COntrol System

BENDIGO MINING LIMITED
BENDIGO GOLD PROJECT
PROCESS CONTROL PHILOSOPHY
Client Approval:
Date:
Document No. Rev.
1475-CP-001-E E
REV. DATE DESCRIPTION AUTHOR APPROVED
A 25-01-05 DRAFT FOR REVIEW TH

B 28-04-05 GENERAL UPDATE TH
C 31-08-05 POST HAZOP UPDATE TH
D 05-12-05 GENERAL UPDATE TH MD
E 10-02-06 GENERAL UPDATE TH IJM
257422914.doc
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TABLE OF CONTENTS
1 INTRODUCTION
2 PROCESS DESCRIPTION
3 GENERAL
3.1 Control System

3.2 Drives
3.3 Alarms
3.4 Common Functions
4 PROCESS PLANT CONTROL PHILOSOPHY
4.1 Crushing
4.2 Fine Ore Bin, HPGR, Grinding and Gravity
4.3 Flotation
4.4 Reagents and Consumables
4.5 Services
4.6 Gravity Concentrate Leaching
4.7 Flotation Concentrate Leaching
4.8 Carbon Stripping
4.9 Electrowinning
4.10 Cyanide Detoxification
5 PERMISSIVES AND INTERLOCKS
5.1 General
5.2 Crushing
5.4 Flotation
5.6 Gravity and Flotation Concentrate Leaching
5.8 Electrowinning
6 PROCESS CONTROL LOOPS
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6.1 Crushing
6.3 Flotation
6.7 Electrowinning
7 SEQUENCES AND PROCEDURES
7.1 Crushing
7.2 Grinding and Gravity
7.3 Flotation
7.4 CIL and Detox
7.5 Acid Wash Procedures
7.6 Elution Procedures
APPENDIX 1 SCHEDULE OF ALARMS
APPENDIX 2 PIPING & INSTRUMENTATION DIAGRAMS
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1 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
Processing of gold bearing ore includes the following activities:
 Crushing
 Grinding and gravity concentration
 Flotation
 Cyanidation of gravity and flotation concentrates
 Acid washing and elution of loaded carbon
 Regeneration of eluted carbon
 Detoxification of cyanidation tailings slurry
 Electrowinning and smelting of doré bullion
 Reagent mixing, storage and distribution

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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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 re-
crushed 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 doré 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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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, not-
ready 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 vendor’s 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:
 collect status information of drives, process instrumentation and packaged equipment;
 provide drive control and process interlocking; and
 perform PID control for process control loops.

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 Plant area controls and alarms, control loop set-points, trends
Supervisor As per Operator, plus alarm set-points, reset of totalisers bypass interlocks
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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COLOUR DENOTATION
YELLOW Drive Fault , Drive Isolated - LOS, Lanyard or De-
contactor operated
ORANGE Drive ready, but with unhealthy process interlocks
RED Drive and interlocks ready - stopped able to be started
GREEN Running
All controlled valves are shown in graphical format. The colour of the symbol represents the
state of the valve as follows:
COLOUR DENOTATION
RED Valve closed

GREEN Valve open
YELLOW Fault
BLUE Valve travelling
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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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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:
 Maintenance Mode = turquoise.
 Manual = pale blue.
 Auto = clear (no colour)
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:
 Drive Stopped and Ready for Start = Red
 Drive Running = Green
 Drive Faulted = Yellow
 Drive Interlock is present = Orange.
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 Bypass Interlocks in auto or manual mode

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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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
Alarms are categorised according to relative importance as follows:
1. CRITICAL = RED TEXT
These are those alarms that may cause harm to personnel or equipment damage if condition
remains unattended.
2. PROCESS = YELLOW
These are process type alarm conditions, such as equipment stopping, levels, or other field
devices that stop or have certain effect on the process plant areas and require operator
intervention.
3. EVENT= GREEN
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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 Pump Hopper Levels

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
Slurry samplers are provided at the following locations:
Sampler Sampler Type Location
Flotation feed sampler Airlift Conditioning tank
Flotation tail samplers Double Stage cross-cut Flotation cell 5 outlet
Flotation concentrate sampler Single Stage cross-cut Concentrate thickener
underflow pump delivery
CIL tail sampler Airlift CIL tank 7
Detox tail sampler Airlift Detox tank
Final CIL tail sampler Poppet valve Delivery of CIL tails pumps
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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 Spillage Sump Pumps

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 Positive Displacement Pumps

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 Gland Seal Water

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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3.4.10 General Monitoring
Selected critical equipment drives are monitored for motor current. They are:
 Primary crusher
 Secondary crusher
 HPGR
 Ball mill
 Mill pump
 Cyclone pump
 Detox tank agitator

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 PROCESS PLANT CONTROL PHILOSOPHY
4.1 Crushing
Refer to P&ID 1475-P051 Crushing.
The crushing area is generally controlled from the crusher control room. The MCR can only
monitor operations in the crushing plant up to the discharge of crushed ore intro the fine ore bin.
Equipment is generally started and stopped as part of start-up and shutdown sequences.
The rate of tipping into the ROM bin is a controlled by the visual observation of the loader driver
in communication with the crusher operator. A level element in the ROM bin provides and
indication of the bin level. At a high level, the crusher operator manually activates a switch to
illuminate a red light to advise the loader driver that he may not tip. A high level alarm is
provided and a low-low level alarm is interlocked to stop the primary jaw crusher feeder. The
low-low level interlock ensures that material cannot normally be tipped into an empty bin and
damage the feeder.
The variable speed of the primary jaw crusher feeder is set to match the primary jaw crusher
capacity as observed by the crusher operator. A level detection element is installed in the
primary jaw crusher feed chute which stops the primary jaw crusher feeder in the event of high
level.
A self-cleaning belt magnet is installed at the discharge of crusher product conveyor (CV-001) for
tramp metal removal. The magnet is started and stopped as part of the crushing sequence.
A variable speed vibrating feeder delivers ore from the secondary crusher feed bin to the
secondary cone crusher. The feeder speed is controlled by a level element in the secondary
crusher feed bin. A level element in the crusher feed cavity stops the feeder at a high level.
A high level in the secondary crusher feed bin stops the primary crusher feeder. A high-high
level in the secondary crusher feed bin stops the secondary crusher feed bin conveyor. A metal
detector is installed on the secondary crusher bin feed conveyor. If crusher magnet 1 fails to
remove tramp metal or non-magnetic metal is present, the secondary crusher metal detector
activates the secondary crusher feed bin diverter gate in the secondary crusher feed bin, forcing
material to bypass the bin by diverting back to the crusher product conveyor for a set period.
This period is long enough to ensure any metal detected bypasses the bin. If the position switch
on the secondary crusher feed bin diverter gate does not register the gate has moved to the
divert position in time, the secondary crusher bin feed conveyor trips.
The secondary cone crusher has an alarm after a certain idling time (e.g. 30 minutes). The
control room operator is directed to shut-off the crusher if no feed is available.
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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.

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 Fine Ore Bin & HPGR

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 bin’s 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.
257422914.doc Page 13
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.
257422914.doc Page 14
4.2.2 Grinding and Gravity
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 unit’s 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.
257422914.doc Page 15
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.
257422914.doc Page 16
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 Feed Thickener

Refer to P&ID 1475-P056 Flotation Feed Thickener.
Mill cyclone overflow gravitates to the flotation feed thickener feed box and is mixed with dilute
flocculant. Thickener feed slurry gravitates into the thickener feed well. Thickener overflow
reports to the process water tank and is recycled by the process water pump to the grinding
circuit. Thickener underflow slurry at a controlled density from the flotation feed thickener is
pumped to the conditioning tank. A duty and a standby underflow pump are installed. Each
flotation feed thickener underflow pump has actuated valves for isolation of suction, discharge
and gland water.
Spillage from the flotation feed thickener area is pumped back to the flotation feed thickener feed
box by the flotation feed thickener spillage pump.
4.3.2 Flotation
Refer to P&ID 1475-P057 Flotation 1.
The flotation activator, collector are added to the conditioning tank. Frothing agent is added to
the first flotation cell. The flotation reagent addition rate is ratio controlled by the integrated dry
tonnage flowrate measurement on the flotation feed thickener underflow pump delivery to the
conditioning tank. Facilities are provided for the addition of small extra quantities of collector
and frother to the feed to second and third banks of cells.
The flotation section consists of rougher cells in three banks in series of one, two and two cells
respectively. The concentrate froth launders gravitate to the flotation concentrate pump (one
duty/one standby). Concentrate is pumped to the concentrate thickener. The flotation
concentrate pumps are fixed speed. The flotation cell levels are controlled by actuated pinch
valves located in the discharge of the cell banks. Flotation cell 1, 3 and 5 levels are measured
by an ultrasonic level probe and used to adjust the position of the valve on the cell outlet.
Flotation tails from the final cell gravitate via the flotation tails primary sampler into the flotation
tail pump hopper. The flotation tail pumps (one duty/one standby) pump to either the sand
cyclone or directly to the flotation tail thickener feed box depending on whether the sand cyclone
is online or not. The primary flotation tails sample passes through the flotation tails secondary
sampler and into the flotation tail concentrator. The concentrator is installed to sample the
flotation tail slurry and detect any gravity recoverable free gold particles to identify any deficiency
in the operation of the gravity gold recovery section. Concentrator tails gravitate to the flotation
tails sampler transfer sump pump and are pumped to the flotation tails thickener feed box.
Concentrate is collected and transferred by hand to the plant laboratory.
The flotation tail pump hopper level is measured and is controlled automatically by adjusting the
flotation tail pump speed. Each pump has actuated valves for isolation of suction, discharge and
gland water.
The low-pressure airflow to the individual flotation cells is regulated by a vendor supplied flow
control valve and flow meter at each flotation cell.
257422914.doc Page 17
Spillage from the flotation bunded area is hosed to the flotation spillage pump and pumped to
the conditioning tank.
4.3.3 Concentrate Thickener

Refer to P&ID 1475-P058 Concentrate thickener.
Flotation concentrate slurry is pumped to the concentrate thickener and is mixed with dilute
flocculant in the thickener feed well. Overflow reports to the process water tank. Underflow from
the thickener is pumped by the concentrate thickener underflow pump to the trash screen. A
duty and a standby underflow pump are installed. Each underflow pump has actuated valves for
isolation of suction and discharge.
Spillage from the concentrate thickener area is pumped back to the concentrate thickener by the
flotation concentrate spillage pump.
4.3.4 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.
257422914.doc Page 18
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

Refer to P&ID 1475-P061 goldroom - Gravity Area.
Gravity concentrate from the ball mill screen gold trap is discharged into a kibble located above
the gravity concentrate screen. The contents are fed to the gravity concentrate screen. The
screen has a 4mm aperture. Screen oversize and undersize is collected in concentrate kibbles.
When the goldroom is manned, the kibble containing the screen undersize is emptied into the
oversize concentrate transfer pump tank. The kibble containing the screen oversize is emptied
onto the concentrate sorting table where the goldroom operators may remove oversize gold
nuggets by a combination of hand sorting and use of a hand held metal detector. Sorted
concentrate is swept into a kibble and charged into the oversize concentrate bin. Concentrates
are reclaimed from the bin by the oversize concentrate feeder onto the oversize concentrate
sorting belt where any remaining observable nuggets can be recovered by the goldroom
operator. The oversize concentrate feeder has a variable speed set by the goldroom operator.
The oversize concentrate sorting belt delivers into the concentrate roll crusher. Crushed
concentrate, nominally minus 1 mm, is discharged into the gold room spinner wetting box.
Dilution water is added and the wetting box discharges into the goldroom gravity spinner.
Concentrate is collected for drying and smelting and tailings gravitate to the oversize
concentrate transfer pump. The pump delivers tailings to goldroom fine screen with the gravity
concentrates from the spinners and centrifugal concentrator from the gravity concentrate tank
fed by the concentrate rotary feeder. The feeder has a variable speed set by the goldroom
operator.
257422914.doc Page 19
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

Refer to P&ID 1475-P062 Goldroom - Smelting.
Electrowinning gold sludge from the pan filter is loaded into trays and the trays lifted by hand into
the calcine oven. The oven temperature is controlled by the vendor supplied oven thermostat.
The required amount of fluxing chemicals (silica, borax, sodium nitrate, and soda ash) are
weighed on the flux balance then loaded by hand from the flux bin and mixed with the weighed
amount of calcine in the flux mixer. The mixed furnace charge is added by hand to the smelting
furnace.
Slag is poured as required prior to pouring Doré bullion. Doré is cast into bar moulds. Bars are
water quenched and then cleaned manually with needle guns at the bar cleaning table followed
by stamping and packaging and storage in the vault before shipment for refining. Slag is initially
re-melted and final slag is returned to the ball mill.
The smelting furnace is covered by the furnace hood. Smelt furnace fumes along with fumes
from the calcine oven flue and electrowinning cells are ducted to the goldroom scrubber by the
goldroom scrubber fan. The wet scrubber system uses a weak sodium hydroxide solution
circulated through the tower by the goldroom scrubber pump to remove contaminants. A bleed
stream from the scrubber is pumped to the cyanide detoxification section and scrubbed fume is
vented via the goldroom scrubber stack. The scrubber is controlled by a vendor supplied PLC
that interfaces to the plant PLC system.
The goldroom is located inside a building fitted with secured entrances, surveillance and alarm
systems. An upper operating floor is provided for the electrowinning cells, while the lower floor is
used for filtration, calcination, smelting, bullion handling, vault and office.
The goldroom is monitored by a video surveillance system incorporating sufficient CCTV
cameras located and cabled to the mine security office for recording. The cameras cover all
access doors, the calcine oven door, smelt furnace and vault door, electrowinning cells and
vacuum filter.
An alarm system is installed in the goldroom area with passive motion detection, door proximity
switches and system arming/disarming keypad transmitting to the mine security offices. The
alarm system is armed whenever the goldroom is vacated. Security checks of staff working in
the goldroom are made using handheld metal detectors.

Reagent makeup is performed by operators on day shift and the design of these systems is
based on this philosophy.
257422914.doc Page 20
4.4.1 Collector and Frother
Refer to P&ID 1475-P063 Reagents & Consumables Sheet 1 of 4.
Dithio-phosphate collector and frother are delivered in bulk-a-boxes. The handling and storage
is identical for both reagents.
Both bulk-a-boxes are connected to stand pipes. The stand pipe provides a reserve while an
empty bulk-a-box is changed. Duty and standby variable speed double diaphragm dosing
pumps connected to the stand pipes meter the reagent additions from the collector and frother
standpipes tanks to the conditioning tank and first flotation cell respectively. The pump speeds
are controlled by the flotation feed thickener underflow mass flow measurement. A low level
switch is installed in both stand pipes to indicate if the bulk-a-box is empty and alarms at the
SCADA screen if the level is low.
Spillage from the collector and frother storage area is hosed to the flotation bunded area.
4.4.2 Copper Sulphate

Copper sulphate pentahydrate (CuSO4.5H2O) is delivered in 25 kg bags and is dissolved in raw
water to produce a solution at 20% w/v for use at flotation and cyanide detoxification. Usage is a
relatively small volume so make-up and storage use the same tank. The tank is split by a
vertical plate into the main make up and storage compartment and a reserve compartment. A
level switch is installed in both sections of the tank and a low level alarms at the SCADA.
Normally copper sulphate solution is dosed from the main section of the tank. Make up of
copper sulphate is a manual operation, initiated by the operator when the tank is close to empty.
When a fresh batch of solution is being made up, the dosing pump suction manifold valve from
the main compartment of the tank is closed and the valve from the reserve compartment
opened.
The operator then opens a manual valve to add fresh water partially filling the main section of
the tank. The water valve is then closed and the copper sulphate agitator started by the
operator who can then add sufficient bags of copper sulphate using the bag breaker. On
completion of mixing, the agitator maybe stopped. The operator opens a valve on a balancing
line between the two compartments to refill the now partially empty reserve compartment. The
suction manifold valve from the main section of the tank is reopened and the suction valve from
the reserve compartment closed.
Three variable speed double-diaphragm dosing pumps are installed. Normally one pumps to the
conditioning tank and another to the detox tank, with a common standby. The copper sulphate
addition rate to flotation is ratio controlled by the integrated dry tonnage flowrate measurement
on the flotation feed thickener underflow pump delivery to the conditioning tank. Flow is
controlled by varying the speed of copper sulphate dosing pump A or the common standby
pump.
The flow rate of copper sulphate to the detox tank is controlled by varying the speed of the
copper sulphate dosing pump C or the common standby pump. The pump speed is ratio
controlled to the CIL tails volumetric flowrate measured by a magnetic flow meter on the CIL tails
line.
Spillage from the copper sulphate make up area is pumped to the detox tank by reagents
spillage pump 1.
257422914.doc Page 21
4.4.3 Flocculant
Flocculant powder is delivered in bulk by road tanker and pneumatically offloaded into the
storage vessel. Dry powder is dissolved in raw water to produce a solution at 0.2 % w/w for
subsequent dilution and use at the thickeners.
Dissolution of flocculant is a fully automatic operation, initiated by a signal from a low level
switch in the flocculant tank. The flocculant preparation plant is a vendor supplied package. The
operator is required to maintain an adequate amount of dry flocculant in the feed hopper. A low
level signal in the feed hopper alerts the operator.
The batch controller of the flocculant make-up system automatically controls the addition of
water, transfer of dry flocculant to the dispersion head, the mixing time for solution aging, and
the transfer to the flocculant tank. A single “general fault” alarm notifies the operator to check
the system.
The flocculant tank has a level switch, which initiates mixing and transfer and a level
measurement element, with a low-low level alarm to notify the operator of problems, and protect
the dosing pumps from running dry.
The operator must ensure that the hopper contains dry flocculant powder, the water supply
isolating valve is open and check that there is sufficient water pressure to the Auto Jet Wet by
observing the pressure gauge reading and ensure the power supply is on and the Duty Selector
Switch is set to "AUTO" mode. For further details, refer to the Ciba Specialty Chemicals
Operating, Maintenance & Installation Manual.
A dedicated flocculant dosing pump is provided for flocculant addition at each thickener. A
common standby is provided for the pumps delivering to the flotation feed and flotation tail
thickeners. A duty and a dedicated standby pump are provided for flocculant addition to the
concentrate thickener.
Strong flocculant solution (0.2%) is pumped into inline mixers, where process water is added to
the flocculant solution to dilute the concentration to 0.02% to ensure better dispersion in the
slurry stream. Each thickener’s flocculant pump delivers flocculant to a dedicated inline mixer.
The pumps are equipped with variable speed drives to allow the flocculant solution dosage to be
adjusted manually. Dilution is controlled by the operator. The operator adjusts the flocculant
dilution water valve and checks by inspection of rotameters, the flow of water and flocculant
respectively until the correct degree of dilution is achieved. Manual valve controlled addition
points are provided at each thickener feed pipe to ensure adequate dispersion of dilute
flocculant solution.
Flocculant spillage from the flocculant make up area is hosed to the flocculant spillage pump and
pumped to the flotation tailings thickener overflow launder.
4.4.4 Sodium Cyanide

Sodium cyanide is delivered as briquettes in bulk bags packed into boxes. Sodium cyanide
solution make-up and storage use the same tank. The tank is split by a vertical plate into the
main make up/storage compartment and a reserve compartment.
Normally sodium cyanide solution is dosed from the main section of the tank. Make up of
sodium cyanide solution is a manual operation, initiated by the operator when the tank is close to
empty. While a fresh batch of solution is made up, the dosing pump suction manifold valve from
the main compartment of the tank is closed and the valve from the reserve compartment
opened.
257422914.doc Page 22
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

Sodium hydroxide is received in bulk-a-boxes, at a solution strength of 50% w/v. 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. A low-low level
switch trips the sodium hydroxide pumps to prevent them running dry.
Two double-diaphragm dosing pumps are installed.
Sodium hydroxide pump A is a fixed speed pump and delivers to either the elution or the acid
wash tanks. The delivery valve to either tank is opened and the other valve closed manually.
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.
Sodium hydroxide pump B delivers to the ILR and goldroom scrubber via a ringmain returning to
the stand pipe. Addition of sodium hydroxide from the ringmain to the ILR and goldroom
scrubber is controlled by vendor supplied actuated valves on the respective equipment.
Sodium hydroxide spillage from the bulk-a-box laydown area is hosed into the CIL bunded area
for disposal using the CIL spillage pump. Drainage from the sodium hydroxide pipelines is piped
directly to the CIL spillage pump sump.
4.4.6 Hydrochloric Acid

257422914.doc 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
Sodium metabisulphite (SMBS) is delivered in 1000 kg bags and is dissolved in raw water to
produce a solution at 20% w/v for use at cyanide detoxification. SMBS solution make-up and
storage use the same tank. The tank is split by a vertical plate into the main make up and
storage compartment and a reserve compartment.
Normally SMBS solution is dosed from the main section of the tank. Make up of SMBS solution
is a manual operation, initiated by the operator when the tank is close to empty. While a fresh
batch of solution is made up, the dosing pump suction manifold valve from the main
compartment of the tank is closed and the valve from the reserve compartment opened.
The main section of the tank is partially filled with raw water via an actuated valve. The valve is
then closed and the SMBS agitator started by the operator who can then add a bag of SMBS
using the bag breaker. On completion of mixing, the agitator is stopped. The operator reopens
the water filling valve to fill the main compartment.
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.
The SMBS tank is equipped with a level measurement device indicating at the SCADA in both
the compartments. A high level alarm in the main compartment is interlocked to the water
addition valve. A low level in either compartment will alarm at the SCADA. A low-low level in the
main compartment or low level in the reserve compartment is interlocked to trip the SMBS pump.
A duplex strainer is installed on the suction of the SMBS pumps.
The variable speed SMBS pumps (one duty/one standby) deliver solution as required to the
detox tank. The flow rate of SMBS to the detox tank is controlled by varying the speed of the
SMBS pump. The pump speed is ratio controlled to the CIL tails volumetric flowrate measured
by a magnetic flow meter on the CIL tails pump delivery line.
Spillage from the SMBS make up area is pumped to the detox tank by reagents spillage pump 1.
Reagent hoist 1 services the SMBS make up facilities.
4.4.8 Lime
Hydrated lime is delivered by road tanker and pneumatically off-loaded into the lime silo. The
silo is equipped with a dust collector. The dust collector is cleaned by a reverse pulse of air
when a high pressure differential is detected over the bag filter.
Lime powder is slurried in the agitated lime tank and pumped via ringmain to the CIL and detox
tank by the lime pump (one duty/one standby). A diaphragm valve on the return line is used to
provide adequate pressure in the ringmain circulation line.
257422914.doc 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 Raw & Potable Water

Refer to P&ID 1475-P067 Services - Water Sheet 1.
Fresh water is delivered from the Bendigo water supply to the potable water tank via the potable
water jockey pump.
Water gravitates to the safety showers from the elevated potable water tank. In the event of a
plant power failure, the safety showers are assured a limited volume of water feeding them
under pressure. The potable water jockey pump is installed to boost the available water supply
pressure to fill the potable water tank. A thermal flow switch is installed on the pump delivery. If
a no flow situation is detected by the switch (due to the potable water tank being full and the
outlet float valve being closed) the switch stops the pump. The switch is linked to a timer and
the pump will restart after a 30-minute delay.
The potable water tank is equipped with a mechanical level indicator device.
Fresh water is delivered from the Bendigo water supply to the raw water tank. Water addition is
controlled by a float valve. The tank is equipped with a hydrostatic level measurement device
and a low level alarms at the SCADA.
The raw water pump (one duty/one standby) distributes water to reagent make-up, the ILR, acid
wash, elution and tabling in the goldroom from the raw water tank.
The gland water tank is supplied from the mine water supply (underground pumping). Water
addition is controlled by a float valve. The tank is interconnected to the raw water tank, which
acts as a back-up water supply and is equipped with a level measurement element.
A low level in the raw and gland water tanks alarms at the SCADA and trips the HPGR feed
conveyor.
Gland water is provided as gland seal water to several pumps. Two gland water pumps
(duty/standby) are provided, drawing from the gland water tank.
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

Refer to P&ID 1475-P068 Services - Water Sheet 2.
257422914.doc Page 25
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
Refer to P&ID 1475-P069 Services - Air.
Duty and standby low-pressure air flotation blowers supply the flotation cells. A local pressure
gauge indicator and a transducer indicating at the SCADA are fitted on the low-pressure air
main.
Compressor 1 and 2 operate in lead/lag mode and provide high-pressure compressed air for
general distribution. Air compressors are rotary screw type complete with vendor controller
package, which senses load and starts the second unit or puts the compressor on idle, as
required.
All high-pressure compressed air is filtered and dried to produce instrument quality air. All
compressed air is filtered using a “Class B” grade filter element in instrument air filter 1 and dried
to a 3 degree Celsius dew point using the refrigerant type air dryer. Dry air is filtered using a
“Class C” grade filter element in instrument air filter 2 and stored in the plant air receiver then
distributed to the plant. Duty and standby air filters are installed. An extra mill air receiver is
installed at the mill area to ensure a reliable compressed air supply is available for the mill and
jigs.
Air filters are equipped with their own vendor supplied high differential pressure indication to
warn when the filter cartridge element is blocked. Each air receiver is equipped with a pressure
gauge and pressure transducer indicating at the SCADA.
Compressed air is used for pneumatic tools, chute diverters, and valve and dart plug actuation.
Service points are provided throughout the plant.
The CIL LP air blower provides low pressure air that is used for airlifts and interstage screens.
Plant air (high pressure) can be used for additional CIL LP air if required.
257422914.doc Page 26
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 run-
off water can be pumped either to the process water tank or to underground using the
stormwater collection pump.
4.6 Gravity Concentrate Leaching

Refer to P&ID 1475-P070 Gravity Concentrate Leaching.
The ILR has its own dedicated vendor supplied PLC, which will control all of the ILR integral
operations.
Shaking table tails from the goldroom are pumped to the ILR feed cone and excess water
overflows to the process water tank.
Settled concentrate slurry drains from the ILR feed cone into the ILR drum. The feed cone de-
waters the feed by a load cell and pinch valve combined in a PID timer loop. The load cell
measures the mass in the cone and a timer circuit opens and shuts the feed valve to feed the
desired flow rate into the ILR drum.
The fresh reagents and return barren solution from the electrowinning circuit are added at the
feed. The drum rotates around a horizontal axis. The drum is rotated only fast enough to
ensure fresh solution is mixed through the solids. The drum inlet and outlet are set to create a
low angle of repose across the drum. The solids are agitated only enough to keep the mass
moving from feed to outlet. A set of internal baffles allows movement of solids through the drum
but inhibits short-circuiting and helps to hold very coarse gold particles back.
Solution passes through at a controlled rate. The solution and solids pass through at rates
independent to each other. This enables the equivalent of a low leach density to be achieved.
The low density leach allows high levels of fresh reagent to be passed through the solids.
Solids and solution pass out of the drum and into the ILR pump hopper. ILR pump transfers the
slurry to the ILR cyclone. Cyclone underflow drops into the ILR thickener. The ILR thickener
underflow reports to the trash screen feed box. The ILR thickener de-waters the tails by a load
cell and pinch valve combined in a PID timer loop. The load cell measures the mass in the
thickener cone and a timer circuit opens and shuts the feed valve to feed the desired flow rate
into the ILR drum.
Cyclone overflow gravitates to the ILR clarifier. The clarifier removes fine suspended solids that
gravitate back to the ILR pump hopper. The clarified solution overflowing the ILR clarifier
gravitates to the ILR electrowinning cell. The cell tail solution gravitates to the ILR cell tail pump
hopper. The ILR cell tail pump (one duty/one standby) pumps the low-grade cell tail solution to
the ILR thickener. Therefore diluting the solution gold grade in the ILR tail slurry discharged
from the ILR thickener.
The ILR solution tank is equipped with a level element that controls the speed of the ILR pump.
Sodium hydroxide solution for pH control is added to the ILR solution tank. A pH probe is
located in the ILR clarifier and controls an actuated valve that adds sodium hydroxide from the
ring main. Cyanide addition is ratio controlled from the ILR drum solids feedrate from the ILR
feed cone. The output of the control loop controls the position of the cyanide dosing valve from
the ring main. Water addition to the circuit is controlled via a level element in the ILR solution
tank that controls the opening and closing of the water make up valve on the CIL spray water
main.
257422914.doc 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 Flotation Concentrate Leaching

Refer to P&IDs 1475-P071 Flotation Concentrate Leaching 1 and 1475-P072 Flotation
Concentrate Leaching 2.
Sodium cyanide solution is added to the feed to CIL tank 1 from the cyanide ringmain by a
control valve into the first CIL tank. 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.
Manually operated cyanide “spiking” valves are provided to dose extra sodium cyanide solution,
and lime slurry from the ringmain pipelines to CIL tanks 1, 2, 3 and 4.
CIL tanks are each equipped with a hollow shaft agitators. Oxygen can be sparged into the any
of the CIL tanks down the agitator shaft. Oxygen flow indication is provided in the field using
rotameters with provision for manual adjustment by needle valves.
CIL tanks are equipped with an air swept in-tank screen for carbon retention. Each in-tank
screen is formed from stainless steel wedge-wire. The screens are serviced by the flotation
hoist. A spare screen is provided so that when a screen is removed for cleaning, it is replaced
by the spare screen. If a CIL tank is to be taken offline for maintenance, a manually operated
knifegate valve is used to close the feed to the pipe feeding the selected tank from the upstream
tank interstage screen outlet and the knifegate valve feeding the next tank downstream is
opened.
The recovery of loaded carbon from the CIL and correction of carbon concentrations in each CIL
tank is carried out by the operator every shift. Carbon recovery to the Carbon Stripping section
is undertaken from the first CIL tank using an airlift. Loaded carbon is cleaned and dewatered by
screening over the loaded carbon screen. Loaded carbon gravitates into the acid wash column.
Screen underflow slurry gravitates back to CIL tank 1.
Interstage carbon transfers are carried out using airlifts. The operator checks the carbon
inventory in CIL tank 1 and 2 and transfers carbon as required to obtain the desired carbon
concentration in CIL tank 1. Alternatively, the operator proceeds to the next CIL tank
downstream if no transfer is required. After transfer, the operator checks carbon concentration in
the tanks and proceeds to the next tank downstream.
When a CIL tank is off-line for maintenance, operators must temporarily connect flexible piping in
order to perform interstage carbon transfer across the bypassed stage.
257422914.doc 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.

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

Refer to P&ID 1475-P073 Acid Wash.
The carbon in the acid wash column is rinsed with raw water and then acid washed to remove
calcium carbonate fouling by pumping dilute acid solution (~3% HCl) from the acid wash tank
through the column and back to the acid wash tank using the acid wash pump. The acid wash
strainers (one duty/one standby) are installed on the outlet of the column to retain any carbon
particles carried out of the column by the acid wash flow.
The acid wash spillage pump is installed in the acid wash area. Acidic spillage is pumped to the
acid wash tank.
On completion of the acid wash, the carbon in the column is rinsed to remove residual chlorides
and avoid the possible generation of hydrogen cyanide gas during elution. The rinse effluent is
discharged to the CIL tails pump hopper and the batch of acid-washed carbon is then transferred
into the elution column.
The acid wash sequence is manually controlled by the operator and all valves are opened or
closed manually. The acid wash column is equipped with diaphragm-protected pressure gauge
to indicate blockage of the acid wash strainer.
To transfer acid washed carbon, residual acid solution in the acid wash column is drained back
to the acid wash tank. The transfer water pump pressurises the acid wash column and supplies
transport water to the outlet bend at the base of the acid wash column. A slurry of carbon in
water is delivered to the elution column. Excess water is drained from the elution strainer back
to the transfer water tank.
257422914.doc Page 29
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
Refer to P&ID 1475-P074 Elution.
The elution section uses the pressure Zadra method. The elution liquor, a dilute sodium
hydroxide-cyanide solution is pumped from the elution tank via the recovery heat exchanger and
elution heater into the elution column under elevated temperature. The heater burners heat the
eluate solution directly. Hot eluant solution exiting the elution column is cooled in the recovery
heat exchanger by contacting with fresh eluate solution being pumped into the heater.
To start an elution, the sodium hydroxide and cyanide concentrations in a sample of the eluate
solution in the elution tank are checked and if required, corrected by adding fresh reagents. The
eluate solution is pumped, using the elution pump, through the heat exchanger, heater, elution
column and elution strainers (one duty/one standby) to the CIL electrowinning cell. Barren
electrolyte is returned from the cell outlet to the elution tank.
On completion of an elution, carbon is transferred to the eluted carbon screen above the kiln
feed hopper. The transfer water pump pressurises the elution column and supplies transport
water to the outlet bend at the base of the column. A slurry of carbon in water is delivered to the
screen. Carbon drops into the hopper and excess water is drained back to the transfer water
tank.
Eluate solution can be reused for a number of elutions until the level of contamination becomes
unacceptable. The spent eluate is pumped to CIL via the spent eluate tank by the elution pump
after opening the spent eluate discharge valve (XV8730). The benefit of any available sodium
hydroxide and cyanide in the spent eluate is used and the carbon in the CIL can recover the
residual gold values. The elution heater is interlocked to the valve open position so the heater
cannot be operated without eluate flow nor eluate disposed of by accident during an elution.
To make a new batch of eluate solution, the elution tank is filled with raw water and sufficient
cyanide and sodium hydroxide solutions added. Water addition to the elution tank to make-up
fresh eluant solution is controlled by a manual valve.
The elution system requires operator intervention at various times during the sequence as all
valves are opened or closed manually.
The elution tank is equipped with a low level switch interlocked to trip the elution pump at low
level. The elution pump is a helical rotor type pump and cannot be run dry.
The elution column outlet is equipped with a pressure and temperature gauges. Pressure and
temperature gauges are supplied at the inlets and outlets of the heat exchanger. A temperature
gauge is installed at the elution tank.
The outlet of the heater is equipped with a temperature gauge as well as a temperature
measurement device. This is used to control the elution heating system. The heater system is
automated and has a local control panel. The elution column pressure is controlled by the
operator who manually adjusts the position of a throttling valve on the eluate outlet of the
recovery heat exchanger.
257422914.doc Page 30
4.8.3 Regeneration
Refer to P&ID 1475-P075 Regeneration.
When the elution sequence is complete, the operator can divert the transfer of carbon direct to
CIL via the regen carbon screen or to regeneration via the eluted carbon screen.
Screened eluted carbon is discharged into the kiln feed hopper. Carbon is fed to the
regeneration kiln situated on top of the CIL tanks by the kiln screw feeder.
Regenerated carbon from the kiln is quenched in the carbon quench pan and passes over the
regen carbon screen at the CIL. The screen removes excess water and carbon fines. Carbon is
discharged into the last CIL tank to replace loaded carbon transferred upstream.
Water and carbon fines passing through the eluted carbon screen gravitate to the transfer water
tank. Water and carbon fines passing through the regen carbon screen gravitate to the detox
tank.
The regeneration section operates intermittently depending on the availability and activity of
eluted carbon and the requirements for regenerated carbon to be added to the CIL.
Regeneration is performed as a manually controlled sequence and all valves are opened or
closed manually. Operator intervention or acknowledgement is required at various times during
the procedure. Kiln heating is controlled by the vendor’s instrumentation and control system. An
emergency drive system is incorporated to protect the heated kiln retort tube from distortion if
the main power supply is interrupted. Changeovers from mains supply to emergency supply and
vice versa are automatic and instantaneous. The battery supply will drive the tube for a
minimum period to allow the tube to cool to a safe temperature.
4.9 Electrowinning
Refer to P&ID 1475-P076 Electrowinning.
Gold in the ILR electrolyte and eluate is plated separately onto cathodes in the dedicated ILR
and CIL electrowinning cells.
Periodically, the operator uses the electrowinning hoist to remove the anodes from the cells after
isolating the rectifier and feed systems. The anodes are stored in an anode “horse” allowing the
operator to raise the cathodes utilising the same hoist. The gold sludge adhering to the cathode
mesh is removed by washing with a high-pressure water spray and collected in the body of the
electrowinning cell.
Rectifier voltage and current is displayed and adjusted at the rectifiers located adjacent to the
outside wall of the goldroom.
The plated precious metals are washed from the stainless steel mesh cathodes using the high-
pressure cathode wash pump directly into the cell. The pan filter dewaters the resultant sludge
that is collected and this is then dried in the calcine oven prior to mixing with fluxes and
placement into the smelting furnace.
To collect cathode sludge, after electrowinning is complete, the rectifier is switched off and
electrically isolated, the cells are drained via a decant line, to within 100 mm of the cell bottom to
discard the majority of the solution. This decant line is run to the electrowinning spillage pump
sump. The electrowinning spillage pump delivers to the elution tank Solution flow from the cell
during the decant draining step is controlled by a manual valve to ensure cell exit velocities are
low enough to avoid solids entrainment and to match the flow rate to the electrowinning spillage
pump capacity.
After draining, the fume hood is removed and the anode pack is carefully lifted from the cell with
the cathode hoist, hosing off any residual sludge that may have adhered to the anode plates into
the cell. The anode pack is then removed from the cell and placed in the anode holding frame,
freeing the overhead monorail and electric hoist for lifting and removal of the cathode pack.
257422914.doc 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 cell’s 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.

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.
257422914.doc Page 32
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 PERMISSIVES AND INTERLOCKS
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.
257422914.doc Page 33
5.2 Crushing
Drive Drive Permissive to Start Running Interlock
Description Number
Primary crusher 10-FE-001 Primary jaw crusher running Primary jaw crusher stops
feeder
Crusher product conveyor running Crusher product conveyor stops
LAH1003 not activated LAH1003 activated
LALL1079 activated
Primary jaw 10-CR-001 Primary crusher healthy Primary crusher lubrication system
crusher OFF for a set time
Lubrication system selected to ON
Lubrication system running
Crusher product 10-CV-001 Secondary screen running Secondary screen stops
conveyor
Pull-wire switch not activated Pull-wire switch activated XA1006
XA1006
Belt drift switch activated ZA1007
Belt drift switch not activated
ZA1007 Conveyor underspeed switch
activated SAL1005
Secondary screen 10-SC-001 Secondary crusher feed bin feed Secondary crusher feed bin feed
conveyor running conveyor stops
Fine ore bin feed conveyor running Fine ore bin feed conveyor stops
Secondary 10-CV-002 LAHH1015 not activated OR LAHH1015 activated
crusher feed bin ZSC1076 activated (bin bypassed)
feed conveyor Pull-wire switch activated XA1011
Pull-wire switch not activated
XA1011 Belt drift switch activated ZS1012
Belt drift switch not activated ZSA1076 activated

ZS1012 Conveyor underspeed switch
ZSA1076 not activated activated SAL1010
Fine ore bin feed 10-CV-003 LAHH1023 not activated LAHH1023 activated
conveyor
XA1019
Belt drift switch activated ZS1020
activated SAL1018
HPGR magnet switched on
HPGR magnet switched off
Secondary 10-FE-002 Secondary cone crusher running Crusher product conveyor stops
crusher feeder
LAH1016 not activated Secondary cone crusher stops
LAH1016 activated
Secondary cone 10-CR-002 Crusher product conveyor running Secondary crusher lubrication system
crusher OFF for a set time
Secondary cone crusher healthy
Lubrication system selected to ON
Lubrication system running
Crusher spillage 10-PU-001 LAHH1051 not activated LAHH1051 activated
pump
Stormwater 10-PU-054 LAH7008 not activated LAH7008 activated
collection pump
257422914.doc Page 34
257422914.doc Page 35
Description Number
Fine ore bin belt 10-FE-003 HPGR feed conveyor running HPGR feed conveyor stops
feeder
LAL1023 not activated LAL1023 activated
XA1025
activated SAL1024
HPGR feed 10-CV-004 HPGR running HPGR stops
conveyor
LAHH1044 not activated OR Mill feed conveyor stops
ZSC1042 activated
LAHH1044 activated
XA1030 Pull-wire switch activated XA1030
Belt drift switch activated ZS1031 Belt drift switch activated ZS1031
LAL7003 not activated (process Conveyor underspeed switch

water tank) activated SAL1029
LAL7008 not activated (raw water LAL7003 activated

tank) LAL7008 activated
PALL7005 not activated (gland PALL7005 activated (gland water)
water)
ZSA1042 activated
ZSA1042 not activated
Mill feed conveyor 10-CV-005 Ball mill screen running Ball mill screen stops
XA1046
activated SAL1045
Mill pump running
Mill pump stops
Cyclone pump running
Cyclone pump stops
Mill screen 10-CV-006 LAHH1044 not activated OR LAHH1044 activated
oversize conveyor ZSC1042 activated
Pull-wire switch activated ZA1036
ZA1036 Belt drift switch activated ZS1037
Belt drift switch not activated Conveyor underspeed switch

ZS1037 activated SAL1035
ZSA1042 not activated ZSA1042 activated
Ball mill screen 20-SC-002 Mill screen oversize conveyor Mill screen oversize conveyor stops
running
Mill pump stops
Mill pump running
HPGR 20-CR-003 Mill feed conveyor running Mill feed conveyor stops
HPGR healthy HPGR not healthy
Mill pump 20-PU-003 XV2017 or XV2018 or XV2019 open XV2017 & XV2018 & XV2019 all
closed
Process water pump running
FAL2006/08 not activated
257422914.doc Page 36
Description Number
Primary jig no.1 XV2017 Primary jig no.1 running Primary jig no.1 stops (valve closes)
feed valve open
feed valve open
feed valve open
Cyclone pump 20-PU-004 Flotation feed thickener running
Process water pump running
Primary jig no.1 20-GC-001 Process water pump running
Centrifugal 20-GC-004A Process water pump running
concentrator No 1
Ball mill 20-ML-001 Refer Outokumpu design document Refer Outokumpu design document
7330-DD01 Rev0 7330-DD01 Rev0
257422914.doc Page 37
5.4 Flotation
Description Number
Flotation feed 30-PU-006 FAL3006/09 not activated
thickener
underflow pump
Flotation tail 30-PU-007 Flotation tail thickener running LAH4023 activated
pump
LAH4023 not activated
Flotation 30-PU-008 Concentrate thickener running
concentrate pump
Flotation tails 30-PU-081 Flotation tail thickener running
sampler transfer
pump
Flotation 30-PU-010 Trash screen running LAHH8319 activated
concentrate
thickener LAHH8319 not activated
underflow pump
Flotation tail 40-PU-013 FAL4007/09 not activated
thickener
underflow pump
Sand pump 1 40-PU-072 FAL4031/33 not activated
Sand pump 2 40-PU-072 Sand pump 1 running

Flotation feed 30-SA-001 Flotation feed thickener underflow Flotation feed thickener underflow
sampler pump running pump stops
XV3014 open XV3014 closed
Flotation tails 30-SA-006 Flotation feed thickener underflow Flotation feed thickener underflow
primary sampler pump running pump stops
XV3014 open XV3014 closed
257422914.doc Page 38
Description Number
Collector dosing 60-PU-038 LAL6001 not activated Flotation feed thickener underflow
pump pump stops for longer than 60
seconds
Frother pump 60-PU-041 LAL6003 not activated Flotation feed thickener underflow
pump stops for longer than 60
seconds
Copper sulphate 60-PU-039A LALL6047 not activated Flotation feed thickener underflow
dosing pump A pump stops for longer than 60
LAL6023 not activated seconds
Copper sulphate 60-PU-039B LALL6047 not activated XC6051 selected for flotation &
dosing pump B flotation feed thickener underflow
LAL6023 not activated pump stops for longer than 60
seconds
XC6051 selected for Detox & CIL tails
pump stops for longer than 60
seconds
Copper sulphate 60-PU-039C LALL6047 not activated CIL tails pump stops for longer than
dosing pump C 60 seconds
LAL6023 not activated
Flocculant dosing 60-PU-043A LALL6005 not activated LALL6005 activated
pump A
Cyclone pump stops
Flocculant dosing 60-PU-043B LALL6005 not activated LALL6005 activated
pump B
XC6052 selected for flotation feed &
cyclone pump stops
XC6052 selected for Flotation tails &
flotation tail pump stops
Flocculant dosing 60-PU-043C LALL6005 not activated LALL6005 activated
pump c
Flotation tail pump stops
Flocculant dosing 60-PU-043D LALL6005 not activated LALL6005 activated
pump d
Flotation concentrate pump stops
Flocculant dosing 60-PU-043E LALL6005 not activated LALL6005 activated
pump e
Flotation concentrate pump stops
Cyanide pump 60-PU-047 LAL6014 not activated LAL6014 activated
LALL6012 not activated LALL6012 activated
Cyanide tank XV6013 LAHH6012 not activated LAHH6012 activated
water addition
valve open
Sodium hydroxide 60-PU-044A LALL6034 not activated LALL6034 activated
pump A
Sodium hydroxide 60-PU-044B LALL6034 not activated LALL6034 activated
pump B
SMBS pump 60-PU-067 LAL6021 not activated LAL6021 activated
LALL6019 not activated LALL6019 activated
SMBS tank water XV6020 LAH6019 not activated LAH6019 activated
addition valve
open
257422914.doc Page 39
Description Number
Trash screen 80-SC-005 Trash screen underflow pump
running
Trash screen 83-PU-079 CIL agitator No 1 running
underflow pump
Flotation 83-SA-003 Flotation concentrate thickener Flotation concentrate thickener
concentrate underflow pump running underflow pump stops
sampler
CIL tails sampler 83-SA-005 Trash screen underflow pump Trash screen underflow pump stops
airlift running
Detox tails 90-SA-004 Trash screen underflow pump Trash screen underflow pump stops
sampler running
Final CIL tail 90-SA-008 CIL tails pump running CIL tails pump stops
sampler
Loaded carbon 83-SC-006 LAH8702 not activated LAH8702 activated
screen

Description Number
Acid wash pump 87-PU-025 LAL8701 not activated LAL8701 activated
Elution heater 1 87-HE-001 Refer to vendor manual Refer to vendor manual
XV8730 closed XV8730 opens
LAL8705 not activated LAL8705 activated
Elution pump running Elution pump stops
Elution pump 87-PU-024 LALL8705 not activated LALL8705 activated
Regeneration kiln 87-KN-001 Refer to vendor manual Refer to vendor manual
5.8 Electrowinning
Description Number
Pan filter vacuum 85-VP-001 LAH8504 not activated LAH8504 activated
pump
Refer to vendor manual Refer to vendor manual
257422914.doc Page 40
Description Number
CIL tails pump 90-PU-022 FAL9011/13 not activated Nil
LAL9007 not activated
5.10 Goldroom -Smelting

Description Number
Smelting furnace 50-FU-001 PDAH5005 not activated PDAH5005 activated
257422914.doc Page 41
6 PROCESS CONTROL LOOPS
6.1 Crushing
6.1.1 Primary Crusher Feeder

Objective:
Feed rate to the primary crusher is controlled to maintain required throughput.
Modes of Operation:
a) Remote Manual
Control Controlle Controlle Controller Input Controller Output
Mode r r
Tag Mode
Remote SC1002 Manual Nil To primary crusher feeder speed ratio
controller SC1002
6.1.2 Secondary Crusher Feeder

Objective:
Feed rate to the secondary crushing circuit is controlled to maintain required throughput.
Modes of Operation:
a) Remote Auto - the operator selects a bin level set-point and the level controller adjusts
the speed of the feeder.
b) Remote Manual - the operator selects the speed of the feeder through the bin level
controller.
Mode r r
Tag Mode
Remote LIC1015 Auto Set-point for LIC1015 To secondary crusher feeder VVVF
drive SC1089
Process variable for LIC1015
LIC1015 Manual Nil To secondary crusher feeder VVVF
drive SC1089
257422914.doc Page 42
6.2.1 Fine Ore Bin Belt Feeder

Objective:
Feed rate to the HPGR is controlled to maintain required throughput.
Modes of Operation:
a) Remote Auto - the operator selects the desired HPGR feed rate set-point through the
HPGR feed rate controller, which regulates the speed of the feeder so that the
weightometer reading will match the set-point.
b) Remote Auto (Override) - the output of the HPGR feed rate controller is driven to a
minimum while the HPGR feed bin high level alarm condition is active.
c) Remote Manual - the operator selects the speed of the feeder through the HPGR feed
rate controller.
d) Remote Manual (Override) - the output of the HPGR feed rate controller is driven to a
minimum while the HPGR feed bin high level alarm condition is active.
Control Controlle Controller Controller Input Controller Output
Mode r Mode
Tag
Remote WIC1033 Auto Set-point for WIC1033 To fine ore bin belt feeder VVVF
drive SC1033
Process variable for WIC1033
LIC1044 Auto(Override) LAH1044 Fine ore bin belt feeder VVVF drive
SC1033 to minimum
WIC1033 Manual Nil To fine ore bin belt feeder VVVF
drive SC1033
LIC1044 Manual LAH1044 To fine ore bin belt feeder VVVF
(Override) drive SC1033 to minimum
6.2.2 HPGR Roll Speed

Objective:
Feed rate to the HPGR rolls is controlled to maintain required throughput and choke feed
condition.
Modes of Operation:
a) Remote Auto - the operator selects a HPGR feed bin level set-point and the level
controller adjusts the speed of the HPGR rolls.
b) Remote Manual - the operator selects the speed of the HPGR rolls through the HPGR
feed bin level controller.
Mode r r
Tag Mode
Remote WIC1033 Auto Set-point for LIC1044 To HPGR VVVF drive SC1090A/B
WIC1033 Manual Nil To HPGR VVVF drive SC1090A/B
257422914.doc Page 43
6.2.3 Mill Pump Hopper Level
Objective:
Level of the mill pump hopper is controlled to maintain required throughput.
Modes of Operation:
a) Remote Auto - the operator selects a mill pump hopper level set-point and the level
controller adjusts the speed of the mill pump.
b) Remote Auto (Override) - the output of the mill pump hopper level controller is driven to
a minimum while the cyclone underflow launder high-level alarm condition is active.
c) Remote Manual - the operator selects the speed of the mill pump through the mill pump
hopper level controller.
d) Remote Manual (Override) - the output of the mill pump hopper level controller is driven
to a minimum while the cyclone underflow launder high-level alarm condition is active.
Mode r r
Tag Mode
Remote LIC2009 Auto Set-point for LIC2009 To mill pump VVVF drive SC2089A/B
LIC2009 Auto LAH2067 Mill pump VVVF drive SC2089A/B to
(Override) minimum
LIC2009 Manual Nil To mill pump VVVF drive SC2089A/B
LIC2009 Manual LAH2067 Mill pump VVVF drive SC2089A/B to
(Override) minimum
6.2.4 Mill Pump Hopper Water Addition

Objective:
Mill pump hopper water addition is controlled to maintain required mill pump delivery
slurry density.
Modes of Operation:
a) Remote Auto - the operator selects a mill pump delivery density set-point and the
density controller adjusts the position of the flow control valve.
b) Remote Manual - the operator selects the position of the flow control valve through the
mill pump delivery density controller.
Mode r r
Tag Mode
Remote DIC2016 Auto Set-point for DIC2016 To FCV-2003 positioner
Process variable for DIC2016
DIC2016 Manual Nil To FCV-2003 positioner
257422914.doc Page 44
6.2.5 Mill Feed End Water Addition
Objective:
Flowrate of mill feed end water addition is controlled to maintain mill operating slurry
density.
Modes of Operation:
a) Remote Auto - the operator selects a mill feed end water addition flow set-point and the
flow controller adjusts the position of the flow control valve.
mill feed end water addition flow controller.
Mode r r
Tag Mode
Remote FIC2097 Auto Set-point for FIC2097 To FCV-2092 positioner
Process variable for FIC2097
FIC2097 Manual Nil To FCV-2092 positioner
6.2.6 Mill Screen Gold Trap Feed Water

Objective:
Density of the mill screen gold trap feed is controlled to maintain flow through the trap.
Modes of Operation:
a) Remote Auto - the operator selects a mill screen gold trap feed water addition flow set-
point and the flow controller adjusts the position of the flow control valve.
mill screen gold trap feed water addition flow controller.
Mode r r
Tag Mode
Remote FIC2091 Auto Set-point for FIC2091 To FCV-2091 positioner
Process variable for FIC2091
257422914.doc Page 45
6.2.7 Cyclone Pump Hopper Level
Objective:
Level of the cyclone pump hopper is controlled to maintain required throughput.
Modes of Operation:
a) Remote Auto - the operator selects a cyclone pump hopper level set-point and the level
controller adjusts the speed of the cyclone pump.
b) Remote Auto (Override) - the output of the cyclone pump hopper level controller is
driven to a minimum while the cyclone underflow launder high-level alarm condition is
active.
c) Remote Manual - the operator selects the speed of the cyclone pump through the
cyclone pump hopper level controller.
d) Remote Manual (Override) - the output of the cyclone pump hopper level controller is
driven to a minimum while the cyclone underflow launder high-level alarm condition is
active.
Mode r r
Tag Mode
Remote LIC2048 Auto Set-point for LIC2048 To cyclone pump VVVF drive
SC2090A/B
LIC2048 Auto LAH2067 Cyclone pump VVVF drive
(Override) SC2090A/B to minimum
LIC2048 Manual Nil To cyclone pump VVVF drive
SC2090A/B
LIC2048 Manual LAH2067 Cyclone pump VVVF drive
(Override) SC2090A/B to minimum
6.2.8 Cyclone Pump Hopper Water Addition

Objective:
Cyclone pump hopper water addition is allowed if the hopper level reaches a low level.
a) Remote Auto - the water dilution valve is opened fully while the cyclone pump hopper
low level alarm condition is active.
b) Remote Manual - the operator selects the position of the water dilution valve through the
cyclone pump hopper water addition valve controller.
Mode r r
Tag Mode
Remote XV2072 Auto LAL2048 XV2072 positioner to open
XV2072 Manual Nil XV2072 positioner to open
257422914.doc Page 46
6.2.9 Gravity Concentrate Surge Tank Level
Objective:
Level of the gravity concentrate surge tank is controlled to prevent overfilling with
concentrate by successive concentrate flushing from the spinners and centrifugal
concentrator.
Modes of Operation:
a) Remote Auto - the supervisor selects a high-level alarm set-point. At high-level, the
PLC opens the actuated valve feeding slurry to the concentrate tank and inhibits any
unit from flushing.
Mode r r
Tag Mode
Remote LIC2061 Auto LAH Set-point for LI2061 XV2066 positioner to open at LAH
LAHH Set-point for LI2061 LAHH inhibit flush signal (order of
priority):
Process variable for LI2061
Centrifugal concentrator
Spinner No 1
Spinner No 2
Spinner No 3
Spinner No 4
6.2.10 Mill Screen Gold Trap Purge

Objective:
The mill screen gold trap is purged on a timer set basis or manually by the operator as
required.
Modes of Operation:
a) Remote Auto - the operator selects a running time and the controller purges the trap on
expiry and restarts the timer.
b) Remote Manual - the operator selects a purge cycle through the controller.
Mode r r
Tag Mode
Remote KC2002 Auto running time set-point for Timer expires
KC2002
XV2001 open for set time
open time set-point for XV2001
XV2001 to close
open time set-point for XV2002
XV2002 to close
KC2002 Manual open time set-point for XV2001 XV2001 open for set time
open time set-point for XV 2002 XV2001 to close
XV2002 to close
257422914.doc Page 47
6.3 Flotation
6.3.1 Flotation Feed Thickener Underflow Slurry Density

Objective:
Density of flotation feed slurry is controlled to maintain required throughput and optimum
flotation performance.
Modes of Operation:
a) Remote Auto - the operator selects a flotation feed thickener underflow slurry density
set-point and the density controller adjusts the speed of the flotation feed thickener
underflow pump.
b) Remote Manual - the operator selects the speed of the flotation feed thickener
underflow pump through the flotation feed thickener underflow slurry density controller.
Mode r r
Tag Mode
Remote DIC3012 Auto Set-point for DIC3012 To flotation feed thickener underflow
pump VVVF drive SC3074A/B
DIC3012 Manual Nil To flotation feed thickener underflow
pump VVVF drive SC3074A/B
6.3.2 Conditioning Tank Slurry Density

Objective:
Density of flotation feed slurry is by a cascade loop to maintain required throughput and
optimum flotation performance. The dilution water addition flow meter set-point is
calculated in the PLC. The PLC measures the thickener underflow slurry density and
slurry volumetric flow. The solids dry tonnage flowrate and solution flowrate in the
thickener underflow is calculated. The desired conditioning tank slurry density set-point
is entered. The PLC calculates the thickener underflow slurry solution flowrate and the
required conditioning tank overflow slurry solution flowrate based on the flotation feed
density set-point and calculated solids dry tonnage flowrate. The difference in volumetric
flow cascades to the flow control loop as the flow set-point.
Modes of Operation:
a) Remote Auto 1 - the operator selects a conditioning tank slurry density (entered as
solids % w/w) and the PLC calculates a flow set-point for the conditioning tank dilution
water flow controller. The flow controller adjusts the position of the flow control valve to
match the set-point.
b) Remote Auto 2 - the operator selects a conditioning tank dilution water flow set-point
and the flow rate controller adjusts the position of the flow control valve.
c) Remote Manual - the operator selects the position of the flow control valve through the
conditioning tank dilution water flow controller.
257422914.doc Page 48
Mode r r
Tag Mode
Remote FIC3001 Auto 1 Set-point for FIC3001 from To FCV-3011 positioner
FY3012
FY3012 inputs:
Process variable from WIC3012
Process variable from DIC3012
Set-point from HX3012
Solids SG (t/m³) (Supervisor
level access only)
FIC3001 Auto 2 Set-point for FIC3001 To FCV-3011 positioner
6.3.3 Flotation Tails Pump Hopper Level

Objective:
Level of the flotation tails pump hopper is controlled to maintain required throughput.
Modes of Operation:
a) Remote Auto - the operator selects a flotation tails pump hopper pump hopper level set-
point and the level controller adjusts the speed of the flotation tails pump.
b) Remote Manual - the operator selects the speed of the flotation tails pump through the
flotation tails hopper level controller.
Mode r r
Tag Mode
Remote LIC3020 Auto Set-point for LIC3020 To flotation tails pump VVVF drive
SC3075A/B
LIC3020 Manual Nil To flotation tails pump VVVF drive
SC3075A/B
257422914.doc Page 49
6.3.4 Flotation Concentrate Thickener Underflow Slurry Density
Objective:
Density of flotation concentrate thickener underflow slurry is controlled to maintain
required throughput, optimum thickener performance and optimum CIL feed slurry
density.
Modes of Operation:
a) Remote Auto - the operator selects a flotation concentrate thickener underflow slurry
density set-point and the density controller adjusts the speed of the flotation concentrate
thickener underflow pump.
b) Remote Manual - the operator selects the speed of the flotation concentrate thickener
underflow pump through the flotation concentrate thickener underflow slurry density
controller.

Mode r r
Tag Mode
Remote DIC3035 Auto Set-point for DIC3035 To flotation concentrate thickener
underflow pump VVVF drive
Process variable for DIC3035 SC3076A/B
DIC3035 Manual Nil To flotation concentrate thickener
SC3076A/B
6.3.5 Flotation Tailings Thickener Underflow Slurry Density

Objective:
Density of flotation tailings thickener underflow slurry is controlled to maintain required
throughput, optimum thickener performance and correct TSF feed slurry density.
Modes of Operation:
a) Remote Auto - the operator selects a flotation tailings thickener underflow slurry density
set-point and the density controller adjusts the speed of the flotation tailings thickener
underflow pump.
b) Remote Manual - the operator selects the speed of the flotation tailings thickener
underflow pump through the flotation tailings thickener underflow slurry density
controller.
Mode r r
Tag Mode
Remote DIC4010 Auto Set-point for DIC4010 To flotation tailings thickener
Process variable for DIC4010 SC4055A/B
DIC4010 Manual Nil To flotation tailings thickener
SC4055A/B
257422914.doc Page 50
6.3.6 Sand Pump Delivery Slurry Density
Objective:
Density of the sand pump delivery slurry is controlled to maintain required throughput,
optimum and correct TSF feed slurry density.
Modes of Operation:
a) Remote Auto - the operator selects a sand pump delivery slurry density set-point and
the density controller adjusts the position of the sand pump hopper dilution water flow
control valve.
b) Remote Manual - the operator selects the position of the sand pump hopper dilution
water flow control valve through the sand pump delivery density controller.
Control Controlle Controller Controller Input Controller Output
Mode r Mode
Tag
Remote DIC4038 Auto Select DIC4038 A or B To FCV-4039 positioner
Set-point for DIC4038
DIC4038 Manual Nil To FCV-4039 positioner
6.3.7 Sand Pump Hopper Level

Objective:
Level of the sand pump hopper is controlled to maintain required throughput. The
variable speed sand pump controller has a minimum speed setting to prevent the pipeline
sanding up under normal conditions.
Modes of Operation:
a) Remote Auto - the operator selects a sand pump hopper level set-point and the level
controller adjusts the speed of sand pump 2.
b) Remote Auto (Override) - the sand pump hopper water dilution valve is opened fully
while the alarm condition is active.
c) Remote Manual - the operator selects the speed of sand pump 2 through the sand
pump hopper level controller.
d) Remote Manual (Override) - the sand pump hopper water dilution valve is opened fully
while the alarm condition is active.
Mode r r
Tag Mode
Remote LIC4023 Auto Set-point for LIC4023 To sand pump 2 VVVF drive
SC4056A/B
LIC4023 Auto LAL4023 activated FCV-4039 positioner to open
(Override)
LIC4023 Manual Nil To sand pump 2 VVVF drive
SC4056A/B
LIC4023 Manual LAL4023 activated FCV-4039 positioner to open
(Override)
257422914.doc Page 51
6.3.8 Flotation Tails Decant Pump
Objective:
The flotation tails decant pump is stopped if the process water tank is full and the float
valve closes.
Modes of Operation:
a) Local Auto
Mode r r
Tag Mode
Local FAL4017 Auto FAL4017 activated Flotation tails decant pump stop
Initiate restart timer
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
Mode r r
Tag Mode
Local LSL4018 Auto LSL018 activated Seepage decant pump start
Local LSL4019 Auto LSL019 activated Seepage decant pump stop
6.3.10 Tailings Drainage Containment Pump

Objective:
Tailings drainage containment pump is started if the sump is full and stopped if the sump
is empty.
Modes of Operation:
a) Local Auto
Mode r r
Tag Mode
Local LSL4046 Auto LSL046 activated Tailings drainage containment pump
start
Local LSL4047 Auto LSL047 activated Tailings drainage containment pump
decant pump stop
257422914.doc Page 52
6.4.1 Collector Dosing Pump Speed

Objective:
Collector addition is ratio controlled to the flotation feed rate measured by the flotation
feed thickener underflow mass flow system. Both pumps may be operated at the same
time if required.
Modes of Operation:
a) Remote Auto - the operator selects a ratio of pump speed to the flotation feed thickener
integrated dry tonnage flow rate and the collector addition rate controller adjusts the
speed of the collector dosing pump.
b) Remote Manual - the operator selects the speed of the collector dosing pump through
the collector addition rate controller.

Mode r r
Tag Mode
Remote SIC6002 Auto Collector solution concentration Collector dosing pump VVVF drive
(Supervisor level access only) SC6002A/B
Pump flowrate at 100% output
(Supervisor level access only)
Operator entered ratio (g/t)
SIC6002 Manual Nil Collector dosing pump VVVF drive
SC6002A/B
257422914.doc Page 53
6.4.2 Frother Dosing Pump Speed
Objective:
Frother addition is ratio controlled to the flotation feed rate measured by the flotation feed
thickener underflow mass flow system. Both pumps may be operated at the same time if
required.
Modes of Operation:
integrated dry tonnage flow rate and the frother addition rate controller adjusts the
speed of the frother dosing pump.
b) Remote Manual - the operator selects the speed of the frother dosing pump through the
frother addition rate controller.
Mode r r
Tag Mode
Remote SIC6004 Auto Frother solution concentration To frother dosing pump VVVF drive
(Supervisor level access only) SC6004A/B
SIC6004 Manual Nil To frother dosing pump VVVF drive
SC6004A/B
6.4.3 Copper Sulphate (Flotation) Dosing Pump Speed

Objective:
Flotation copper sulphate addition is ratio controlled to the flotation feed rate measured
by the flotation feed thickener underflow mass flow system. As copper sulphate dosing
pump B is a common standby, a selection (XC6051) must be made to ensure the correct
controller output is fed to the pump.
Modes of Operation:
integrated dry tonnage flow rate and the flotation copper sulphate addition rate controller
adjusts the speed of the copper sulphate dosing pump.
b) Remote Manual - the operator selects the speed of the flotation copper sulphate dosing
pump through the copper sulphate addition rate controller.
Mode r r
Tag Mode
Remote SIC6045 Auto CuSO4 mix strength (Supervisor To copper sulphate dosing pump
level access only) VVVF drive SC6024/25
SIC6045 Manual Nil To copper sulphate dosing pump
VVVF drive SC6024/25
257422914.doc Page 54
6.4.4 Copper Sulphate (Detox) Dosing Pump Speed
Objective:
Detox copper sulphate addition is ratio controlled to the detoxified CIL tails flow rate. As
copper sulphate dosing pump B is a common standby, a selection (XC6051) must be
made to ensure the correct controller output is fed to the pump.
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.
The speed of the copper sulphate dosing pump adding solution to the detox tank is ratio
controlled from the adjusted CIL tails volumetric flowrate and a manually input CIL tails
slurry density and the copper addition rate set point in grams Cu2+ per cubic metre of
solution.
Modes of Operation:
a) Remote Auto - the operator selects the copper sulphate mix concentration, copper
addition rate set point and estimated average CIL tails slurry density. The ratio is
applied to the adjusted CIL tails volumetric flow rate and the detox copper sulphate
addition rate controller adjusts the speed of the detox copper sulphate dosing pump.
b) Remote Manual - the operator selects the speed of the detox copper sulphate dosing
pump through the detox copper sulphate addition rate controller.
Mode r r
Tag Mode
Remote SIC6040 Auto Operator entered of Cu2+ To copper sulphate dosing pump
addition per m³ (Supervisor level VVVF drive SC6026/25
access only)
CuSO4 mix strength input
CIL tails slurry density
FIC9018 adjustment for dilution
Process variable from FIC9018
SIC6040 Manual Nil To copper sulphate dosing pump
VVVF drive SC6026/25
257422914.doc Page 55
6.4.5 Flotation Feed Thickener Flocculant Dosing Pump Speed
Objective:
Flotation feed thickener flocculant addition is controlled based on the flotation feed
thickener bed level. As flocculant dosing pump B is a common standby, a selection
(XC6052) must be made to ensure the correct controller output is fed to the pump.
Modes of Operation:
a) Remote Auto - the operator selects a set point for the flotation feed thickener bed level
and the flotation feed thickener bed level controller adjusts the speed of the flocculant
dosing pump.
b) Remote Manual - the operator selects the speed of the flotation feed thickener
flocculant dosing pump through the flotation feed thickener bed level controller.
Control Controller Controlle Controller Input Controller Output
Mode Tag r
Mode
Remote LIC3044 Auto Set-point for LIC3044 To flocculant dosing pump VVVF
drive SC6031A/B
LIC3044 Manual Nil To flocculant dosing pump VVVF
drive SC6031A/B
6.4.6 Flotation Tail Thickener Flocculant Dosing Pump Speed

Objective:
Flotation tail thickener flocculant addition is manually controlled based on the flotation tail
thickener bed level. As flocculant dosing pump B is a common standby, a selection
(XC6052) must be made to ensure the correct controller output is fed to the pump.
Modes of Operation:
a) Remote Auto - the operator selects a set point for the flotation tail thickener bed level
and the flotation tail thickener bed level controller adjusts the speed of the flocculant
dosing pump.
b) Remote Manual - the operator selects the speed of the flocculant dosing pump through
the flotation tail thickener bed level controller.
Mode Tag r
Mode
drive SC6031E/B
drive SC6031E/B
257422914.doc Page 56
6.4.7 Concentrate Thickener Flocculant Dosing Pump Speed
Objective:
Concentrate thickener flocculant addition is controlled based on the concentrate
thickener bed level.
Modes of Operation:
a) Remote Auto - the operator selects a set point for the concentrate thickener bed level
and the concentrate thickener bed level controller adjusts the speed of the flocculant
dosing pump.
b) Remote Manual - the operator selects the speed of the flocculant dosing pump through
the concentrate thickener bed level controller.
Mode Tag r
Mode
drive SC6031C/D
drive SC6031C/D
6.4.8 SMBS Dosing Pump Speed

Objective:
Detox SMBS is ratio controlled to the CIL tails flow rate and CNfree level in the CIL tails.
Modes of Operation:
a) Remote Auto - the operator selects a ratio based on the SMBS mix concentration,
normal CNfree level in the CIL tails and the normally experienced ratio of CNwad to CNfree in
the CIL tails. The ratio is applied to the adjusted CIL tails volumetric flow rate and the
SMBS addition rate controller adjusts the speed of the SMBS dosing pump.
b) Remote Manual - the operator selects the speed of the SMBS dosing pump through the
SMBS addition rate controller.
Mode r r
Tag Mode
Remote SIC9018 Auto Operator entered ratio of SMBS To SMBS dosing pump VVVF drive
addition to CNwad level SC6039A/B
SMBS mix strength input
CNfree level input (Supervisor
level access only)
CNwad to CNfree ratio input
FIC9018 adjustment for dilution
Process variable from FIC9018
SIC9018 Manual Nil To SMBS dosing pump VVVF drive
SC6039A/B
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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
Mode r r
Tag Mode
Remote LI6017 Auto LAL6017 active Lime feeder drive on
Lime silo vibrated fluidiser air open
(XV6053)
XV6018 open
LAH6017 active Lime feeder drive off
Lime silo vibrated fluidiser air closed
(XV6053)
XV6018 close
6.4.10 Potable Water Jockey pump

Objective:
Potable water jockey pump is stopped if the potable water tank is full and the float valve
closes.
Modes of Operation:
a) Local Auto
Mode r r
Tag Mode
Local FAL4017 Auto FAL7001 activated Potable water jockey pump stop
Initiate restart timer
257422914.doc Page 58
6.5.1 CIL Lime Addition

Objective:
Lime slurry addition is controlled by the pH measured in CIL tank 1 to maintain the
required pH in the CIL slurry.
Modes of Operation:
a) Remote Auto - the operator selects a CIL tank 1 pH set-point and the CIL lime addition
controller adjusts the open position time (seconds) of the pulsing CIL lime addition
valve. The closed position time (seconds) of the pulsing lime addition valve is closed.
b) Remote Manual - the operator selects the open position time (seconds) of the pulsing
CIL lime addition valve through the CIL tank 1 pH controller.
Mode r r
Tag Mode
Remote AIC8301 Auto Selection (XC8301) of AIC8301A To KC8301 to XV8301 pulse rate
or B
Set-point for AIC8301A/B
Process variable from
AIC8301A/B
AIC8301 Manual Nil KC8301 To XV8301 pulse rate
6.5.2 CIL Cyanide Addition

Objective:
Cyanide addition to CIL tank 1 is controlled by a cascade loop. The cyanide addition flow
meter set-point is calculated in the PLC. The PLC calculates the set-point based on the
concentrate thickener underflow mass flow derived from the measured slurry density and
volumetric flow. The cyanide solution concentration and required cyanide dosage
(expressed in g/t) is entered and the PLC calculates the desired cyanide solution flowrate
that cascades to the flow control loop as the flow set-point.
Modes of Operation:
a) Remote Auto 1 - the operator selects a ratio (entered as m³/h per t/h) of cyanide solution
to flotation concentrate thickener underflow tonnage flow rate. The PLC calculates a
flow set-point for the CIL cyanide addition flow rate controller. The flow controller
adjusts the position of the flow control valve to match the set-point.
b) Remote Auto 2 - the operator selects a flow set-point and the CIL cyanide addition flow
rate controller adjusts the position of the CIL cyanide flow control valve.
c) Remote Manual - the operator selects the position of the CIL cyanide flow control valve
through the CIL cyanide addition flow rate controller.
257422914.doc Page 59
Mode r r
Tag Mode
Remote FIC8303 Auto 1 Cyanide solution concentration To FCV-8303 positioner
Set-point for FIC8303 from
WIC3035
FIC8303 Auto 1 Set-point for FIC8303 To FCV-8303 positioner
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.
Mode r r
Tag Mode
Remote TIC8708 Auto Set-point for TIC8708 To elution heater burner controller
(vendor supply)
Process variable for TIC8708
TIC8708 Manual Nil To elution heater burner controller
(vendor supply)
6.7 Electrowinning
6.7.1 ILR Cell Tail Pump Hopper Level

Objective:
To prevent spillage of high value cyanide bearing solution in the goldroom, a high-level
alarm in the ILR cell tail pump hopper forces an isolation valve on the ILR electrowinning
cell feed pipeline to close and recirculates pregnant solution back into the ILR pump
hopper.
Modes of Operation:
a) Remote Auto
Mode r r
Tag Mode
Remote LAH8503 Auto LAH8503 activated XV6053 closed
257422914.doc Page 60
6.8.1 CIL Tails Pump Hopper Level

Objective:
Level of the CIL tails pump hopper is controlled to maintain required throughput.
Modes of Operation:
a) Remote Auto - the operator selects a CIL tails pump hopper level set-point and the level
controller adjusts the speed of the CIL tails pump.
b) Remote Manual - the operator selects the speed of the CIL tails pump through the CIL
tails pump hopper level controller.
Mode r r
Tag Mode
Remote LIC9007 Auto Set-point for LIC9007 To CIL tails pump VVVF drive
SC9022A/B
LIC9007 Manual Nil To CIL tails pump VVVF drive
SC9022A/B
6.8.2 Detox Lime Addition

Objective:
Lime slurry addition is controlled by the pH measured in the detox tank to maintain the
required pH in the detox tank slurry.
Modes of Operation:
a) Remote Auto - the operator selects a detox tank pH set-point and the detox lime
addition controller adjusts the open position time (seconds) of the pulsing detox lime
addition valve. The closed position time (seconds) of the pulsing lime addition valve is
closed.
b) Remote Manual - the operator selects the open position time (seconds) of the pulsing
detox lime addition valve through the detox tank pH controller.
Mode r r
Tag Mode
Remote AIC9001 Auto Selection (XC9001) of AIC9001A To KC9001 to XV9001 pulse rate
or B
Set-point for AIC9001A/B
Process variable from
AIC9001A/B
AIC9001 Manual Nil To KC9001 to XV9001 pulse rate
257422914.doc Page 61
7 SEQUENCES AND PROCEDURES
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 Crusher Plant Services Start Sequence

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 Sequence Comment
Step Delay
(sec)
Crusher area fan 10-FA-003 n/a Started simultaneously
HPGR & secondary screen area fan 10-FA-007
Crusher dust collector rotary valve 10-VV-001
Crusher dust collector 10-BH-001
Crusher dust collector ID fan 10-FA-017
HPGR & secondary screen dust screw 10-FE-010
feeder
HPGR & secondary screen dust 10-VV-002
collector rotary valve
HPGR & secondary screen dust 10-BH-001
collector
HPGR & secondary screen dust 10-FA-018
collector ID fan
257422914.doc Page 62
7.1.2 Crusher Plant Start-up Sequence
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.

Step Delay
(sec)
Secondary crusher feed bin feed 10-CV-002 n/a
conveyor
Fine ore bin feed conveyor 10-CV-003 5
Secondary screen 10-SC-001 5
Crusher magnet 10-MA-001 5
Crusher product conveyor 10-CV-001 5
Secondary cone crusher 10-CR-002 5
Primary jaw crusher 10-CR-001 5
Secondary crusher feeder 10-FE-002 5 Start with control loop LIC1015
in manual mode at minimum
output
Primary crusher feeder 10-FE-001 5 Start with control loop SC1002
at minimum output
7.1.3 Crusher Plant Shut-down Sequence

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.
Step Delay
(sec)
Primary crusher feeder 10-FE-001 n/a
Secondary crusher feeder 10-FE-002 Variable Stop at 20% on LIC1015
Crusher product conveyor 10-CV-001 60
Secondary screen 10-SC-001 40
Secondary crusher feed bin feed 10-CV-002 60 Delay to empty conveyors
conveyor
Stopped simultaneously
Fine ore bin feed conveyor 10-CV-003
Crusher magnet 10-MA-001 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 Crusher Plant Services Shut-down Sequence
by the operator clicking on the Crusher Plant Services sequence stop button.
Step Delay
(sec)
Crusher dust collector ID fan 10-FA-017 n/a Stopped simultaneously
Crusher dust collector 10-BH-001
Crusher dust collector rotary valve 10-VV-001
Crusher area fan 10-FA-003
HPGR & secondary screen dust 10-FA-018
collector ID fan
HPGR & secondary screen dust 10-BH-001
collector
HPGR & secondary screen dust 10-VV-002
collector rotary valve
HPGR & secondary screen dust screw 10-FE-010
feeder
HPGR & secondary screen area fan 10-FA-007
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 Grinding and Gravity

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 Grinding and Gravity Services Start-up Procedure

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)
257422914.doc Page 64
7.2.2 Gravity Circuit Start-up Procedure
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.
Step Delay
(sec)
Gravity concentrate transfer pump 20-PU-065 5 Select duty/standby
Ensure suction and delivery
pipes correctly connected in
field.
XV2066 closed
Spinner tails pump 20-PU-080 5
Spinner no 1 20-GC-005A 5 Simultaneous start
Spinner no 2 20-GC-005B
Spinner no 3 20-GC-006A
Primary jig no 1 20-GC-001 5 Field operator intervention
required to open hutch water
Primary jig no 2 20-GC-002 5 valves and bleed air
Primary jig no 3 20-GC-003 5
Gravity screen 20-SC-003 5 Field operator intervention
required to open spray valves
Primary jig no 1 feed valve open XV2017 0 Simultaneous open
Primary jig no 2 feed valve open XV2018
Primary jig no 3 feed valve open XV2019
Mill pump 20-PU-003 5 Select duty/standby
Cyclone pump 20-PU-004 5 Select duty/standby
Centrifugal concentrator no 1 20-GC-004 5 Start with XV2046 closed.
Open XV2046 manually after
completion of HPGR sequence
start.
257422914.doc Page 65
7.2.3 HPGR Start-up Procedure
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.
Step Delay
(sec)
Mill feed, seal & trommel spray water XV2093 n/a Actuated valve opened
valve
Ball mill 20-ML-001 5 Refer Outokumpu design
document 7330-DD01 Rev0
Ball mill screen 20-SC-002 5 Open spray valves in field
Mill screen oversize conveyor 10-CV-006 5
Mill feed conveyor 10-CV-005 5
HPGR 10-CR-003 n/a
HPGR feed conveyor 10-CV-004 10
Fine ore bin belt feeder 10-FE-003 5 Start in manual mode -
minimum output
Flocculant dosing pump A/B 60-PU-043A/B 30 Select duty/standby
Feeds float feed thickener
7.2.4 HPGR Shut-down Procedure

The procedure covers shut-down of the HPGR section. The PLC controlled function group shut-
down sequence will be initiated from the SCADA screen by the operator clicking on the HPGR
sequence stop button.
Step Delay
(sec)
Fine ore bin belt feeder 10-FE-003 n/a Delay to empty conveyor
HPGR feed conveyor 10-CV-004 100 Delay to empty conveyor
HPGR 10-CR-003 100 Delay to empty HPGR feed bin
Mill feed conveyor 10-CV-005 100 Delay to empty conveyor
Mill screen oversize conveyor 10-CV-006 100 Delay to empty conveyor
257422914.doc Page 66
7.2.5 Gravity Shut-down Procedure
The procedure covers shut-down of the Gravity section.
by the operator clicking on the Gravity sequence stop button.
Step Delay
(sec)
Purge Mill Screen Gold Trap XV2001 & 2 n/a The operator selects a purge
cycle through the controller
Ball mill screen 20-SC-002 15 Close spray valves in field
Primary jig no 1 feed valve close XV2017 0 Simultaneous closure
Primary jig no 2 feed valve close XV2018
Primary jig no 3 feed valve close XV2019
Mill pump 20-PU-003 0
Primary jig no 1 20-GC-001 120 Simultaneous shut-down after
jigs flushed.
Primary jig no 2 20-GC-002
Field operator intervention
Primary jig no 3 20-GC-003 required to close hutch water
valves
Spinner no 1 20-GC-005A 20 Simultaneous shut-down
Spinner no 3 20-GC-006A
Spinner tails pump 20-PU-080 5
Gravity screen 20-SC-003 5 Close spray valves in field
Centrifugal concentrator no 1 feed XV2046 30 Delay to empty screen
valve closed underpan
Centrifugal concentrator no 1 20-GC-004 30 Stop initiates a controlled
shutdown and timed rinse
Ball mill 20-ML-001 5 Refer Outokumpu design
document 7330-DD01 Rev0
Mill feed, seal and trommel spray water XV2093 n/a
valve close
Flocculant dosing pump A/B 60-PU-043A/B 5
Cyclone pump 20-PU-004 5
7.2.6 Grinding and Gravity Services Shut-down

The following equipment items are stopped individually at the relevant point, during the shut-
down procedure, if a prolonged shut down (longer than 15 minutes) is anticipated and the
flotation and CIL AND Detox section are not operating:
257422914.doc Page 67
7.3 Flotation
7.3.1 Flotation Services Start-up

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:
7.3.2 Flotation Start-up Procedure

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.
257422914.doc Page 68
Drive Description Drive Number Comment
Open flotation cell launder sprays n/a Field operator action
water valves
Flotation cell no 1 30-FC-001 Field operator action
Flotation concentrate pump 30-PU-008 Select duty/standby
Flotation feed thickener underflow 30-PU-006 Select duty/standby
pump
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
Collector dosing pump 60-PU-038 Select duty/standby
minimum output
Copper sulphate dosing pump A/B 60-PU-039A/B Select duty/standby
minimum output
Flotation tail thickener underflow pump 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)
Sand pump hopper dilution water valve FCV4039 Place Sand Pump Delivery
Slurry Density control loop in
Remote Manual mode and fully
open the sand pump hopper
dilution water flow control valve
Sand pump 1 40-PU-072 Select duty/standby
Sand pump 2 40-PU-073 Select duty/standby
Flotation tail pump 30-PU-007 Select duty/standby
Flotation tails concentrator 50-GC-009
Flocculant dosing pump B/E 60-PU-043B/E Select duty/standby
Feeds float tail thickener
257422914.doc Page 69
Flocculant dosing pump C/D 60-PU-043C/D Select duty/standby
Feeds Concentrate thickener
7.3.3 Flotation Shut-down Procedure

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.
Flotation feed thickener underflow 30-PU-006 Maybe left running on circuit
pump shutdown in recirculation mode
if XV3013 open & XV3014
closed
Flocculant dosing pump B/E 60-PU-043BE
Flocculant dosing pump C 60-PU-043C/D
Flotation tail pump 30-PU-007
Flotation tails concentrator 50-GC-009
Flotation tail thickener underflow pump 40-PU-013 Maybe left running on circuit
shutdown in recirculation mode
if XV4011 open & XV4013
closed
Sand pump 2 40-PU-073 Allow line to flush. Delay
maybe shortened if DIC <= 1.00
Sand pump 1 40-PU-072
Open flotation cell launder sprays n/a Field operator action
water valves
Flotation concentrate pump 30-PU-008
Close flotation cell launder spray water n/a Field operator action
valves
257422914.doc Page 70
7.3.4 Flotation Plant Services Shut-down
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:
7.4 CIL and Detox
7.4.1 CIL and Detox Services Start-up

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:
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 CIL and Detox Start-up Procedure

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
CIL tails pump 90-PU-022 Dilution water valve must be
opened manually by field
operator
Carbon safety screen 90-SC-014 Screen spray water must be
operator
Trash screen underflow pump 83-PU-079 Select duty/standby
Trash screen 80-SC-005 Screen spray water must be
operator
SMBS pump 60-PU-067 Select duty/standby
minimum output
Copper sulphate dosing pump B/C 60-PU-039B/C Select duty/standby
minimum output
Flotation concentrate thickener 30-PU-010 Select duty/standby
underflow pump
ILR n/a System stopped or left in
internal recycle
7.4.3 CIL and Detox Shut-down Procedure

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.
Flotation concentrate thickener 30-PU-010
underflow pump
ILR n/a System stops and goes into
internal recycle
Trash screen 80-SC-005 Screen spray water must be
closed manually by field
operator
Trash screen underflow pump 83-PU-079
Carbon safety screen 90-SC-014 Screen spray water must be
operator
CIL tails pump 90-PU-022 Dilution water valve must be left
opened to flush line
SMBS pump 60-PU-067
Copper sulphate dosing pump B/C 60-PU-039B/C
257422914.doc Page 72
7.4.4 CIL and Detox Services Shut-down
The following equipment items are stopped individually at the relevant point, during the shut-
down 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.
257422914.doc Page 73
7.5 Acid Wash Procedures
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 Pre-Rinse

Close acid wash column carbon filling valve.
Ensure acid wash pump delivery valve to the column is closed.
Ensure acid wash column floor drain, back drain and carbon outlet valves are closed.
Select which acid wash strainer is to be used and open selected strainer inlet and outlet valves.
Open acid wash column solution inlet valve.
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 carbon to rinse for the required period.
Close acid wash rinse discharge valve and open acid wash recycle valve.
7.5.2 Acid Wash

Check acid wash tank level and acid strength.
If fresh dilute acid solution is to be made-up, refer to section 7.5.6 before proceeding.
If the acid wash tank is to be topped-up, refer to section 7.5.7 before proceeding.
Open acid wash pump suction and delivery isolation valves.
Open acid wash pump delivery valve to the column.
Start acid wash pump and allow dilute acid to circulate for required period.
Stop acid wash pump and close acid wash pump delivery to column inlet valve.
Close acid wash pump suction and delivery isolation valves.
Open acid wash column back drain valve and allow acid in the column to drain back to the tank.
Close acid wash column back drain valve.
7.5.3 Post Acid Wash Rinse

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.
257422914.doc Page 74
7.5.4 Carbon Transfer to Elution Column
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 Acid Wash Solution Neutralisation and Disposal

Open acid wash sodium hydroxide addition valve.
Ensure elution sodium hydroxide addition valve is closed.
Start sodium hydroxide pump and run for the required period.
Ensure acid wash column solution inlet valve is closed.
Open acid wash pump delivery valve to the column and acid wash column back drain valve.
Open acid wash pump suction and delivery isolation valves.
Start acid wash pump and allow mixture to circulate back to the tank for the required period.
Check pH of acid wash tank contents is neutral or slightly alkaline.
Open acid wash disposal valve and close acid wash pump delivery to column valve and check
for neutralised spent acid flow at the CIL tails pump hopper.
The acid wash pump will stop by interlock when the acid wash tank reaches a low level.
257422914.doc Page 75
7.5.6 Dilute Acid Make up
Check acid wash tank is empty.
Open acid wash tank raw water addition valve and partially fill the tank.
Close acid wash tank raw water addition valve.
Start hydrochloric acid offload pump and run for the required period.
Stop hydrochloric acid offload pump.
Re-open the acid wash tank raw water addition valve and fill the tank.
Check acid wash tank level and dilute acid concentration.
7.5.7 Dilute Acid Top-up

Check acid wash tank level and dilute acid concentration.
Start hydrochloric acid offload pump and run for the required period.
Recheck acid wash tank level and acid strength.
Repeat acid addition if required.
Open acid wash tank raw water addition valve and fill the tank.
7.6 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

Ensure elution column carbon filling valve is closed.
Ensure a spent eluate disposal valve is closed.
If fresh eluate solution is to be made-up, refer to section 7.6.2 before proceeding.
Check sodium hydroxide and cyanide concentrations in the eluate and if required refer to section
7.6.3 to correct them.
Select which elution strainer is to be used. Open strainer inlet and outlet valves.
Open recovery heat exchanger inlet and outlet isolation valves.
Open elution heater inlet and outlet isolation valves.
Ensure transfer water recycle valve at the inlet to the heat exchanger is closed.
Ensure electrowinning cell drain and decant valves are closed and cell is ready to start elution
i.e. busbars connected, hood in place and ventilation (goldroom scrubber) system running.
Open elution pump suction and delivery isolation valves.
Start elution pump.
Switch on elution heater.
Switch on CIL electrowinning rectifier.
Monitor temperatures and differential pressures using installed gauges around the circuit.
Confirm eluant temperature reaches the set-point.
257422914.doc Page 76
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 Fresh Eluate Make Up Procedure

Check elution tank is empty.
Open elution tank raw water addition valve and partially fill the tank.
Close elution tank raw water addition valve.
Open elution sodium hydroxide addition valve.
Ensure acid wash sodium hydroxide addition valve is closed.
Stop sodium hydroxide pump.
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.
Re-open elution tank raw water addition valve and fill the tank.
7.6.3 Eluate Concentration Correction Procedure

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.
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.
257422914.doc Page 77
7.6.4 Eluted Carbon Transfer Procedure
Close elution heater outlet isolation valve.
Close elution strainer inlet valve.
If carbon is to bypass the regeneration kiln, open eluted carbon screen bypass valve, close the
eluted carbon screen feed valve and switch on the regen carbon screen and open the carbon
quench pan water valve.
If carbon is to be regenerated ensure eluted carbon screen feed valve is open and eluted carbon
screen bypass valve is closed and check availability of space in the kiln feed hopper.
Open transfer water valves to elution column and carbon outlet.
Start transfer water pump.
Open elution column carbon outlet valve.
Allow carbon to transfer for the required period (i.e. until all carbon is transferred)
Close elution column carbon outlet valve.
Close transfer water valves to elution column and carbon outlet.
Stop transfer water pump.
7.6.5 Spent Eluate Disposal

Check space is available in the spent eluate tank.
Open spent eluate disposal valve.
Close recovery heat exchanger inlet valve is closed.
Start elution pump.
The elution pump will stop by interlock when the elution tank reaches a low level.
Close spent eluate disposal valve.
Open recovery heat exchanger inlet valve.
257422914.doc Page 78
ERROR: REFERENCE SOURCE NOT FOUND APPENDICES
APPENDIX 1
SCHEDULE OF ALARMS
16/01/15257422914.doc Appendix 1 Page 79


Description Alarm
Category
BH-001 crushing area dust collector ID fan failure 3
BN-001 ROM bin high level 3
BN-001 ROM bin low-low level 2
BN-002 fine ore bin high level 3
BN-002 fine ore bin high-high level 2
BN-002 secondary crusher feed bin high level 2
BN-002 secondary crusher feed bin high-high level 2
BN-005 HPGR feed bin diverter gate valve 1 closed 3
BN-005 HPGR feed bin diverter gate valve 1 open 3
BN-005 HPGR feed bin high level 3
BN-005 HPGR feed bin high-high level 2
CR-001 primary jaw crusher high level 2
CR-001 primary jaw crusher motor current high 3
CR-002 secondary cone crusher high level 2
CR-002 secondary cone crusher motor current low 3
Crusher spillage sump flood warning 3
Crusher spillage sump high level 2
CV-001 crusher product conveyor belt drift switch A (head lhs) 3
CV-001 crusher product conveyor belt drift switch B (head rhs) 3
CV-001 crusher product conveyor belt drift switch C (tail lhs) 3
CV-001 crusher product conveyor belt drift switch D (tail rhs) 3
CV-001 crusher product conveyor belt rip detector A 3
CV-001 crusher product conveyor belt rip detector B 3
CV-001 crusher product conveyor pull wire switch A (walkway side) 2
CV-001 crusher product conveyor pull wire switch B (non-walkway side) 2
CV-001 crusher product conveyor start-up warning system 3
CV-001 crusher product conveyor underspeed switch 3
CV-002 secondary crusher bin feed conveyor belt drift switch A (head lhs) 3
CV-002 secondary crusher bin feed conveyor belt drift switch B (head rhs) 3
CV-002 secondary crusher bin feed conveyor belt drift switch C (tail lhs) 3
CV-002 secondary crusher bin feed conveyor belt drift switch D (tail rhs) 3
CV-002 secondary crusher bin feed conveyor pull wire switch A (walkway side) 2
CV-002 secondary crusher bin feed conveyor pull wire switch B (non-walkway side) 2
CV-002 secondary crusher bin feed conveyor start-up warning system 3
CV-002 secondary crusher bin feed conveyor underspeed switch 3
CV-003 fine ore bin feed conveyor belt drift switch A (head lhs) 3
CV-003 fine ore bin feed conveyor belt drift switch B (head lhs) 3
CV-003 fine ore bin feed conveyor belt drift switch B (head rhs) 3
CV-003 fine ore bin feed conveyor belt drift switch B (tail rhs) 3
CV-003 fine ore bin feed conveyor pull wire switch A (walkway side) 2

Description Alarm
Category
CV-003 fine ore bin feed conveyor pull wire switch B (non-walkway side) 2
CV-003 fine ore bin feed conveyor start-up warning system 3
CV-003 fine ore bin feed conveyor underspeed switch 3
CV-004 HPGR feed conveyor belt drift switch A (head lhs) 3
CV-004 HPGR feed conveyor belt drift switch B (head rhs) 3
CV-004 HPGR feed conveyor belt drift switch C (tail lhs) 3
CV-004 HPGR feed conveyor belt drift switch D (tail rhs) 3
CV-004 HPGR feed conveyor pull wire switch A (walkway side) 2
CV-004 HPGR feed conveyor pull wire switch B (non-walkway side) 2
CV-004 HPGR feed conveyor start-up warning system 3
CV-004 HPGR feed conveyor underspeed switch 3
FA-003 crusher area fan low air flow switch 1
MA-002 HPGR magnet hoist down limit switch 3
MA-002 HPGR magnet hoist up limit switch 3
MA-002 HPGR magnet trolley in limit switch 3
MA-002 HPGR magnet trolley out limit switch 3
MD-002 HPGR metal detector 1 metal detected 2
MD-003 HPGR metal detector 2 metal detected 2
Secondary crusher metal detector metal detected 2
Stormwater collection pond flood warning 3
Stormwater collection pond high level 2
CH-030 Ball Mill Screen feed box high 2
CV-005 mill feed conveyor belt drift switch A (head lhs) 3
CV-005 mill feed conveyor belt drift switch B (head rhs) 3
CV-005 mill feed conveyor belt drift switch C (tail lhs) 3
CV-005 mill feed conveyor belt drift switch D (tail rhs) 3
CV-005 mill feed conveyor pull wire switch A (walkway side) 2
CV-005 mill feed conveyor pull wire switch B (non-walkway side) 2
CV-005 mill feed conveyor start-up warning system 3
CV-005 mill feed conveyor underspeed switch 3
CV-006 mill screen oversize conveyor belt drift switch A (head lhs) 3
CV-006 mill screen oversize conveyor belt drift switch B (head rhs) 3
CV-006 mill screen oversize conveyor belt drift switch C (tail lhs) 3
CV-006 mill screen oversize conveyor belt drift switch D (tail rhs) 3
CV-006 mill screen oversize conveyor pull wire switch (non-walkway side) 2
CV-006 mill screen oversize conveyor pull wire switch (walkway side) 2
CV-006 mill screen oversize conveyor start-up warning system 3
CV-006 mill screen oversize conveyor underspeed switch 3
FE-003 fine ore bin belt feeder belt drift switch A (head lhs) 3
FE-003 fine ore bin belt feeder belt drift switch B (head rhs) 3

Description Alarm
Category
FE-003 fine ore bin belt feeder belt drift switch C (tail lhs) 3
FE-003 fine ore bin belt feeder belt drift switch D (tail rhs) 3
FE-003 fine ore bin belt feeder pull wire switch A (lhs) 2
FE-003 fine ore bin belt feeder pull wire switch B (rhs) 2
FE-003 fine ore bin belt feeder start-up warning system 3
FE-003 fine ore bin belt feeder underspeed switch 3
HP-001 mill pump hopper high level 3
HP-001 mill pump hopper low level 3
HP-002 cyclone pump hopper high level 3
HP-002 cyclone pump hopper high-high level 3
HP-002 cyclone pump hopper low level 2
HP-010 gravity concentrate surge tank high level 2
HP-010 gravity concentrate surge tank high-high level 2
HP-010 gravity concentrate surge tank low level 2
Jig feed distributor density high 3
Jig feed distributor density low 3
Primary cyclone feed density high 3
Primary cyclone feed density low 3
PU-003A mill pump A gland water low flow 3
PU-003B mill pump B gland water low flow 3
PU-004A cyclone pump A gland water low flow 3
PU-004B cyclone pump B gland water low flow 3
PU-005 mill spillage sump high level 2
PU-074 mill spillage sump 2 high level 2
XM-001 ball mill screen gold trap discharge valve 1 closed 3
XM-001 ball mill screen gold trap discharge valve 1 open 3
XM-001 ball mill screen gold trap discharge valve 2 closed 3
XM-001 ball mill screen gold trap discharge valve 2 open 3
Concentrate thickener underflow density high 3
Concentrate thickener underflow density low 3
Concentrate thickener bed level high 3
Concentrate thickener bed level low 3
CY-001 mill cyclone pressure high 3
CY-001 mill cyclone pressure low 3
CY-002 sand cyclone inlet pressure high 3
CY-002 sand cyclone inlet pressure low 3
CY-001 cyclone underflow launder high level 2
DB-001 jig feed distributor pressure high 3
DB-001 jig feed distributor pressure low 3
Flotation feed thickener underflow density high 3

Description Alarm
Category
Flotation feed thickener underflow density low 3
Flotation feed thickener bed level high 3
Flotation feed thickener bed level low 3
PU-006A float feed thickener underflow pump A gland water low flow 3
PU-006B float feed thickener underflow pump B gland water low flow 3
PU-007A flotation tail pump 1 gland water low flow 3
PU-007B flotation tail pump 2 gland water low flow 3
PU-009 flotation spillage sump 1 high level 2
PU-011 float concentrate spillage sump high level 2
PU-055 float feed thickener spillage sump high level 2
PU-077 flotation spillage sump 2 high level 2
PU-081 flotation tails sampler transfer sump high level 3
SC-003 gravity screen underflow chute discharge valve closed 3
SC-003 gravity screen underflow chute discharge valve open 3
Flotation tails thickener underflow density high 3
Flotation tails thickener underflow density low 3
Flotation tails thickener bed level high 3
Flotation tails thickener bed level low 3
Flotation tails to east flotation TSF dam pipeline pressure high 3
Flotation tails to east flotation TSF dam pipeline pressure low 3
HP-003 flotation tail pump hopper high level 3
HP-003 flotation tail pump hopper high-high level 3
HP-003 flotation tail pump hopper low level 3
HP-018 sand pump hopper low level 3
HP-018 sand pump hopper low-low level 2
PU-012 flotation tails thickener spillage sump high level 2
PU-013A float tails thickener underflow pump A gland water low flow 3
PU-013B float tails thickener underflow pump B gland water low flow 3
PU-072A sand pump 1A gland water low flow 3
PU-072B sand pump 1B gland water low flow 3
PU-073A sand pump 2A gland water low flow 3
PU-073B sand pump 2B gland water low flow 3
Sand pump discharge pipeline pressure A high 3
Sand pump discharge pipeline pressure A low 3
Sand pump discharge pipeline pressure B high 3
Sand pump discharge pipeline pressure B low 3
PU-015 goldroom spillage sump high level 2
PV-001 pan filtrate receiver high level 2
Smelting furnace hood high differential pressure high 3
CM-001 acid wash column high level 3

Description Alarm
Category
Flocculant system fault 2
HP-019 collector stand pipe low level 3
HP-020 frother stand pipe low level 3
HP-021 sodium hydroxide stand pipe high level 3
HP-022 hydrochloric acid stand pipe high level 3
HP-024 trash screen underflow hopper low level 3
HP-024 trash screen underflow hopper high level 3
HP-024 trash screen underflow hopper high-high level 2
hydrochloric acid sump high level 3
PU-048 reagents spillage sump 1 high level 2
PU-049 reagents spillage sump 2 high level 2
PU-075 flocculant spillage sump high level 3
TK-023 copper sulphate tank low level 3
Flotation blower low pressure air pressure low 3
Potable water jockey pump low flow 3
PU-032 gland water pressure low 2
PU-076 CIL water tank spillage sump high level 2
PV-003 plant air receiver pressure low 3
PV-004 mill air receiver pressure low 3
TK-019 raw water tank low level 3
TK-020 process water tank high level 2
TK-020 process water tank low level 2
TK-020 process water tank low-low level 3
PU-016 ILR spillage sump high level 2
CIL differential pH high 3
PU-018 CIL spillage sump high level 2
HP-017 ILR cell tail pump hopper high level 2
PU-030 electrowinning spillage sump high level 2
CIL tanks area HCN gas high 1
FA-012/013 CIL tanks area vent failure 1
FA-014/015/016 CIL tanks area vent failure 1
HE-001 elution heater discharge temperature high 3
Kiln package fault 2
PU-026 acid wash spillage sump high level 3
TK-013 elution tank high level 3
TK-013 elution tank low level 2
TK-013 elution tank low-low level 2
TK-014 acid wash tank high level 2
TK-014 acid wash tank low level 2
CIL/Detox area HCN gas high 1

Description Alarm
Category
Detox differential pH high 3
Detox differential pH low 3
HP-007 CIL tails pump hopper low level 2
PU-021 detox spillage sump high level 2
PU-022A CIL tails pump A gland water low flow 3
PU-022B CIL tails pump B gland water low flow 3

APPENDICES
APPENDIX 2
PIPING & INSTRUMENTATION DIAGRAMS
257422914.doc Appendix 2 Page 87

APPENDICES
REFERENCE DOCUMENTS & DRAWINGS

Name Number Revision Source
CRUSHING AND SCREENING AREA 1475-P-051 1 Ausenco
HPGR 1475-P-052 1 Ausenco
GRINDING GRAVITY CIRCUIT - SHEET 1 OF 3 1475-P-053 2 Ausenco
GRINDING 1475-P-055 0 Ausenco
FLOTATION FEED THICKENER 1475-P-056 2 Ausenco
FLOTATION 1475-P-057 2 Ausenco
CONCENTRATE THICKENER 1475-P-058 1 Ausenco
FLOTATION TAILINGS - SHEET 1 1475-P-059 2 Ausenco
FLOTATION TAILINGS - SHEET 2 1475-P-060 2 Ausenco
GOLDROOM GRAVITY AREA 1475-P-061 1 Ausenco
GOLDROOM SMELTING 1475-P-062 2 Ausenco
REAGENTS AND CONSUMABLES SHEET 1 OF 4 1475-P-063 1 Ausenco
SERVICES - WATER SHEET 1 1475-P-067 2 Ausenco
SERVICES - WATER SHEET 2 1475-P-068 2 Ausenco
SERVICES - AIR 1475-P-069 2 Ausenco
GRAVITY CONCENTRATE LEACHING 1475-P-070 2 Ausenco
FLOTATION CONCENTRATE LEACHING SHEET 1 1475-P-071 2 Ausenco
FLOTATION CONCENTRATE LEACHING SHEET 2 1475-P-072 2 Ausenco
ACID WASH 1475-P-073 2 Ausenco
ELUTION 1475-P-074 2 Ausenco
CARBON REGENERATION 1475-P-075 2 Ausenco
ELECTROWINNING 1475-P-076 2 Ausenco
CYANIDE DETOXIFICATION SHEET 1 1475-P-077 2 Ausenco
CYANIDE DETOXIFICATION SHEET 2 1475-P-078 2 Ausenco
FIRE WATER RETICULATION 1475-P-080 1 Ausenco
SERVICES - PROCESS WATER 1475-P-081 1 Ausenco
SERVICES - RAW WATER 1475-P-082 2 Ausenco
SERVICES - SAFETY SHOWER WATER (SW) 1475-P-083 2 Ausenco
SERVICES - CIL SPRAY WATER (CW) 1475-P-084 2 Ausenco
SERVICES - GLAND WATER (GW) 1475-P-085 2 Ausenco
SERVICES - TRANSFER WATER (TW) 1475-P-086 0 Ausenco
SERVICES - INSTRUMENT AIR (IA) 1475-P-087 1 Ausenco
257422914.doc Appendix 2 Page 88

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BENDIGO MINING LIMITED

BENDIGO GOLD PROJECT

PROCESS CONTROL PHILOSOPHY

Document No. Rev.

REV. DATE DESCRIPTION AUTHOR APPROVED

A 25-01-05 DRAFT FOR REVIEW TH

3.1 Control System

4 PROCESS PLANT CONTROL PHILOSOPHY

5 PERMISSIVES AND INTERLOCKS

6 PROCESS CONTROL LOOPS

257422914.doc Contents Page 1

7 SEQUENCES AND PROCEDURES

APPENDIX 1 SCHEDULE OF ALARMS

APPENDIX 2 PIPING & INSTRUMENTATION DIAGRAMS

257422914.doc Contents Page 2

 Grinding and gravity concentration

 Cyanidation of gravity and flotation concentrates

 Acid washing and elution of loaded carbon

 Regeneration of eluted carbon

 Detoxification of cyanidation tailings slurry

 Electrowinning and smelting of doré bullion

 Reagent mixing, storage and distribution

3.1 Control System

 collect status information of drives, process instrumentation and packaged equipment;

 provide drive control and process interlocking; and

 perform PID control for process control loops.

RED Valve closed

3.2.1 Auto Mode

3.2.2 Manual Mode

3.2.3 Maintenance Mode

Switching of the drive mode from MAINTENANCE to MANUAL mode or MAINTENANCE to

3.2.4 General Features

 Maintenance Mode = turquoise.

 Manual = pale blue.

 Auto = clear (no colour)

The drives depicted on the mimic pages change colour to denote:

 Drive Stopped and Ready for Start = Red

 Drive Running = Green

 Drive Faulted = Yellow

 Drive Interlock is present = Orange.

3.2.5 Bypass Interlocks in auto or manual mode

3.4 Common Functions

3.4.3 Pump Hopper Levels

3.4.5 Dust Collectors

3.4.6 Spillage Sump Pumps

3.4.7 Positive Displacement Pumps

3.4.8 Gland Seal Water

3.4.9 Safety Showers

 Detox tank agitator

3.4.11 Mass Flow Measurement

3.4.13 Cranes and Hoists

4 PROCESS PLANT CONTROL PHILOSOPHY

4.2 Fine Ore Bin, HPGR, Grinding and Gravity

4.2.1 Fine Ore Bin & HPGR

4.3.1 Flotation Feed Thickener

4.3.3 Concentrate Thickener

4.3.4 Flotation Tailings

4.3.6 Shaking Tables

4.3.7 Goldroom - Smelting

4.4 Reagents and Consumables

4.4.2 Copper Sulphate

4.4.4 Sodium Cyanide

4.4.5 Sodium Hydroxide

4.4.6 Hydrochloric Acid