oxygen
(DO) levels and perform titrations to check reagent levels and prepare samples for the assay
laboratory. Manually taken slurry samples from the tanks are used to check the slurry density
using a Marcy scale. Manual samples are used to check carbon concentrations. Slurry samples
are taken from selected CIL tanks every 2 hours, filtered, the solution titrated for sodium cyanide,
and the slurry pH measured using a pH meter. Action can then be taken to increase or decrease
cyanide and pH modifier addition as needed.
The CIL spillage pump delivers to the spillage from the CIL bunded area back to the CIL tank 1.
4.8
Carbon Stripping
Carbon stripping consists of an ambient acid wash and pressure Zadra elution system and a
horizontal carbon regeneration kiln. Gold recovery from pregnant eluate is achieved in a single
electrowinning cell. The eluted, barren carbon is reactivated through a horizontal gas fired
carbon reactivation kiln before being returned to the CIL.
The acid wash and elution procedures consist of a number of manually controlled procedures
that require minimal operator intervention between steps. Procedures are paused at critical
points to provide opportunity for monitoring, sampling and selection of stripped carbon discharge
location.
The carbon stripping system is sized to handle a 0.5 tonne batch of loaded carbon. The design
requirement is to treat five batches every week although this can be increased or diminished
depending on plant operating requirements.
4.8.1
Acid Wash
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Periodically (typically every 3 to 4 acid washes) the dilute acid in the acid wash tank becomes
too contaminated for further use. Sufficient sodium hydroxide is pumped to the acid wash tank
to neutralise the spent acid. The acid wash pump is used to pump the discarded liquor to the
CIL tails pump hopper. Fresh raw water is used to refill the acid wash tank and sufficient fresh
concentrated hydrochloric acid is added to make up the required hydrochloric acid strength
(~3%). Water addition to the acid wash tank to make-up fresh dilute acid solution is controlled
by a manual valve.
The acid wash system requires operator intervention at various times during the sequence as all
valves are opened or closed manually.
4.8.2
Elution
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4.8.3
Regeneration
Electrowinning
Page 31
The vacuum system is then started and the receiver evacuated. The remaining cell solution is
drained to the vacuum filter and the operator matches the filter feed and vacuum receiver inlet
flows, to prevent filter overflows, by adjusting feed and discharge valves. Once the remaining
cell solution has been filtered, the vacuum system is regulated to accept the lower flow of solids
and wash water being drained from the cell during the cell cleaning step.
Using the cathode hoist, the cathode pack is carefully raised from the cell and each cathode is
progressively hosed off, into the cell, using the cathode wash pump. This stream of sludge and
wash water is filtered concurrently with the cell cleaning process. The vacuum receiver is sized
to contain the residual cell solution after decanting plus a nominal volume of wash water, such
that it should not be necessary to drain the receiver during the cell clean out process. This
volume is later drained from the receiver to the electrowinning spillage pump sump. If this
nominal volume of wash water is exceeded during the cell clean out process, it is necessary to
shut down the vacuum pump and drain the receiver. A high-level switch in the receiver will trip
the vacuum pump to protect against overfilling of the receiver and consequently filling the
vacuum pump with filtrate.
After filtering, the solids are recovered from the vacuum filter by tilting the filter pan and
shovelling to metal drying trays. The trays are manually lifted into a drying oven to remove any
remaining moisture.
Each electrowinning cell is fitted with a fume hood. This is arranged over the cell and connected
to a plenum chamber that in turn connects to the goldroom scrubber to scrub the fume and
vapours before discharge to atmosphere via the stack. Control of the airflows through this
venting system is by means of manually adjusted slide plate dampers. The anode and cathode
packs of the cell are fitted with a dedicated laminated busbar to conduct current. Air drawn into
the cell enters via spaces between the laminations of the cells cathode and anode busbars, thus
providing cooling.
The tails from the ILR electrowinning cell gravitate to the ILR cell tail pump hopper. The ILR cell
tail pump (one duty/one standby) delivers the cell tail solution back to the ILR thickener. The
level in the hopper is maintained by a float valve connected to the pump delivery.
A high level in the ILR cell tail pump hopper closes an actuated valve in the pregnant solution
pipeline from the ILR to prevent flooding in the goldroom.
4.10
Cyanide Detoxification
Refer to P&ID 1475-P077 Cyanide Detoxification Sheet 1 and 1475-P078 Cyanide Detoxification
Sheet 2.
The discharge of the last CIL tank, combined with the underflow from the regen carbon screen
gravitates into the detox tank where cyanide in solution is reduced to acceptable levels before
disposal of the CIL tailings. Cyanide detoxification is based on SO 2/air technology. The detox
tank provides approximately 90 minutes retention time at design throughputs and is equipped
with the detox tank agitator.
A magnetic flowmeter is installed on the CIL tails pump delivery. The volume of CIL tails pumped
is measured. The slurry density pumped is measured by the operator from samples using a
Marcy scale and entered into the SCADA system. The volumetric flowrate and slurry density is
used to calculate the solution flowrate.
The speed of the SMBS dosing pump adding solution to the detox tank is ratio controlled from
the CIL tails volumetric flowrate measured by a flowmeter and calculated CN wad level in the tails
solution. A fixed adjustment is made to the CIL tails volumetric flowrate as measured by the
flowmeter to account for the volume of carbon safety screen sprays and dilution water into the
CIL tails pump hopper.
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The free cyanide (CNfree) level in the detox tank feed slurry is routinely measured by the operator
by titration of slurry filtrate samples. The CN free level is input via the SCADA along with a ratio for
predicting weak acid dissociable cyanide (CNwad) levels based on actual CNwad compared to
actual CNfree measurements determined from operating experience.
The speed of the copper sulphate dosing pump adding solution to the detox tank is ratio
controlled from the CIL tails volumetric flowrate and manually input slurry density and the copper
sulphate addition rate set point in grams Cu2+ per cubic metre of solution.
Duplicate pH probes are installed in the detox tank. A selected probe provides input to the detox
pH control loop. The loop output controls a pulsing lime-dosing valve on the lime ringmain to
maintain a pH in the tank between 8.5 and 9.5. The signals from the two probes are compared
in the event one probe is out of calibration. If a significant difference in signal is detected, an
alarm advises the operator of the discrepancy. The most accurate pH probe is determined and
control switched to this probe. The inaccurate probe is cleaned, recalibrated or replaced so that
the readings from the two probes coincide.
Oxygen is added to the tank through a sparger system. Rotameters measure the gas-flow and
flow is adjusted by manual operated needle valves.
The detoxified slurry discharging from the tank passes through the CIL tail screen. Screen
oversize reports to the carbon basket. The carbon basket is equipped with wedge wire mesh
panels to allow excess slurry to drain away, retaining the carbon. The basket can be removed
with a forklift or hoisted with a crane and emptied. The empty basket can then be replaced.
Screen undersize gravitates to the CIL tails pump hopper. Discharge from the hopper is pumped
to the CIL tails storage facility by the variable speed CIL tails pump (one duty/one standby).
Pump speed is adjusted to maintain a specified level in the pump hopper. Each pump has
actuated valves for isolation of suction, discharge and gland water.
Water is reclaimed from the CIL tails storage facility by the CIL tails decant pump (one duty) and
returned to the CIL water tank for re-use.
A thermal flow switch is installed on each decant pump delivery. If a no flow situation is detected
by the switch, due to the CIL water tank being full and the outlet float valve being closed, or the
TSF being dry, the switch stops the decant pump. The switch is linked to a timer and the pump
will restart after a 20 minute delay.
5
5.1
General
Interlocks and permissives are programmed into the control system consistent with the
control philosophy.
Permissives need to be satisfied prior to starting equipment to ensure that equipment is not
damaged and that operational hazards are prevented. Similarly, interlocks have been
programmed into the control system to stop and protect equipment, or equipment around it,
under circumstances where associated equipment stops or process conditions dictate it.
The following sections list the permissives and interlocks required to operate the equipment
in the respective areas.
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5.2
Crushing
Drive
Drive
Description
Number
Primary crusher
feeder
10-FE-001
Permissive to Start
Running Interlock
LAH1003 activated
LAH1015 activated
LALL1079 activated
Primary jaw
crusher
10-CR-001
10-CV-001
Secondary
crusher feed bin
feed conveyor
10-SC-001
10-CV-002
LAHH1015 activated
10-CV-003
LAHH1023 activated
Secondary
crusher feeder
Secondary cone
crusher
10-CR-002
10-PU-001
LAHH1051 activated
Stormwater
collection pump
10-PU-054
LAH7008 activated
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5.3
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Drive
Drive
Description
Number
10-FE-003
Permissive to Start
LAL1023 activated
10-CV-004
10-CV-005
LAL7003 activated
20-SC-002
LAL7008 activated
ZSA1042 activated
LAH2067 activated
LAH2098 activated
LAHH1044 activated
10-CV-006
Mill screen
oversize conveyor
HPGR running
Running Interlock
ZSA1042 activated
Mill pump
20-CR-003
20-PU-003
HPGR healthy
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Drive
Drive
Description
Number
Permissive to Start
Running Interlock
XV2017
XV2018
XV2019
Cyclone pump
20-PU-004
20-GC-001
20-GC-002
20-GC-003
Centrifugal
concentrator No 1
20-GC-004A
Ball mill
20-ML-001
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5.4
Flotation
Drive
Drive
Description
Number
Permissive to Start
Flotation feed
thickener
underflow pump
30-PU-006
Flotation tail
pump
30-PU-007
Running Interlock
LAH4023 activated
Flotation
concentrate pump
30-PU-008
Flotation tails
sampler transfer
pump
30-PU-081
Flotation
concentrate
thickener
underflow pump
30-PU-010
Flotation tail
thickener
underflow pump
40-PU-013
Sand pump 1
40-PU-072
Sand pump 2
40-PU-072
LAHH8319 activated
Flotation tails
primary sampler
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30-SA-001
30-SA-006
XV3014 open
XV3014 closed
XV3014 open
XV3014 closed
Page 38
5.5
Drive
Description
Number
Permissive to Start
Running Interlock
Collector dosing
pump
60-PU-038
Frother pump
60-PU-041
Copper sulphate
dosing pump A
60-PU-039A
Copper sulphate
dosing pump B
60-PU-039B
Copper sulphate
dosing pump C
60-PU-039C
Flocculant dosing
pump A
60-PU-043A
Flocculant dosing
pump B
60-PU-043B
LALL6005 activated
XC6052 selected for flotation feed &
cyclone pump stops
XC6052 selected for Flotation tails &
flotation tail pump stops
Flocculant dosing
pump c
60-PU-043C
Flocculant dosing
pump d
60-PU-043D
Flocculant dosing
pump e
60-PU-043E
Cyanide pump
60-PU-047
LALL6005 activated
Flotation tail pump stops
LALL6005 activated
Flotation concentrate pump stops
LALL6005 activated
Flotation concentrate pump stops
LAL6014 activated
LALL6012 activated
Cyanide tank
water addition
valve open
XV6013
LAHH6012 activated
Sodium hydroxide
pump A
60-PU-044A
LALL6034 activated
Sodium hydroxide
pump B
60-PU-044B
LALL6034 activated
SMBS pump
60-PU-067
LAL6021 activated
LALL6019 activated
LAH6019 activated
257422914.doc
XV6020
Page 39
5.6
Drive
Description
Number
Permissive to Start
Running Interlock
Trash screen
80-SC-005
Trash screen
underflow pump
83-PU-079
Flotation
concentrate
sampler
83-SA-003
83-SA-005
Detox tails
sampler
90-SA-004
90-SA-008
Loaded carbon
screen
83-SC-006
LAH8702 activated
5.7
Carbon Stripping
Drive
Drive
Description
Number
Permissive to Start
Running Interlock
87-PU-025
LAL8701 activated
Elution heater 1
87-HE-001
XV8730 closed
XV8730 opens
LAL8705 activated
Elution pump
87-PU-024
LALL8705 activated
Regeneration kiln
87-KN-001
5.8
Electrowinning
Drive
Drive
Description
Number
257422914.doc
85-VP-001
Permissive to Start
Running Interlock
LAH8504 activated
Page 40
5.9
Cyanide Detoxification
Drive
Drive
Description
Number
90-PU-022
Permissive to Start
Running Interlock
Nil
5.10
Goldroom -Smelting
Drive
Drive
Description
Number
Smelting furnace
257422914.doc
50-FU-001
Permissive to Start
Page 41
Running Interlock
PDAH5005 activated
6.1
Crushing
6.1.1
Control
Mode
Remote
6.1.2
Controlle
r
Tag
Controlle
r
Mode
SC1002
Manual
Controller Input
Nil
Controller Output
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC1015
Auto
Controller Input
LIC1015
257422914.doc
Manual
Nil
Controller Output
Page 42
6.2
6.2.1
Control
Mode
Controlle
r
Tag
Remote
WIC1033
Controller
Mode
Controller Input
Auto
6.2.2
Controller Output
LIC1044
Auto(Override)
LAH1044
WIC1033
Manual
Nil
LIC1044
Manual
(Override)
LAH1044
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
WIC1033
Auto
Controller Input
Controller Output
257422914.doc
Manual
Nil
Page 43
6.2.3
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC2009
Auto
Controller Input
Controller Output
6.2.4
LIC2009
Auto
(Override)
LAH2067
LIC2009
Manual
Nil
LIC2009
Manual
(Override)
LAH2067
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
DIC2016
Auto
Controller Input
Controller Output
To FCV-2003 positioner
257422914.doc
Manual
Nil
To FCV-2003 positioner
Page 44
6.2.5
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
FIC2097
Auto
Controller Input
Controller Output
To FCV-2092 positioner
6.2.6
Manual
Nil
To FCV-2092 positioner
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
FIC2091
Auto
Controller Input
Controller Output
To FCV-2091 positioner
257422914.doc
Manual
Nil
To FCV-2091 positioner
Page 45
6.2.7
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC2048
Auto
Controller Input
6.2.8
Controller Output
LIC2048
Auto
(Override)
LAH2067
LIC2048
Manual
Nil
LIC2048
Manual
(Override)
LAH2067
Control
Mode
Remote
257422914.doc
Controlle
r
Tag
Controlle
r
Mode
Controller Input
XV2072
Auto
LAL2048
XV2072
Manual
Nil
Page 46
Controller Output
6.2.9
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC2061
Auto
Controller Input
Controller Output
Centrifugal concentrator
Spinner No 1
Spinner No 2
Spinner No 3
Spinner No 4
Controlle
r
Tag
Controlle
r
Mode
KC2002
Auto
Controller Input
Controller Output
Timer expires
XV2001 open for set time
XV2001 to close
XV2002 open for set time
XV2002 to close
KC2002
Manual
XV2001 to close
XV2002 open for set time
XV2002 to close
257422914.doc
Page 47
6.3
Flotation
6.3.1
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
DIC3012
Auto
Controller Input
DIC3012
6.3.2
Manual
Nil
Controller Output
257422914.doc
Page 48
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
FIC3001
Auto 1
Controller Input
Controller Output
To FCV-3011 positioner
FY3012 inputs:
Process variable from WIC3012
Process variable from DIC3012
Set-point from HX3012
Solids SG (t/m) (Supervisor
level access only)
6.3.3
FIC3001
Auto 2
To FCV-3011 positioner
FIC3001
Manual
Nil
To FCV-3011 positioner
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC3020
Auto
Controller Input
LIC3020
257422914.doc
Manual
Nil
Controller Output
Page 49
6.3.4
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
DIC3035
Auto
Controller Input
DIC3035
6.3.5
Manual
Nil
Controller Output
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
DIC4010
Auto
Controller Input
DIC4010
257422914.doc
Manual
Nil
Controller Output
Page 50
6.3.6
Control
Mode
Remote
Controlle
r
Tag
Controller
Mode
DIC4038
Auto
Controller Input
Select DIC4038 A or B
Controller Output
To FCV-4039 positioner
6.3.7
Manual
Nil
To FCV-4039 positioner
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC4023
Auto
Controller Input
257422914.doc
Controller Output
LIC4023
Auto
(Override)
LAL4023 activated
LIC4023
Manual
Nil
LIC4023
Manual
(Override)
LAL4023 activated
Page 51
6.3.8
Control
Mode
Local
Controlle
r
Tag
Controlle
r
Mode
FAL4017
Auto
Controller Input
FAL4017 activated
Controller Output
6.3.9
Seepage Pump
Objective:
Seepage pump is started if sump is full and stopped if sump is empty.
Modes of Operation:
a) Local Auto
Control
Mode
Controlle
r
Tag
Controlle
r
Mode
Controller Input
Controller Output
Local
LSL4018
Auto
LSL018 activated
Local
LSL4019
Auto
LSL019 activated
Controlle
r
Tag
Controlle
r
Mode
Local
LSL4046
Auto
LSL046 activated
Local
LSL4047
Auto
LSL047 activated
257422914.doc
Controller Input
Page 52
Controller Output
6.4
6.4.1
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
SIC6002
Auto
Controller Input
Controller Output
257422914.doc
Manual
Nil
Page 53
6.4.2
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
SIC6004
Auto
Controller Input
Controller Output
6.4.3
Manual
Nil
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
SIC6045
Auto
Controller Input
Controller Output
257422914.doc
Manual
Nil
6.4.4
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
SIC6040
Auto
Controller Input
Controller Output
257422914.doc
Manual
Nil
Page 55
6.4.5
Control
Mode
Remote
Controller
Tag
LIC3044
Controlle
r
Mode
Auto
Controller Input
LIC3044
6.4.6
Manual
Nil
Controller Output
Control
Mode
Remote
Controller
Tag
LIC4013
Controlle
r
Mode
Auto
Controller Input
LIC4013
257422914.doc
Manual
Nil
Controller Output
Page 56
6.4.7
Control
Mode
Remote
Controller
Tag
LIC3039
Controlle
r
Mode
Auto
Controller Input
LIC3039
6.4.8
Manual
Nil
Controller Output
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
SIC9018
Auto
Controller Input
Controller Output
257422914.doc
Manual
Nil
6.4.9
Lime Make-Up
Objective:
Lime and water addition to the lime tank controlled to maintain the lime slurry level in the
tank. The relative feedrate of lime and make up water are set to produce the required
lime slurry density.
Modes of Operation:
a) Remote Auto
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LI6017
Auto
Controller Input
LAL6017 active
Controller Output
LAH6017 active
Controlle
r
Tag
Controlle
r
Mode
FAL4017
Auto
Controller Input
FAL7001 activated
Controller Output
257422914.doc
Page 58
6.5
6.5.1
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
AIC8301
Auto
Controller Input
Controller Output
6.5.2
Manual
Nil
257422914.doc
Page 59
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
FIC8303
Auto 1
Controller Input
Controller Output
To FCV-8303 positioner
Auto 1
To FCV-8303 positioner
FIC8303
Manual
Nil
To FCV-8303 positioner
6.6
Carbon Stripping
6.6.1
Elution Temperature
Objective:
Temperature of the elution column feed solution is controlled by a temperature element
on the heater outlet linked to the heater burner control.
Modes of Operation:
a) Remote Auto - the operator selects an elution temperature set-point and the elution
temperature controller adjusts the heater burner output.
b) Remote Manual - the operator selects heater burner output through the elution
temperature controller.
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
TIC8708
Auto
Controller Input
TIC8708
Manual
Nil
Controller Output
6.7
Electrowinning
6.7.1
Control
Mode
Remote
257422914.doc
Controlle
r
Tag
Controlle
r
Mode
LAH8503
Auto
Controller Input
LAH8503 activated
Page 60
Controller Output
XV6053 closed
6.8
Cyanide Detoxification
6.8.1
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
LIC9007
Auto
Controller Input
LIC9007
6.8.2
Manual
Nil
Controller Output
Control
Mode
Remote
Controlle
r
Tag
Controlle
r
Mode
AIC9001
Auto
Controller Input
Controller Output
257422914.doc
Manual
Nil
Page 61
Selected automated sequences and manually controlled procedures for start-up and shutdown
of the plant are listed below. Note that for an automated sequence or manually controlled
procedure to progress permissives and interlocks as detailed above must be satisfied.
Sequences and procedures assume normally continuously running equipment e.g. thickeners,
the conditioning tank, Detox and CIL tank agitators are left operating.
Start or stop of a pump with actuated suction and delivery valves automatically opens or closes
the valves after the pump running indication is received by the PLC.
Flotation cell mechanisms are started and stopped locally at the field stop/start station located
adjacent to the cell.
The compressors are only able to be started and stopped locally at the field stop/start station
and are under the control of the vendor controller package, which senses load and starts the
second unit or puts the compressor on idle, as required.
7.1
Crushing
Start-up and shut-down of the crushing section is split into two PLC controlled group sequences.
One covers services such as dust collection equipment and the other covers the crushing
equipment (conveyors, screens and feeders).
7.1.1
This PLC controlled group sequence covers start up of Crusher plant services equipment. The
sequence will be initiated from the SCADA screen by the operator clicking on the Crusher Plant
Services sequence start button.
Drive Description
Drive Number
10-FA-003
10-FA-007
10-VV-001
10-BH-001
10-FA-017
10-FE-010
10-VV-002
10-BH-001
10-FA-018
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Page 62
Sequence
Step Delay
(sec)
n/a
Comment
Started simultaneously
7.1.2
This PLC controlled group sequence covers start up of crushing equipment feeding the fine ore
bin. The sequence will be initiated from the SCADA screen by the operator clicking on the
Crusher Plant sequence start button.
Drive Description
Drive Number
Sequence
Step Delay
(sec)
Comment
10-CV-002
n/a
10-CV-003
Secondary screen
10-SC-001
Crusher magnet
10-MA-001
10-CV-001
10-CR-002
10-CR-001
10-FE-002
10-FE-001
7.1.3
The PLC controlled function group shut-down sequence will be initiated from the SCADA screen
by the operator clicking on the Crusher Plant sequence stop button.
Drive Description
Drive Number
Sequence
Step Delay
(sec)
10-FE-001
n/a
10-FE-002
Variable
10-CV-001
60
Secondary screen
10-SC-001
40
10-CV-002
60
10-CV-003
Crusher magnet
10-MA-001
Comment
n/a
The primary jaw crusher and secondary cone crusher must be stopped individually when the
area operator confirms they are clear.
257422914.doc
Page 63
7.1.4
The PLC controlled function group shut-down sequence will be initiated from the SCADA screen
by the operator clicking on the Crusher Plant Services sequence stop button.
Drive Description
Drive Number
10-FA-017
10-BH-001
10-VV-001
10-FA-003
10-FA-018
10-BH-001
10-VV-002
10-FE-010
10-FA-007
Sequence
Step Delay
(sec)
n/a
Comment
Stopped simultaneously
The Crusher Plant Services shut-down sequence should not be used if the Grinding and Gravity
circuit is operating as the HPGR & secondary screen area fan and HPGR & secondary screen
dust collector equipment is required to operate while the HPGR is running. The Crusher dust
collection equipment may be stopped individually by the control room operator in Manual mode
7.2
Start-up and shut-down of the Grinding and Gravity section is split into two PLC controlled group
sequences. One covers the gravity gold recovery equipment and the other covers the mill circuit
feed and HPGR equipment.
7.2.1
The following services equipment items are started individually at the relevant point, during the
Grinding and Gravity start up procedures:
Process water pump (70-PU-035)
Raw water pump (70-PU-033)
Gland water pump (70-PU-032)
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Page 64
7.2.2
This PLC controlled group sequence covers start up of equipment in the Gravity circuit. The
sequence will be initiated from the SCADA screen by the operator clicking on the Gravity
sequence start button.
Drive Description
Drive Number
20-PU-065
Sequence
Step Delay
(sec)
5
Comment
Select duty/standby
Ensure suction and delivery
pipes correctly connected in
field.
XV2066 closed
20-PU-080
Spinner no 1
20-GC-005A
Simultaneous start
Spinner no 2
20-GC-005B
Spinner no 3
20-GC-006A
Spinner no 4
20-GC-006B
Primary jig no 1
20-GC-001
Primary jig no 2
20-GC-002
Primary jig no 3
20-GC-003
Gravity screen
20-SC-003
XV2017
Simultaneous open
XV2018
XV2019
Mill pump
20-PU-003
Select duty/standby
Cyclone pump
20-PU-004
Select duty/standby
Centrifugal concentrator no 1
20-GC-004
257422914.doc
Page 65
7.2.3
This PLC controlled group sequence covers start up of equipment in the HPGR circuit. The
sequence will be initiated from the SCADA screen by the operator clicking on the HPGR
sequence start button.
Drive Description
Drive Number
Sequence
Step Delay
(sec)
Comment
XV2093
n/a
Ball mill
20-ML-001
20-SC-002
10-CV-006
10-CV-005
HPGR
10-CR-003
n/a
10-CV-004
10
10-FE-003
60-PU-043A/B
30
Select duty/standby
Feeds float feed thickener
7.2.4
The procedure covers shut-down of the HPGR section. The PLC controlled function group shutdown sequence will be initiated from the SCADA screen by the operator clicking on the HPGR
sequence stop button.
Drive Description
Drive Number
Sequence
Step Delay
(sec)
Comment
10-FE-003
n/a
10-CV-004
100
HPGR
10-CR-003
100
10-CV-005
100
10-CV-006
100
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Page 66
7.2.5
Drive Number
Sequence
Step Delay
(sec)
Comment
XV2001 & 2
n/a
20-SC-002
15
XV2017
Simultaneous closure
XV2018
XV2019
Mill pump
20-PU-003
Primary jig no 1
20-GC-001
120
Primary jig no 2
20-GC-002
Primary jig no 3
20-GC-003
Spinner no 1
20-GC-005A
Spinner no 2
20-GC-005B
Spinner no 3
20-GC-006A
Spinner no 4
20-GC-006B
20-PU-080
Gravity screen
20-SC-003
XV2046
30
Delay
to
underpan
Centrifugal concentrator no 1
20-GC-004
30
Ball mill
20-ML-001
Refer
Outokumpu
design
document 7330-DD01 Rev0
XV2093
n/a
60-PU-043A/B
Cyclone pump
20-PU-004
7.2.6
20
Simultaneous shut-down
empty
screen
The following equipment items are stopped individually at the relevant point, during the shutdown procedure, if a prolonged shut down (longer than 15 minutes) is anticipated and the
flotation and CIL AND Detox section are not operating:
Process water pump (70-PU-035)
Raw water pump (70-PU-033)
Gland water pump (70-PU-032)
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Page 67
7.3
Flotation
7.3.1
The flotation blower (70-CP-002) is started individually at the relevant point, during the Flotation
start up procedure:
If the grinding and gravity circuit is not already running, the following services equipment items
are also started individually at the relevant point:
Process water pump (70-PU-035)
Raw water pump (70-PU-033)
Gland water pump (70-PU-032)
7.3.2
This procedure covers start up of services for the Flotation section. The procedure will be
manually controlled, i.e. control room operator will start each item individually in Manual mode
in conjunction with the field operator, who will confirm the selection of duty pumps and open
manual (e.g. spray water) valves as required.
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Page 68
Drive Description
Drive Number
Comment
n/a
Flotation cell no 1
30-FC-001
Flotation cell no 2
30-FC-002
Flotation cell no 3
30-FC-003
Flotation cell no 4
30-FC-004
Flotation cell no 5
30-FC-005
30-PU-008
Select duty/standby
30-PU-006
Select duty/standby
Start in recirculation mode
(XV3013 open & XV3014) then
reset valves if underflow density
acceptable
May have been left running on
circuit shutdown in recirculation
mode (i.e. XV3013 open &
XV3014 closed)
Frother pump
60-PU-041
Select duty/standby
Start in manual mode minimum output
60-PU-038
Select duty/standby
Start in manual mode minimum output
60-PU-039A/B
Select duty/standby
Start in manual mode minimum output
40-PU-013
Select duty/standby
Start in recirculation mode
(XV4011 open & XV4013) then
reset valves if underflow density
acceptable
May have been left running on
circuit shutdown in recirculation
mode (i.e. XV4011 open &
XV4013 closed)
FCV4039
Sand pump 1
40-PU-072
Select duty/standby
Sand pump 2
40-PU-073
Select duty/standby
30-PU-007
Select duty/standby
50-GC-009
60-PU-043B/E
Select duty/standby
Feeds float tail thickener
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Page 69
Drive Description
Flocculant dosing pump C/D
Drive Number
60-PU-043C/D
Comment
Select duty/standby
Feeds Concentrate thickener
7.3.3
The procedure covers shut-down of the Flotation section. The procedure will be manually
controlled, i.e. control room operator will stop each item individually in Manual mode in
conjunction with the field operator, who will confirm the draining of duty pumps and close manual
(e.g. spray water) valves as required.
Drive Description
257422914.doc
Drive Number
Comment
30-PU-006
Flotation cell no 1
30-FC-001
Flotation cell no 2
30-FC-002
Flotation cell no 3
30-FC-003
Flotation cell no 4
30-FC-004
Flotation cell no 5
30-FC-005
60-PU-043BE
60-PU-043C/D
30-PU-007
50-GC-009
40-PU-013
Sand pump 2
40-PU-073
Sand pump 1
40-PU-072
n/a
30-PU-008
n/a
Page 70
7.3.4
The flotation blower (70-CP-002) is stopped after the flotation cells are stopped, if a prolonged
shut down (longer than 15 minutes) is anticipated.
If the grinding and gravity circuit or CIL circuits are not running, the following services equipment
items are also stopped individually during the shut-down procedure:
Process water pump (70-PU-035)
Raw water pump (70-PU-033)
Gland water pump (70-PU-032)
7.4
7.4.1
The following services equipment items are started individually at the relevant point, during the
CIL and Detox start up procedure:
CIL LP blower (70-CP-003)
CIL water pump (70-PU-028)
Cyanide pump (60-PU-047)
If the flotation circuit is not already running, the following services equipment items are also
started individually at the relevant point:
Raw water pump (70-PU-033)
Gland water pump (70-PU-032)
The lime pump (60-PU-066) is normally left operating to avoid choking the ringmain pipeline.
The CIL lime addition control loop is left in Remote Manual mode and the operator selects the
open position time (seconds) of the pulsing CIL lime addition valve as zero. On start up, the
control loop is set to Remote Auto.
7.4.2
This procedure covers start up of the CIL section. The sequence will be manually controlled, i.e.
control room operator will start each item individually in Manual mode in conjunction with the
field operator, who will confirm the selection of duty pumps and open manual spray water valves
as required.
257422914.doc
Page 71
Drive Description
Drive Number
Comment
90-PU-022
90-SC-014
83-PU-079
Select duty/standby
Trash screen
80-SC-005
SMBS pump
60-PU-067
Select duty/standby
Start in manual mode minimum output
60-PU-039B/C
Select duty/standby
Start in manual mode minimum output
7.4.3
30-PU-010
Select duty/standby
ILR
n/a
The procedure covers shut-down of the CIL section. The procedure will be manually controlled,
i.e. control room operator will stop each item individually in Manual mode in conjunction with
the field operator, who will confirm the draining of duty pumps and close manual spray water
valves as required.
Drive Description
Flotation
concentrate
underflow pump
257422914.doc
Drive Number
thickener
Comment
30-PU-010
ILR
n/a
Trash screen
80-SC-005
83-PU-079
90-SC-014
90-PU-022
SMBS pump
60-PU-067
60-PU-039B/C
Page 72
7.4.4
The following equipment items are stopped individually at the relevant point, during the shutdown procedure, if a prolonged shut down (longer than 15 minutes) is anticipated:
CIL LP blower (70-CP-003)
CIL water pump (70-PU-028)
Cyanide pump (60-PU-047)
The lime pump (60-PU-066) is normally left operating to avoid choking the ringmain pipeline.
The CIL lime addition control loop is set to Remote Manual mode and the operator selects the
open position time (seconds) of the pulsing CIL lime addition valve as zero.
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Page 73
7.5
The acid wash system is not automated and operator monitoring and intervention is required at
various times during the acid wash sequence.
The extent of calcium scaling of the carbon will dictate the required acid strength and acid wash
period. It may be necessary to increase acid wash solution acid strength or extend the acid
wash time if the carbon is badly fouled. If it is required to complete as many elutions as fast as
possible to meet gold production targets, the acid wash time may be reduced or the acid wash
step maybe omitted completely on occasion.
Once a complete batch of carbon is ready in the acid wash column, the operator can perform the
acid wash procedure.
7.5.1
Acid Wash
Open acid wash rinse discharge valve and close acid wash recycle valve.
Open acid wash rinse water valve and check for rinsings flow at the CIL tails pump hopper.
Allow to rinse for the required period and close acid wash rinse water valve.
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7.5.4
Close acid wash column solution inlet valve and acid wash strainer inlet valves.
Open elution column carbon filling valve
Open selected elution column strainer inlet and outlet valves.
Ensure elution column carbon outlet valve is closed.
Close eluate to electrowinning cell valve at the inlet to the heat exchanger.
Open transfer water recycle valve at the inlet to the heat exchanger.
Open transfer water valves to acid wash column and carbon outlet...
Start transfer water pump.
Open acid wash column carbon outlet valve.
Allow carbon to transfer for the required period (i.e. until all carbon is transferred).
Close acid wash column carbon outlet valve.
Close transfer water valves to acid wash column and carbon outlet.
Stop transfer water pump.
Close elution column carbon filling valve.
Close transfer water recycle valve at the inlet to the heat exchanger.
Open eluate to electrowinning cell valve at the inlet to the heat exchanger.
Open acid wash column floor drain valve and allow transfer water in the column to drain to the
spillage sump.
7.5.5
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7.5.6
Elution Procedures
The elution system is not automated and operator monitoring and intervention is required at
various times during the elution sequence.
Once a complete batch of carbon is ready in the elution column, the operator can perform the
elution procedure.
7.6.1
Elution Procedure
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Monitor column pressure using the column pressure gauge and adjust pressure regulation valve
at the outlet of the recovery heat exchanger if required.
Approximately 1-2 hours prior to the end of the allotted elution time, switch off the elution heater
to allow column to cool.
Stop elution pump.
7.6.2
Check elution tank level and reagent concentrations. Proceed through the following steps as
required.
Open elution sodium hydroxide addition valve.
Ensure acid wash sodium hydroxide addition valve is closed.
Start sodium hydroxide pump and run for the required period.
Stop sodium hydroxide pump.
Recheck eluate sodium hydroxide concentration.
Repeat if required.
Calculate required volume of cyanide solution to be added.
Record elution cyanide flowmeter totaliser reading.
Open elution cyanide valve and monitor elution cyanide flowmeter totaliser reading until the
required volume of cyanide solution has been added.
Close elution cyanide valve.
Recheck eluate cyanide concentration.
Repeat if required.
If required, re-open elution tank raw water addition valve and fill the tank.
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7.6.4
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APPENDIX 1
SCHEDULE OF ALARMS
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Description
Alarm
Category
CV-002 secondary crusher bin feed conveyor belt drift switch A (head lhs)
CV-002 secondary crusher bin feed conveyor belt drift switch B (head rhs)
CV-002 secondary crusher bin feed conveyor belt drift switch C (tail lhs)
CV-002 secondary crusher bin feed conveyor belt drift switch D (tail rhs)
CV-002 secondary crusher bin feed conveyor pull wire switch A (walkway side)
CV-002 secondary crusher bin feed conveyor pull wire switch B (non-walkway side)
CV-003 fine ore bin feed conveyor belt drift switch A (head lhs)
CV-003 fine ore bin feed conveyor belt drift switch B (head lhs)
CV-003 fine ore bin feed conveyor belt drift switch B (head rhs)
CV-003 fine ore bin feed conveyor belt drift switch B (tail rhs)
CV-003 fine ore bin feed conveyor pull wire switch A (walkway side)
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Description
Alarm
Category
CV-003 fine ore bin feed conveyor pull wire switch B (non-walkway side)
CV-006 mill screen oversize conveyor belt drift switch A (head lhs)
CV-006 mill screen oversize conveyor belt drift switch B (head rhs)
CV-006 mill screen oversize conveyor belt drift switch C (tail lhs)
CV-006 mill screen oversize conveyor belt drift switch D (tail rhs)
CV-006 mill screen oversize conveyor pull wire switch (non-walkway side)
CV-006 mill screen oversize conveyor pull wire switch (walkway side)
FE-003 fine ore bin belt feeder belt drift switch A (head lhs)
FE-003 fine ore bin belt feeder belt drift switch B (head rhs)
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Description
Alarm
Category
FE-003 fine ore bin belt feeder belt drift switch C (tail lhs)
FE-003 fine ore bin belt feeder belt drift switch D (tail rhs)
FE-003 fine ore bin belt feeder pull wire switch A (lhs)
FE-003 fine ore bin belt feeder pull wire switch B (rhs)
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Description
Alarm
Category
PU-006A float feed thickener underflow pump A gland water low flow
PU-006B float feed thickener underflow pump B gland water low flow
PU-013A float tails thickener underflow pump A gland water low flow
PU-013B float tails thickener underflow pump B gland water low flow
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Description
Alarm
Category
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Description
Alarm
Category
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APPENDICES
APPENDIX 2
PIPING & INSTRUMENTATION DIAGRAMS
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APPENDICES
Number
Revision
Source
1475-P-051
Ausenco
HPGR
1475-P-052
Ausenco
1475-P-053
Ausenco
1475-P-054
Ausenco
GRINDING
1475-P-055
Ausenco
1475-P-056
Ausenco
FLOTATION
1475-P-057
Ausenco
CONCENTRATE THICKENER
1475-P-058
Ausenco
1475-P-059
Ausenco
1475-P-060
Ausenco
1475-P-061
Ausenco
GOLDROOM SMELTING
1475-P-062
Ausenco
1475-P-063
Ausenco
1475-P-064
Ausenco
1475-P-065
Ausenco
1475-P-066
Ausenco
1475-P-067
Ausenco
1475-P-068
Ausenco
SERVICES - AIR
1475-P-069
Ausenco
1475-P-070
Ausenco
1475-P-071
Ausenco
1475-P-072
Ausenco
ACID WASH
1475-P-073
Ausenco
ELUTION
1475-P-074
Ausenco
CARBON REGENERATION
1475-P-075
Ausenco
ELECTROWINNING
1475-P-076
Ausenco
1475-P-077
Ausenco
1475-P-078
Ausenco
1475-P-079
Ausenco
1475-P-080
Ausenco
1475-P-081
Ausenco
1475-P-082
Ausenco
1475-P-083
Ausenco
1475-P-084
Ausenco
1475-P-085
Ausenco
1475-P-086
Ausenco
1475-P-087
Ausenco
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