DESIGN CONSIDERATIONS

FOR

MERRILL-CROWE PLANTS

R , L. Atwood

R. H. Atwood

Crater Exploration
Salt Lake City, Utah

For ~ ~ e s e n t a t i oat
n the SME-AIME Fall Meeting
Albuquerque, New Mexico - October 16-18, 1985

Permission is hereby given to publish with appropriate acknowDedgrnen9s,

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must be obtained from the Executive Director of the Society of Mining Engineers
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Design Considerations f o r Mrrill-Crowe P l a n t s
I. Abstract
This paper discusses t h e X e t a l l u r g i c a l and
.Chnufacturing i n ~ u t t o ~ P k r r i l l - C r a ~pel a n t s .
Toplcs t r e a t e d a r e pregnant s o l u t i o n chemistry,
c l a r i f i c a t i o n , degassing, z i n c a d d i t i o n , product
f i l t r a t i o n , accounting, and c o s t s .
11. Introduction
The removal of metal values f r m cyanide
s o l u t i o n s , f o r t u n a t e l y , can be done i n s e v e r a l
ways. The o l d e s t p r a c t i c e d method i s , cerent-
a t i o n with z i n c , o r Merrill-Crowe.
The o r i g i n a l p a t e n t f o r recovery of gold
and s i l v e r f r m cyanide solutions described
p r e c i p i t a t i o n with z l n c <us-t. %st e a r l y prac-
t i t i o n e r s , however, used granules of z i n c i n a
successful a t t e r p t to avold p a y m n t of p a t e n t
royalties.
The e a r l y p l a n t s c l a r i f i e d the s o l u t i o n e l e v a t i o n s :iould r e q u i r e higher vacuums.
using sand f i l t e r s . The c l a r i f i e d l i y c o r was
then passed through z i n c boxes w h c h contained
s e v e r a l chambers designed t o f o r c e t h e solu-
t i o n s t o p a s s through t h e granules of zlnc.
Plant practice cpickly d m n s t r a t e d t h a t
if t h e s o l u t i o n s w e r e not " p r i s t i n e " clear two
problems developed. The rate of precipitation
kvuld d e c l i n e and hence t h e recovery would be
reduced. l s o t h e z i n c boxes would a c t as
f i l t e r s , t r a p t h e suspended p a r t i c l e s , and
d i l u t e t h e grade of p r e c i p i t a t e .
I t was also learned t h a t saw sands in t h e
filters tended t o p m t e b e t t e r p r e c i p i t a t i o n
and lower zinc consumption. Sands with con-
t a i n e d p y r i t e and marcaslte produced these
effects. W e now h o w t h e observed phenorenon
ms caused by t h e r m v a l o f oxygen and a cor-
r e s p n d i n g s h i f t i n eH which is necessary f o r
precipitation. Also oxygen is required t o
l e a c h z i n c and t h e r e m v a l o f oxygen from solu-
t i o n before t h e a d b t i o n of z i n c decreased t h i s
undesired and e x p i v e s i d e reaction.
Early i n t h e twentieth century t h e respc-
t i v e works of Messrs. Yerrill and Crcxve con-
cerning t h e k i n e t i c s of s u r f a c e a r e a o r t h e u s e
of zinc d u s t and t h e advantages of oxygen re-
m v a l by vacuum degzssing Lkcaw accepted.
These ti- g e n t l m n joined f o r c e s and o n a d
t h e X e r r l l l - C r m e company t h a t produced e f f i c l -
e n t p l a n t s used the world over. The essentials
of Lkeir 6esrq-i are still us& .J.y. They are: problem a r e legion! I n mil pac!ucje u n i t s t h e
a ) CLarifying f i l t e r s ,
b) Vacuum degassing,
C ) J d d i t i o n o f z i n c dssr;,
d ) F i l t r a t i o n of t h e product.
Figure I is a flow s h e e t f o r a 2.5~10-"
n';s (40 gpx) s k i d m u t e d p l a n t . .Ui f o u r
a r e a s o f t h e s y s t m a r e shown.
III. C l a r i f y i n g F i l t e r s
Today t h e c l a r i f y i n g f i l t r a t i o n is done
with every k n d of f i l t e r i m g i n a b l e . W s t of
t h e s e f i l t e r s a r e preccated with d i a t o m c e o u s
e a r t h , DE, t o produce extremely clear solu-
tions. The design c r i t e r i o n of t h e s e f i l t e r
~ i a r ywitih t u r b i d i t y of t h e leach s o l u t i o n s . A s
a r u l e of thumb, one should have a t least
2.2x103 m3/s (1.5 f o o t squared Fer c g n ) of
pregnant feed. X o m l l y there a r e bna p r e f l l -
ters arranged such t h a t production does n o t
s t o p during c l e a n up and precoating of t h e p r e
filters .
The s o l i d s rerrsved f r m t h e s e f i l t e r s sre
of no value and can be discarded. ? ? o m 1
p r a c t i c e is t o discharge them t o tails.
C l a i r i f i c a t i o n f i l t e r s can k c m e plugged
by excessive a m u n t s of slimes o r t h e a d d i t i o n
of t o o much f l c c u l a n t .
Vammn degassing is done i n a p c k e d tow-
er. The c l a r i f i e d pregnant s o l u t i o n is i n t r o -
duced i n t o t h e t o p of t h e tower and p r c o l a w
down through t h e packing. Personal experience
has shown t h a t 6.75x10J Pa (20 inches Hg)
gauge v a c m is s u f f i c i e n t f o r e f f e c t i v e pre-
c i p i t a t i o n a t 1500 n (5000 f e e t 1 KSL. Iawer
t h i s thresh-old vacuua is achieved, Increases
i n vacuum a r e only m a r g i m l l y helpful if t h e
tower is l a r g e enoucjh. khny engineers a r e
designing t h e s e towers a t 2 . 4 ~ 1 0 ' ~n3/s/n2 (35
gpx per f t z ) of t a x e r a r e a . A f i w e of
1 . 4 ~ 1 0 - m3/s/rn2
~ (20 g p p r f t 2 ) w i l l produce
a much better degassed prcduct a t equivalent
vacum. The c o s t of t h i s a d d i t i o r u l tower
a r e a is mall, e s p e c i a l l y when ccmpared t o t h e
n e c e s s a r i l y of n n i n t a i n i n g higher vacuums o r
s u f f e r i n g v a l u e s i n t h e barrens. The v o l m
of tower packing is a p r p l a c e t o t r y to
minimize c o s t s .
Discbarge of t h e degassed solutior, solu-
t i o n is through t h e bottom of t h e tower. I n
l a r g e p l a n t s t h e tower is place3 at an eleva-
t l o n szch t h a t t h e s o l u t i o n can e x i t t h e tower
through a b a r o n e t r i c leg. I n the mller
packacjed u n i t s t h e s o l u t i o n m u s t be pmpzd
o u t , which produces a l a r g e n e t s u c t i o n head
on t h e p r d u c t p a p . This can i n t e n s i f y t h e
tendency f o r t h i s pnp t o p u l l a i r back i n t o
t h e solution.
V. Zinc Dust Addition
Zinc f e e d e r s a r e t h e n a s i s of t h e
Ekrrill-Crowe o p r a t o r s . The a n g l e o r r e p s e of
z i n c d u s t is i n excess of 00 d g r e s , it w i l l
" r a t hole" and bridge. The c u r e s f o r t h i s
f e e d e r s a r e b p e r e d bottom& koxes with augers
o r s p r i n g s t o advance t h e zinc LO a discharge
prt. The r z t e of discharge 1s a d j u s t e d by
varying t h e s p e d of t h e auger. T3 'keep the
zir?c flowing t h e e n t i r e f e e d e r is vrbraced
a n d / o r f i n g e r s p r i n g s a r e set t o " c l i c k " d o n g
Lie auger.
I n mll pckacjed .mits t h e z i n c 1s in-
duced i n t o t h e c l a r i f i e d , degassed s o l u t i o n m
f r o n t of t h e pq h i v i n g t h e ?roduct f i l t e r .
I n l a r g e operations t h e tendency is t o f o r c e a
z l n c 'barren s o l u t i o n s l u r r y r n t o t h e l i n e j u s t
i n f r o n t of t h e p r d x c + - f i l t e r . One s i l v e r
p l a n t f o w d t h a t adding t h e z i n c before t h e
~ u m pf i l l e d t h e prFes with s i l v e r and threw t h e
product f i l t e r pmp o u t of balance.
The rjquation f o r c e n t a t i o n is:
 thought that t h e lead s t t e s t o c e n t o u t o n t o
t h e z i n c and form h i g h i y a n o t i c a r e a s t h a t i n -
c r e a s e t h e to'al a c t i v i t y of t h e z m c &.
It is a p r e n t t h a t one r,wle o f z i n c w i l l pre- Lead must bz use2 i n very low dosages t o pre-
c i p i t a t e one m l e o f g o l d ( o r s i l v e r o r c o w r v e n t t h e l e a d from b l i n d i n g o f f t h e s u z f a c e o f
). T h e r e f o r e , one gm o f z i n c should p r e c i p i - t h e z i n c and p r e v e n t i n g p r e c i p i t a t i o n o f t h e
tate 3.02 gm o f gold o r 1.64 g m of s i l v e r o r v a l u e s . An e x c e s s o f l e a d s a l t s w i l l a l s o form
C.97 gm of copper. a Jead hydroxide g e l and b l i n d t h e f i l t e r s .
An e x a p l e z i n c adciition 1s c a l c u l a t e d to M e ~ l l u r g i c a lc o n s i d e r a t i o n s d i c t a t e that
s h w t h e r e a l i t i e s o f t h e system. t h e z i n c must be added i n a n approxir;lately
A s s m e a flow r a t e o f 6 . 3 ~ 1 0 - ~ m3!s (100 cons'ant manner. I n m l 1 systems t h i s can k e
gpn) a t 1 . 0 g o l d , 10.0 s i l v e r , and 1 0 done w i t h screw f e e d e r s and v a r i a b l e - 4
p p n c o p r . The minimum z i n c r q u r e m n t would d r i v e s . On l a r g e r s y s t e m b e l t f e e d e r s can be
b -: used.
It is imprtant to keep t h e z i n c and
100 xl X ?785 gn X 1 . 0 an Au = cover&. P r o v i s i o n must be m d e t o keep t h e
min gal l o i gm t i n ? flowlncj. The a n g l e o f r e m s e of z i n c
p i e r i s 90".
The l i t e r a t u r e shows t h a t aluninum can,
and has k e n , use2 t o p r e c i p i t a - s i l v e r . The
problems encountered a r e any calcium p r e s e n t
forms calcium aluminates. T h i s n e c e s s i t a t e s
t h e u s e o f c a u s t i c (NaOH) f o r @ cI
o n t r o l which
i n c r e a s e s t h e p s s i b i l i t y of sodium silicate
f o m t i o n which g i v e s problems i n b o t h f i l t r a -
S i m i l a r math g i v e s : t i o n and p r e c i p i t a t i o n .
Another problem w i t h a l u m i n m i s t h e
for silver a p p a r e n t emf r e v e r s a l between g o l d and s i l v e r
2.31 gm Zn/min i n cyanide solutions i s , a c c e n t m t e d causing
v e r y low g o l d r e c o v e r i e s u n l e s s l a r g e quan-
for c o w r t i t i e s o f s i l v e r a r e p r e s e n t . The e x p l a n a t i o n
3.91gmzn/min . probably l i e s i n t h e f a c t t h a t t h e f i n e mtal-
Total l i c s i l v e r i n t h e f i l t e r c ~ ! e is a c t i n g and
6.34 gn Zn/min t h e a n o t i c metal.

T h i s can be done by u s i n g the Zn e q u i v a l e n t , t?. F i l t r a t i o n o f Product

Zn(equ).
Exanple: Using t h e above d a t a
This is t h e s t o i c h i m t r i c m u n t of zinc
required t o p r e c i p i t a t e t h e t h r e e principle
metals i n s o l u t i o n . It r e q u i r e s a s l i g h t e s c e s s
t o d r i v e t h e r e a c t i o n to -letion. Exper-
i e n c e h a s shown that a s t h e p r e g n a n t s o l u t i o n
beccx-res weaker t h e mre e x c e s s z i n c must be ad-
ded. Loosely stated h v e 10C p a should re-
q u i r e less t h a n 10% above s t o i c h i m t r i c . A t 5
p n a p p r o x i m t e l y 200% o f s t o i c h i ~ t r i can6 1
p m y r-re a s much a s 1500%.
A few t h i n g s should be obvious f r m t h e
b v e calculations;
a ) C o p p r i n c y a r ~ i d esystems is e x p n s i v e ,
b ) The r i c h e r , t h e p r e g n a n t s o l u t i o n t h e
b e t t e r t h e z i n c is u t i l i z e d .
A c t i v a t i o n o f t h e z i n c w i t h l e a d salts can
be v e r y i x g n - t a n t i n some systems. It is
A word o f warniny is i n o r d e r a b o u t pro-
d u c t f i l t e r f e e d paps. These pmps m have
suherged s e a l s . There is a tendency t o t r y
t o cut c o s t s by n o t n o t p l a c i n g this
under b a r r e n s o l u t i o n . This is especially
t r u e w i t h m a l l "shoe s t r i n g " o p e r a t i o n s and
in scw mil p c k a g e d u n i t s . The problem
s u r f a c e s when t h e seals start to l e a k , and
t h e y w i l l 1-A. Because t h e s e a l s a r e a t t h e
c e n t e r o f t h e pmp?, t h e y are i n a n e g a t i v e
p r e s s u r e a r e a and a i r l e a k s i n t o t h e pmrp. A
anall a i r l e a k c a n q u i c k l y undo e v e r y t h i n g
accomplished i n t h e vacuum t o w e r .
I have s e e n an o p r a t i o n %hen ever)-thing
w a s f u n c t i o n i n g under a c c e p t a b l e limits u s i n g
a p c k a g e d u n i t t h a t d i d n o t have subrrerged
seals. m i n g c l e a n up, t h e p r e c i p i t a t e was
g r a y ( v r s . t h e normal b l a c k 1. The seal i n
t h e p r o d u c t pmp was l e a k i n g , p r o v i d i n g oxygen
to t h e system which p l a c e 6 a l l o f t h e z i n c
i n t o s o l u t i o n and l e f t n o t h i n g but t h e DE
p r e c o a t i n t h e filter.
The b a r r e n Fond was p q e d i n t o the preg-
n a n t p r d ( because t h e s o l u t i o n was p r e g n a n t
) , t h e seal replacec?, and t h e v a l u e s w e r e t h e n
precipitated.
Mst p r o d u c t f i l t e r s a r e o f t h e p l a t e and
f r m e t y p . They a r e used because o f t h e abil-
i t y t o blow t h e n d a m to remove a substan-
tial m u n t of t h e water f r o n t n e precipitzite.
%xmz p l a n t s , where f i l t e r plugging o f the pro-
d u c t f i l t e r h a s been a problem, have found sock
filters to be a c c e p t a b l e .
Pluoging o f t h e f i l t e r s c a n & caused by
many t h i n g s . The p r i n c i p l e c a u s e o f plugging
i n product f i l t e r s is t h e p r e c i p i t a t i o n of
calcium carbonate. This problem i s e a s i l y
solved by a d d i t i o n of a c a l c ~ u msequestering
agent such a s the Cyanimid Q-quest S e r i e s o r
Nalco 8830. Iron hydoxldes can a l s o be a prob-
l e m i n f o u l s o l u t i o n s . Zinc t h a t has an oxlde
coating can a l s o becorre r e f r a c t o r y and prevent
p r e c i p i t a t i o n along with plugging t h e f i l t e r .
Systems which use s o d i m hydroxide, r a t h e r
than l k t o prevent Calcium plugging of the
product f i l t e r , my be generating sodium sil-
i c a t e which w i l l very e f f e c t i v e l y b l i n d off t h e
clarifying f i l t e r s . It i s a l s o t r u e t h a t mst
f l o c u l a n t s work b e t t e r i n lime systems.
The s o l u t i o n to i r o n f o u l i n g is to provide
a bleed from t h e m i l l s o l u t i o n s . This is a l m s t pregnants t h e recovery i s only 83% and 1 ppn
autorrratic with a g i t a t e d systems. I n heap leach- heads t h e recovery drops t o only 50%.
es where w a t e r i s g e n e r a l l y obtained a t a prem-
ium and t h e m r g l n s t h l n it i s mentally d i f f i -
c u l t to discharge solution. However if a bleed
is not provided t h e s o l u t i o n w i l l start to t u r n
a l i g h t b r m n . The next observation is f r o t h
o r foam. This w i l l be seen f l o a t i n g on t h e
p o d s but w i l l g i v e problems i n t h e degassing
tower from which it w i l l be @ l e d into the t r e a t e d . Carbon adsorbtion c o s t s tend t o be
vacuum receiver. This d e s a good case f o r a
r e c e i v e r tank vs. l e t t i n g a problem m n t h e
vacuum plnp.
The grade and t h e m u n t of values i n t h e
product f i l t e r cake is a function of s o l u t i o n
p a r i t y and s t r e n g t h . S i l v e r values of p l u s 80%
and 550 kg/m3 (500 oz per f t 3 ) a r e e a s i l y ob-
tained with s t r o n g c l e a n s o l u t i o n s . Sowever,
low pregnant s t r e n g t h o r t h e presence of copper, s i l v e r and 6 . 2 5 ~ 1 0 - ~
o r s o l i d s can quickly reduce both of t h e above
values.
VII. Clean Cp and .&lting
It is general p r a c t i c e t o wash t h e p r e c i p
itate with s u l f u r i c a c i d t o r m v e excess zinc,
copFer, lead, ,... This wash should not be
done w i t h hydrcchloric a c i d . Despite t h e t h e
l a g s o l u b i l i t y of s i l v e r c h l o r i d e , l a r g e quan-
t i t i e s of s i l v e r can be t a L ~ n i n t o s o l u t i o n i n becorre inprtsnt when considering when t o quit
strong chloride e n v i r o m n t s , especially i n the
presence o f z i n c , a s AgC12-.
I t is irrqprtant t h a t t h e p r e c i p i t a t e s be
x e l l r i n s e d a f t e r t h e s u l f u r i c a c i d wash.
S u l f a t e s , a s a c i d o r salt, w i l l convert t-be
s i l v e r to s i l v e r s u l f i t e and form a mtte when
m l t i n g i n t o a Sore.
The goal i n melting i n t o dore is t o produce p r -1.
GO+% 2016 p l u s s i l v e r c o n t e n t , to redcce re-
f i n i n g charges a t t h e r e f i n i n g houses.
There is an i n t e r e s t i n g c h a i n of im-om-
a t i o n t h a t h a s b e e n passed from one p l a n t t o
anotller, to another, - - -. The flu?: chic
d e s c r i k d i n t h i s d a i s y c.hin is ill advised.
Strong o x i d i z e r s w i l l p l l s i l v e r o u t of Lhe
metal and p l a c e it i n t o t h e s l a g , where it is
n o t wanted. Also viscous s l a g s tend t o t r a p
dore s h o t when pured. I f They have not done s o
eve-y p l a n t would be w e l l advised t o c o n s u l t a
g m d t e x t on f i r e assaying, design a new f l u x
schedule t h a t w i l l rerrove t h e e i t i e s from
t h e cpld and s i l v e r . This new schedule should
be tried on a s ~ l sample, l a d j u s t e d a s mndi-
c a t e d by t h e r e s u l t s and r e t r i e d , u n t i l a c l ~ ~ n
non viscous s l a g is prcduced t h a t y i e l d s a n ac-
c e p t a b l e dore. There is no value t o k i n g tso
gooci with t h e q u a l i t y of t h e mtal. After it
is over 90 percent t h e r e f i n i n g houses q u i t
assessing p e n a l t i e s .
VIII. Advantages and Disadvantages of Pkrrill-
-Cme
The a d v a n t a ~ e sof t h e Xerrill-Crcwe ss;ystm
becore mst apparent with high s t r e n g t h solu-
t i o n s . This is b u s e t h e zinc c o ~ i o n
per values recovered i n c r e a s e s a s t h e s o l u t i o n
s t r e n g t h decreases.
Gold barrens tend t o run about 0.5 and
l e s s than 0.1 ppn s i l v e r . A t 30 ~ p ngold i n
t h e pregnant, t h e recovery is 96%. .%t 5 p
pregnants t h e reccvery drops t o 905. A t 3 p p
While t h e s e e s t i m t e d recoveries can be
improved with harder vacuums and excess zinc
t h e t r e n d towards loxer gold recovery and
higher z i n c c o n ~ i o ans t h e pregnants drop
is s i g n i f i c a n t and real.
The c o s t s t o operate a blerrill-Crowe p l a n t
a r e p r o p r t i o n a l t o t h e g a l l o n s of s o l u t i o n
p r o ~ o r t i o n a lt o t h e ounces recovered and recov-
e r y of gold can be very high. Though no hard
n&r e x i s t s tk,e r u l e of thumb is "Greater
than 5 ppn t o t a l gold p l u s s i l v e r use bkrrill--
Crowe. Less than 5 u s e carbon."
S i l v e r recoveries in Pkrrill-Crcwe r a i n
high a t low concentrations and k m psor f o r
c a r b n adsorbtion. However note t h a t a t 5 ~ p i l
m3/s (100 g p ) w i l l pro-
duce 0.55 kg/da;r (17.5 oz/day) s i l v e r .
A t S320/kg (S100_0 prr o z ) (which I hope
w e see a g a i n m n ) i s only $175 p r day which
w i l l not pay t h e labor t o operate t h e Herrill-
< m e plant.
These considerations b e c o n e - h g a - t a n t when
choosing a recovery q-stem f o r heap leaches
where t h e r e is a s i g n i f i c a n t aro3unt of values
i n t h e low grade s o l u t i o n s a s t h e heap is &ut
finishec.3 and k i n g washed out. They a l s o
processing o r recycle s o l u t i o n s t o a f r e s h e r
heap 4
I'lerrill-Crowe is a t its best with high
grade s o l u t i o n s t h a t can be generated i n aqi-
t a t e d leaching c i r c ~ i t s .
The c o s t s t o c o n s t r u c t a Y ~ r r i l l - C r o w e
p l a n t have been s t a t e d a s S16x10a/m3,fs (S1,OGO
F i w e I 1 shows budget p r i c ~ sf o r
skrd m u n t e d p l a t s as a f u n c t i c n of c a p c i t y . -
The smller packaged u n i t s a r e less e s p n s i v e
than hdicated by t h e h v e r d e . A 2 . 5 ~ 1 0 ~ ~
mJ.'s (10 g p ) mit can sell f o r ahmt $24,000
F03 S a l t h k e City, Utah.
f i l e d a s S:,IE85&3.CTR
 Flgure 1
"VALUE T R A P "
F ~ DIAGRAM
W

VACUUY s15tru

PREOHWIT
SrnLnlQl

SOLUT lOY
M.R.A INC.
OMD AND SILYER SaltLake C t y ,Uf.

c D ~ L Cs n m

F i g u r e I1 Costs f o r
Herrill-Crowe p l a n t s
a s a f u n c t i o n of
c a p a c i t y . Range i n
prices reflects
o p t i o n s such a s f i l t e
s i z e , t y p e and amount
of controlls,----.
Data from >K4, I n c .

I I ! I I I
1 2 3 4 5 6 7 a 9
gprn Feed R a t e