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A dynamic model of the gold leaching and adsorption on activated carbon

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Conference Paper · November 2005

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 ADYNAMIC MODEL OF THE GOLD LEACHINGAND
ADSORPTION ON ACTIVATED CARBON PROCESS
Luiz Rogério P. de Andrade Lima
Departamento de Ciência e Tecnologia dos Materiais
Universidade Federal da Bahia
CP 6974, Salvador-BA,'Brazil, 4 I I I 0-970
e-mail: lelo@uJba.br

Carbon-in-pulp and carbon-in-leach are continuous processes that have been wide used in gold extraction plants. These
processes occur in a cascade of larger agitated tanks, and the carbon-in-pulp process follows the leaching cascade
section of the plant. In the carbon-in-leach process the gold leaching occurs simultaneously with the adsorption of the
aurocyanide ion on activated carbon. In both processes the activated carbon is moved from a tank to another in
countercurrent with the ore pulp until the recovery of the loaded carbon in the first tank. This paper presents a dynamic
model that describes the carbon-in-1each, the carbon-in-pulp and the gold leaching processes. This model is numerically
solved and calibrated with experimental data of a plant, and the calibrated model is used to perform a study of the effect
ofthe activated carbon transfer strategy on the performance ofthe adsorption section ofa plant. Based on the calculated
values of the gold loss in the liquid and on the gold recovered in the loaded activated carbon that leaves the circuit, the
results indicate that the strategies in which an important amount of activated carbon is held in the first tanks and the
contact time between the carbon and the pulp is larger are the most recommended carbon transfer strategies for these
processes.
Keywords: Activated carbon; Adsorption; Gold; Leaching; Modeling

Adsorção em carvão ativado, juntamente com lixiviação, tem sido amplamente usados em usinas de extração de ouro.
Estes processos ocoÍrem de forma continua em cascatas de grandes reatores agitados. A etapa de lixiviação do ouro
precede o processo de carvão-em-polpa, mas no processo de carvão-em-lixiviação a dissolução do ouro ocorre
simultaneamente com a adsorção do íon aurocianeto no carvão ativado. Em ambos processos, o carvão ativado é
movido de forma intermitente de um tanque para o tanque precedente, em contracorrente com a polpa de minério, até a
sua recuperação no primeiro tanque quando está rico em ouro. Este artigo apresenta um modelo dinâmico que descreve
tanto o processo de carvão-em-lixiviação, quanto os processos de carvão-em-polpa ou apenas lixiviação de ouro. Este
modelo é resolvido numericamente e calibrado com dados experimentais de uma usina, em seguida o modelo calibrado
é usado para o estudo do efeito da estratégia de transferência do carvão ativado no desempenho da seção de adsorção da
usina. Baseado na perda de ouro na solução que deixa o circuito de adsorção e na recuperação do ouro no carvão
ativado retirado do circuito, os resultados indicam que as estratégias de transferência de carvão ativado mais
recomendadas para este processo são as que mantêm uma grande quantidade de carvão ativado retido nos primeiros
tanques da usina e um longo tempo de contato entre a polpa de minério e o carvão ativado.

1. INTRODUCTION the reactor and the activated carbon transfer description

Leaching of ores by cyanide in aerated alkaline slurries can be improved and it is the object of the present work.
and metal recovery by adsorption on activated carbon has A typical gold ore processing plant is composed of the
been the dominant processes for gold extraction. The following sequence of unit operations: ore comminution,
continuous processes to gold recovery by adsorption on size classification, gravity concentration, and slurry
activated carbon in agitated tanks, namely carbon-in-pulp dewatering, followed by gold leaching and gold recovery
(CIP) and carbon in leach (CIL), have been widely used on activated carbon, and f,rnally gold elution, electrolytic
since the l970s.t-5 Due to the economic importance of the extraction, melting and casting.i-3
gold extraction industry, the kinetic, the mathematical It is widely accepted that the gold cyanidation is an
modeling and the simulation of these processes have electrochemical process, in which the gold is oxidized and
received larger attention since the 1980s, specially in then complexed to the stable complex ion [Au(CN)2]-, the
South Africa, Australia, and Canada, which have provided oxygen is simultaneously reduced, and hydrogen peroxide
useful insights for process operation and optimization.6-27 decomposed, leading to the following overall reactions:1-3
However, some aspects of the available models, such as,

2Au +O, +4CN - +2HrO-+2 [a"(CN), ]- * zOH- +H2O, (1)

2Au+4CN- +H2O2 -+ 2 [Au(CN), ]- +2OH (2)

In spite the wide industrial use of the gold adsorption on with the increasing of the temperature this process is
activated carbon, there is no consensus regarding the physical. The reaction heat is about 40 kJ/mole and the
mechanism of this process.2-s'28'2e Some authors claim that activation energy is about 8.4 to 13.8 kJ/mole, which is
due the fact that the amount of gold adsorbed decreases low and seems to indicate that the kinetic of aurocyanide

126
adsorption in activated carbon is a process controlled by general dynamic model that can be used to describe the
diffusion in the pores and in the external film.r carbon-in-leach process, but can also be easily simpliÍied
The activated carbon has an structure analogous to to describe the carbon-in-pulp and the gold leaching
graphite, but less organized and with a larger separation processes. This work is signif,rcant because the reactor
between the graphene layers, and at the end ofthe carbon description used here is more realistic than that used in
chains there are the activated sites that seem to play an most of the available models due úe fact that the time
important role during the gold complex ions adsorption; evolution ofthe solid, liquid and activated carbon holdups
these groups are organic radicals such as carboxylic acid (- are taken into account, and the carbon transfer from a
COOH), esters (-COOC-), phenol (-CaIIa-OA, quinone (- reactor to another one is assumed as a transient process in
CeItoO), and hydroxyl (-OÍt).+'t'" Some authors have contrast with the commonly used instantaneous transfer
proposed mechanisms, such as the formation of a ion pair assumption.
M'*[Au(CN)2]n, where Mn* could be Ct*, Mg2*, H*, Li*, This paper is organized as follows. Section 2 presents the
Na*, and K*, and the subsequent partial reduction of the kinetic models for the gold cyanidation and the gold
gold aurocyanide complex ion to Au(CN)*.5'28 However, adsorption on activated carbon processes, and the
other studies demonstrated that the aurocyanide complex mathematical model for the reactor. Section 3 presents the
ion adsorbed without any chemical modification and calibration of the model for the leaching and the
questioned the valid§ of the ion pair theory.28'2e More adsorption sections of a plant. Section 4 presents a case
reÇently, some studies demonstrated that the adsorption of study of the simulator with an analysis of the activated
aurocyanide ion on activated carbon is related to the carbon transfer strategies. Section 5 presents the
electronic structure of the ion and occurs through the conclusions.
electron donation via p orbital; therefore, this process
depends on factors such as the solution equilibria, the 2. GOVERNTNGEQUATTONS
bonding in the gold-cyanide complex, and the carbon The detailed mathematical description of the simultaneous
porous structure.28 gold leaching and adsorption on activated carbon that
The CIP and CIL processes use granulated activated occurs in the carbon-in-leach process has some intrinsic
carbon that is mixed with the pulp, composed by ore and complexity such as the heterogeneous nature of the system
water, and after be loaded with úe aurocyanide ion, the that includes ore, activated carbon, aqueous solution, and
reach activated carbon is pumped out to the adsorption gas; also there are several physical and chemical
circuit and send to the elution process. The main phenomena that happen at the same time. In this section a
difference between the CIL and CIP processes is that in model that includes the description of the leaching and
the latter leaching and adsorption happen simultaneously adsorption on the carbon kinetics and the reactor is
while in the former the gold dissolution is already finished presented. In the next section the calibration and the use of
when the adsorption starts. The CIL process is used to this model is discussed.
treat ores containing organic matter and preg-robbing The reactor model presented in this study can easily
species, while CIP is used in the general case. include the kinetic equations mentioned in the previous
The CIL and CIP are slow processes and in order to section to describe the competitive adsorption, carbon
accelerate the gold recovery they occur continuously in a fouling by organics and fine particles, carbon loading
cascade of large agitated tanks. Figure 1 schematically distribution, carbon loss by athition, and preg-rubbing;
shows the CIL or CIP circuit with three reactors. Note that however, in this study for the sake of conciseness only two
in these reactors the pulp flow is by gravity from a simple models for gold leaching, cyanide consumption,
previous tank and flo.ws to the next by overflow, the fresh and adsorption on activated carbon kinetics will be
activated carbon is added in the last tank and the carbon presented. These models will be calibrated with data from
moves intermittently in countercurrent with the pulp a plant and the resulting equations used to perform an
towards the elution process, and due the fact that its size is evaluation of the carbon transfer strategy that will be
much larger than the ore particles, it can be easily discussed in the next section.
separated by screening. Note also in Fig. I that there are
screens in the reactor exit that confine the carbon in úe 2.1. Kinetic models
tanks until the transfer pulp be activated. The CIP and CIL 2. I . I Adsorption on activated carbon
reactors can also be used to perform the gold leaching The detailed kinetic models for gold adsorption that
without adsorption. include the diffusion on the activated carbon particles or in
The dynamic simulation of the CIP and CIL processes has the external film mentioned in the previous section require
received considerable attention since the 1980s, and the use of several parameters whose estimation using
nowadays, useful models are available and can be used to laboratory and plant experiments can be long and
perform specific process optimization studies.e-25 The expensive. In this study, the simple linear adsorption-
more detailed models available take into account desorption rate equation will be used.
competitive adsorption, carbon fouling by organics and In aqueous solutions, the adsorption of a single chemical
fine particles, carbon loading distribution, carbon loss by specie on a substrate, in a closed reactor and at constant
attrition, leaching and preg-rubbing, and macro and temperature, can be described by equilibrium isotherms,
micropores diffusion kinetic control, but most of them which are empirical equations that relate the concentration
assume perfect mixing in the reactors with no seg[egation, of the chemical species in the liquid phase (Cl) and their
instantaneous carbon transfer and constant solid ánd liquid concentration on úe surface of the substrate (Cc). The
holdup. following classical adsorptíon isotherms have been used to
The objective of this paper is to present an altemative describe the gold adsorption on activated carbon: linear

127
(cc:R ct ), Freundlich (c":acf ), and Langmuir concentration, Cs* is the residual ore gold content, and !
(c.=a cr/(e+Cr)).6'7 In the case of multiple components the reactor order.
adsorption, there is a modification in these equations to
2.1.3 Free cyanide consumption
account for the competition between the solutes. t0,te'22,23
The kinetics of the cyanide consumption can be
Note that the linear isotherm is accurate for low
empirically described by taking into account two
concentration^qyg19{ns, as, in general, is the case for gold
6'13'1 6'17'20 superimposed effects. The first one explains the consüant
adsorption.
cyanide consumption rate by copper and iron minerals,
The adsorption kinetics used in the present study
and the second explains the cyanide consumption effect
is described by the lumped equation given by the linear
proportional to the free cyanide content, such as the losses
adsorption-desorption equation that assumes the
6,tr'13,16,17,20 by hydrolysis to hydrogen cyanide and ammonia, and the
adsorption as a reversible process:
oxidatio^l tg cyanate or cyanogen; the rate of consumption
Rce:k. ct(cc.-cc)-to cc (3) is then: 30-33

where Cl is the gold concentration in the liquid phase, Cc Rcw:e+f Ccn (s)
the activated carbon gold content, Cc* is the maximum where Ccn is the cyanide concentration in the liquid phase,
activated carbon gold content and lq and lq are empirical e is the rate constant of order zero, and f is the rate
kinetic constants of adsorption and desorption for gold. constant oforder one.
Note that at equilibrium conditions (Rce:O) this model
become the classical Langmuir equation, where A : Cc* 2.2. Reactor model
and B : h/k,. The CIL process fakes place in large continuous stirred
tank reactors (CSTRs) where the slurry flow behavior, as
2.1.2 Gotd cyanidation in the case of only leaching process, exhibits some non-
The kinetic of three-phase reactions is quite complex; idealities;rr'34 in this study, without loss of generality, the
however in many cases the pseudo homogeneous approach reactors are assumed as ideal CSTRs. Figure 2
is sufficient to well describe the main features of the schematically shows a general CIL taú and the variables
process.'u'"'30-32 For gold leaching, the kinetics may be that can be used to describe this process, which includes
empirically described as a process of order two with the flow rates, the concentrations, the hold ups, the kinetic
respect to the ore gold content and a process of order one rates, the volume, and pump capacity. The dynamic model
with respect to the free cyanide concentration, as in the for the CIL process, assuming mono-size particles,
following lumped kinetic equation: 30-32 consists in the conservation of the masses of the ore, liquid
Ra,:k Ccn (Cs-Cs- )" (a) phase, carbon, gold in the ore, gold in the liquid phase,
where k is the rate constant, Ccn is the cyanide gold in thg carbon, and cyanide in the liquid phase, as
tt'30'3s
in liquid 1o11o*r'
concentration phase, Cs is the ore gold

dMs
,-Qsi (6)
ii:Qt,,-Qs,+Qsi
+eL,-ell (7)
ff=0L,-ort
dMct Í\^l
'.
-.-r^,
Y!i+l-Yvi (8)
ot
ut'àtt'' :os,-,cs,-, -Qs, cs,+Qsi*,cs*,-Qsf cs,-Ms,Reu, (e)

o''ji t''' :oli-, cli-1 -eli cli +el;,crirr -elí cr, +Ms R,u, -Mc, Rcu, (10)

aluc. cc I
Qci,Cc,_, -Qci Cc, +Mc,Rcu, (11)

o t*'àr"*' ] :Ql,,ccn,-, -Ql,

ccn, +Qli*,ccn,r, -Qli ccn, -Ml,RcN, (t2)

where Qs is the ore flow rate, Ql is the liquid flow rate, Qcand Rç6 is the kinetic of the adsorption of gold on the
is the carbon flow rate, Cw is the solid concentration in theactivated carbon. The subscripts "i-1", "i", aÍtd, "i+1" stand
pulp, Ml is the liquid hold-up, Ms is the ore hold-up, Mc respectively for the variable at the reactor entrance or at
is the carbon hold up, Cs is the ore gold content, Cc is the the previous reactor, inside the reactor, and at the next
carbon gold content, Cl is the liquid gold concentration, reactor. Note that the superscript " ' " stands for the
Ccn is the liquid cyanide concentration, R4, is the gold variable in the stream that transfers with the activated
dissolution rate, Rap is the rate of cyanide consumption, carbon.

128
 To elution O

/--\ + NewadivatedÉóon
Pulp from the
leching circuit
r
/--\
lt
!t
-

> To tillings disposal

aActivated €rbon
. Ore

Pulp flow

Figure 1 . Schematics of a carbon-in-pulp or carbon-in-leach plant with three tanks, showing the interstate screens (IS),
the screen at the exit of thefirst tank (S) and the carbon transfer pumps (P).

o ac,. ^l
q 3:í ; ã3ltl o.,
oti Qt'n,
Cs, Cg.,

Os- Qs,
Qt., QI,
csu, Cs,
cl. - CI,
Ccní1 hn,
Qo,-, co'

Figure 2. Schematics of the i'h adsorption-leaching reactor of a cascade showing the variables used in the model. Qs,
Ql and Qc are the ore, liquid and carbonflow rqtes, Cs and Cc are the ore and carbon gold content, Cl, Co and Ccn
are the concentrations in the liquid phase of gold, oxygen andfree cyanide, M| , and Mc are the liquid, ore and
^ cyanide consumption, oxygen
carbon holdups, R1* Rcn, Ro, Ao, and Rç5 are the rate constantsfor gold leaching,
consumption, oxygen addition, and gold adsorption on activated carbon, Q is the carbon transfer pumps capacity, and
Vt is the net reacíor volume.

Assuming that the segregation is negligible and the slurry simpliff and represent the process during the periods
volume hold-up is constant in the CSTRs, the following where there is not carbon transfer. In the CIL plants, the
1r'30
closure equations hold: activated carbon transfer is intermittent; therefore, the time
evolution pump capacities can be assumed as binary
Ms, , Ml, , Mc, _., ( l3) variables with values zero for no transfer periods and Q for
pr -pl- p. -'' the transfer periods. This approach, which describes what
Q'l*Qli*Q.í=q, (14) is occurring in the process, is more realistic and
ps pr pc numerically flexible than the conventional approach that
Ms, _ Qs, : Qsl _^.. (ls) considers an instantaneous transfer ofthe activated carbon,
-"*
V, *r"rL -qr, A| Qs';+qq which results in different system ofequations for different
stages ofthe transfer cycle.ll
Mc, _ Qcl _.^u [Cw,*(l-Cw,)l (t6)
Equations 6 to 12 describe a general CIL reactor; however,
Msi+Ml +Mc qsi+qq+qc; '"''[Ji- or ] by neglecting the reaction term in Eq.9 they directly
describe the CIP process. Also, by neglecting the carbon
where V is the net volume of the tan\,ps is the ore density, balance (Eq.8), the gold balance on the carbon (Eq.ll ),
pl is the liquid density, pc is the activated carbon density, the ore, liquid and carbon transfer (flow rates with
and Q is the volumetric capacity of the pumps that transfer subscript " ' " in Eqs. 6, 7,9, 10, 12, 14, and l5), and the
the activated carbon. gold adsorption term in Eq.l0, they directly describe the
In the present case, the total volume of the tank is assumed leaching process.
as consúant due to the overflow design of the reactor
outlet, but the solid, liquid and carbon holdups can change 2.3 Plant simulation
with the time. Consequently, the accumulation term in The reactor model presented in the previous section
Eqs. 9 to 12 cannot be neglected, as is the case in most of describes the generic reactor CIL of a cascade; however,
the previous models for this process. the equations for the first and last tanks of the cascade
One remarks that Eqs. 6 to 12 describe the iü CIL reactor have slightly different governing equations due to the fact
with a continuous transfer of activated carbon. However, that from the first tank only the carbon is pumped to the
by setting the pump capacities (Q) to zero, these equations elution section and in the last tank only the activated

129
carbon is added (see Fig. l;.s'tt':o Therefore, the used in this circuit is salted with a total concentration of
transferred pulp flow rates in Eqs. 6 to 12 will not be dissolved solids higher thar, l2oÁ. Figure 3a shows the
present in the equations that describe these tanks. diagram of the leaching section of this plant with three
The CIL model can be directly solved using a numerical mechanically agitated tanks of 2000 m3, and figure 3b
algorithm for differential-algebraic equations;35 however, shows the diagram of the adsorption tank with seven
it could be transformed after algebraic manipulation in two of 1350 m3. In the leaching section of the
agitated tanks
independent systems of ordinary differential equations, the plant, the free cyanide concentration is measured
first for the time evolution of the holdups and the second automatically by using a Kegold electrode and controlled
for the time evolution of the concentrations (see at 450 mg/L by addition of sodium cyanide at the entrance
Appendix).3o Therefore, the governing equations are of the first tank. The pH is also automatically measured in
solved using an algorithm for ordinary differential the outlet of the first tank and controlled at 10.2 by
equations. addition of calcium oxide at the comminution section of
In the continuous adsorption processes only a fraction of the plant. Oxygen is added to the first two leaching tanks,
the activated carbon held in the reactor is transferred, but its concentration is not continuously measured;
which produce a blend of carbon with high gold content therefore, it is not taken into account in the present study.
and carbon with low gold content.t2-l1 h this study, it is The leaching and adsorption section of the plant were
assumed that the empiric factors in the kinetic equation of sampled at each hour, simultaneously with the entry and
gold adsorption for the blended carbon remain the same the outlet side of each tank, during 37 hours. The liquid
and their behavior can be described by a weighted average phase, after filtration the sampled pulp was analyzed. The
concentration; therefore, the concentration of gold pH was measured with a standard pH-meter, the cyanide
adsorbed on the activated carbon in each tank was concentration determined by titration with silver nitrate
calculated by considering the gold mass on activated and rhodanine, and the concentration ofgold measured by
carbon initially present in the tank, the transferred mass of atomic absorption spectrophotometry after the extraction
gold, and the transferred total mass of activated carbon. of this metal by di-iso-butil-ketone (DIBK). The solids
The gold leaching and adsorption plants can have a were washed and the ore gold content measured by fire
cascade as larger as ten reactors and intermittent recycling assay and spectrophotometry of atomic absorption. The
of the pulp with activated carbon. To perform the dynamic concentration of the solids was also given for each sample.
simulation of these processes one uses the simultaneous At each two hours samples of the pulp were taken and
approach35 in each section of the plant, in which Eqs. Ala filtered to measure the concentration of carbon in the tanks
to A4d (see Appendix) for all tanks are solved at the same and their gold content measured by fire assay and atomic
time, using the fourth order Runge-Kutta method and the absorption spectrophotometry.'o
initial conditions, assumed as the first measured The ore flows rate time evolution were measured in the
concentrations and estimated holdups. entrance of the comminutionJeaching section of the plant
but not in the leaching-adsorption circuit entrance;
3. MODEL CALIBRATION therefore in this study estimated values are used, by
In this study, the equations that describe the CIL and only assuming that the comminution circuit behaves as a second
leaching process are calibrated with the data from an order system with time constant equal to 0.37 hours.
Australian plant that treats about 400 tlh of ores from
twelve ore bodies from a greenstone belt and was watered. 3.1 Model calibration for the primary leaching section
The ore contains basalt, no reactive sulfides such as pyrite For the calibration of the model, corresponding to the
(FeS2), pyrrhotite (Fe1-,S), and small amounts of evaluation of cr, k, e, and f, and the net reactor volume, the
marcassite (FeSz), chalcopyrite (CuFeS2), galena (PbS), experimental data for the leaching section of the plant
sphalerite (ZnS), gersdorffite §iAsS) and arsenopyrite reported above were fitted using a conventional
(FeAsS). The gold is well liberated and 20 to 40 Yo is optimization method and the follows least square criteria:
concentrated using gravity methods in the grinding circuit. r 1.30
The ore size is about 50% less than 38 microns. The pulp
has a concentration of solids of about 45 Yo, and, the water

Jl
383
=TI csn -c.n )' (ôr,, -ctn )' (ô"n,, -ccn,, )' (ô*,, -c*n )' ( l7)
[1 10Cs,,2 Cl ,,, Ccn,,' c*,,'

130
 tt
Ilr';l lrl cl

H
Cl2

Oô1
c13

(a)

(b)
Figure 3- Schematics of the plant sections showing the variables and the simulation parameters (see explanation in the
text): (a) Leaching; (b) Adsorption.

where Cs, Cl, Ccn, and Cw are respectively the Table 1: Estimated parameters íor the leaching section
concentrations of gold in the solid and in the liquid phase, cr 2.15
free cyanide concentration in the liquid phase and the solid k 5.50 x l0-3 [(ts.r/ge,)",(triolgcN)/h]
concentrationinthepulp.Thesubscript..^,,StandSfor
estimated variable, and the subscripts i and t stand for tank f I .47 x lO-2 tllhl'
numberinthecascadeandsampletimerespectively.Note
that the measure of the ore gold content is not very precise
as the other measures due to the low value and
diffrculties; it is reflected in the criterion given UV
T.g!"g Figures 4 to 6 present the measured and calibrated values
Iq 17. fof the ore golà content, gold and cyanide concentrations
The estimated parameters of the model for the leaching in the liquiã phase, and solid concántration in the pulp.
section are presented at Table 1. Note that the.reaction 1gol.thaithemodelrepresentswellthemeasuredvariàblés
order is about two as was already repoÍed in the literature, in spite the level of the measured noise and fluctuation.
and the residual ore gold content (Cs.) is assumed as 0.14
mg/kg because this value is found in the plant tilling after 3.2 Model calibration for the CIL section
the leaching and adsorption sections. The high value of úe In the CIL section of this plant the activated carbon is
constant of order zero (e) indicates that there is a strong transferred from a tank to the previous one in
presence of cyanide consumers. The estimated net volume countercurrent with the pulp by using the pumping
of the tank is about 60% of the nominal volume one, sequence shown at Fig. 7-. Note that there is a binary
which is explained by the presence of the gas phase, the behavior and zero
-eú, no pumping period while one
deflectors of the baffles, the. ore deposits, and the means the pumping period. ône remarks also that the
mechanical parts of the agitator.3a pumps 3, 4,-5 aÍrd6 are synchronized working at the same
time while the other pumps are activated following other
criteria. In the present case the transfer capacities of the
pumps 1 to 7 are 90 m3 of pulp per hour, while the rate of
transfer of activated carbon for the last tank is about 0.6
m3 of activated carbon per hour.3o

l3l
 with other reported results. Note also that the gold hold up
in the first tank is remarkable high than the gold in the
other tanks.

500
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o
c
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c
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vc»
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c
o
o
E
o'l
o
!
o §
o
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I
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o 'lo 30 40
rimi(onour)
(c)
Figure 4: Experimental and simulated time evolution of 'r0 20 30 40
the gold ore content and gold concentration in the solution Time (hour)
for the three tqnks ofthe leaching section. (c)
Figure 5: Experimental and simulqted time evolution of
Figure 8 presents the average values of the activated thefree cyanide concentration in the solutionfor the three
carbon concentrations, gold concentration in the liquid tanks of the leaching section.
phase, in the ore and in the activated carbon, the solid,
liquid, carbon and gold holdups in each tank of the
cascade that are estimated with the measured variables.
Note that the first and the last tanks have the highest
concentrations of activated carbon, and the profile of the
carbon gold content is almost exponential, which agrees

132
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Time (hour)
I 40

tgure 7: Carbon transfer sequence in the adsotptio"

Fiç,t t";::i:;O:rrck stands for pump operation and whiÍe for pump rest

133
 consumption kinetic constants (e and f), were obtaíned by
using the relative least squares criteria:

-":,. )' ( 18)

' AAI
,^ = çr'r,_[(o*,
ccn',' I
l
-:,, )' * (c.,' -c",,)'.l
Si[(.', clr----- (le)
,.
"=
=
àtl-- c''l-]
where Cl, Cc, Ccn are respectively the concentrations of
?0 gold in the liquid phase, the activated carbon gold content,
Time (hour)
(a) and the free cyanide concentration in the liquid phase. The
subscript "^" stands for estimated variable, and the
s i
subscripts and t stand for tank number in the cascade and
sample time respectively. Note thaÍ 12 is a function of e
=o and fand is independent ofadsorption parameters, and on
o
E
the other hand, J3 is a function of ku, lq and Cc* and is
.E
c
o
independent of adsorption parameters; therefore, these
§ criteria were minimized separately by using the gradient
C
q) conjugated method.
o
E The best fit parameters are presented at Table 2.
8
E Note that the value of the parameters for the kinetic
ao equation of adsorption agree with the values found in the
literature,ll'r6'17'20 which indicates that the maximum
10 20 30 40
activated carbon loading (Cc*) is about 3600 to 14200 glt,
Time (hour)
(b) the rate constant (k") is about 0.012 to 0.12 tlgh and
desorption rate constant (lq) is about 0.0005 and 0.025 l/h.
s The parameters for the consumption of the cyanide (e and
_o
f
f) are weaker than those found for the circuit of leaching
o. of this plant, but the order zero constant is higher, which
q)
s indicates than the cyanicides chemical species are the
.s
c major responsible for this consumption.
.9 45
6
cq) T4!k2!!!!j.otg4-Wo^eters for the q!;q4p!ion ection
o
I s
c
o
o
p lq 9.10 x l0-2 [tcb/(gA,h)]
=
a k{ 6.27 x lo23 u/hl
40
o 10 30 40
f 3.94 x tr/hl
rime?our) 10-5

(c)
Figure 6: Experimental and simulated time evolution of Figures 9, and 10 show the dynamic measured
variables and the results of the calibration for the seven
the solid percentage in the three tanl<s of the leaching
section. tanks of adsorption. One notes that the simulator
represents well the variations of the gold concentrations in
The gold dissolution in this circuit is weak because the liquid phase and the carbon gold content. On the other
the ore gold content is already low; in addition, there are hand, the dynamic variation of the solid gold content and
uncertainties on the measures, especially for the first two the free cyanide concentrations are more diflicult to
tanks. However, it was taken into account in the represent because the noise and incertitude of the
simulations presented in this study. The kinetic parameters measurements are high; in addition, the values of the ore
previously estimated for the primary leaching section of gold content are very low. However, the overall results of
the plant (sepgk, and Cs- at Table l) are used in the the plant calibration are good, and they describe well the
simulations. main features of the process dynamics.
For the calibration of the simulator, the kinetic
parameters of adsorption (k", Itu, and Cc-) and the cyanide

t34
 l

o
o
E
1
o
c u2
l
o
I
o
o
o l

o
o
E
;f o7s

co
E
o
o,
6
5
o
o
5
o
0.25

=
o
o
0
234
Tank
(c)
l

Éôon {t)

,'
2345671234567
Tank Tank
(e) (0
Figure 8. Average concentrations and holdups in each reactor ofthe cascade ofthe adsorption section.

4. CASE STUDY: EVALUATION OF CARBON In this study the following metallurgical performance
TRANSFER STRATEGIES indices will be used to evaluate the carbon transfer
In this study, the leaching and adsorption circuits of the strategies:
plant, which were calibrated in the previous section, are
simulated and the effect of the carbon transfer strategy in (D Total amount of gold that fed the circuit, given by:
the adsorption section analyzed. The study ofthe activated tf
MAuo= Q0)
carbon transfer strategies in the CIL and CIP processes is a J[cs.(t)es,(t;+cr,(t)er,(t)]at
practical problem of interest for either the design and the
operation of the gold extraction plants.ll,le,tz,zo2a,25 The use
(iD anlount ofgold recovered by activated carbon at the
of simulators to analyze this problem is very convenient exit of the adsorption tf
circuit, given by:
because the experiments in pilot plant are expensive and MAuReccb= Ql)
complex. Some results are available from previous studies, Jcc,(t)Qct,(t)dt
performed . with other minerals and operational (iii) Amount"of gold loss with the liquid phase at the
-
conditions.r6 In the present study, we will take into adsorption circuit exit, given by:
account other strategies not addressed yet and, using the (22)
simulated flow rate and concentrations, calculate the MAuLoLiq = i",, 1,;q,, 1,;0,
performance indices that will be used to the systematic
(iv) Amount of gold loss with the ore at the adsorption
comparison between the strategies and that will help us
circuit exit, given by:
identify the carbon transfer strategies more relevant for
this process.

135
 procedure is repeated for the other tanks until the addition
MAuLoSol : J"., (t) es, (t)at
(23)
of new activated carbon in the seventh tank. After one
hour ofrest the transfer cycle is repeated.
(v) Amount of gold accumulated in the circuit, given by:
Ivl4ur{cc = IVIAuo - MAuRecCb - MAuLoLiq - MAuI-oSol (24)

(vi) Amount of carbon added to the adsorption circuit,

given by: o a Í*3
tf I rd.
o
(2s)
Je.t, (t)at
MCbA = E
C
ri o)
E U,5
(vii) Free cyanide loss at the exit ofthe adsorption circuit, o
given by: E
o
o
o
(26)
Jc",r, (t)Or, (t)ot
MCNLo = o

where Cs is the ore gold content, Cc is the carbon gold

content, Cl is the gold concentration in the liquid solution, 0481216202425323640
Ccn is the cyanide concentration in the liquid solution, Ql Time (hour)

is the liquid flow rate, Qs is the solid flow rate, Qct is the (a)
600 I i1:-
carbon flow rate, ! is the simulation initial time, t6 is the
simulation final time. The subscript I stands for inside the :
J
a
E
first tank and 7 for the exit ofthe last tank. -c 500 I
Tãnk 3

rak4
E
o §
o co
E
p Ê
o
4oo

f
o
oô o
o a Tânk 3 =co
! Íanka
à 300
.E o
c o
.o u
§
o
o
c TiÍne (ho.jr)
! (b)
o
o Figure l0: Experimental and simulated time evolution of
0
16 20 24 40 the variables in the adsorption section: (a) Ore gold
Time (hour) contenÍ; (b) Free cyanide concentration.
(a)
o Strategy #2: After five hours ofrest new activated
o ^a carbon is added to the seventh tank during one hour, after
à) 3000 V another hour of rest the activated carbon is transferred
E a
T from the seventh to the sixth tank, and after another hour
c I
o)
q ofrest the activated carbon is transferred from the sixth to
8 2000 ft the hfth tank. This procedure is repeated for the other
E
o tanks until the loaded activated carbon be transferred from
c the first tank towards the elution stage. After one hour of
o
ۤ looo
rest the transfer cycle is repeated.
o
r Strategy #3: After five hours of rest the activated
carbon is transferred from the sixth to the fifth taú, after
tur,r"'lonorry' 28 3:
another hour of rest úe activated carbon is transferred
(b) from the seventh to the sixth tank, another hour ofrest new
of activated carbon is added to the sevenú tank during one
Figure 9: Experimental and simulated time evolution
hour, and after another hour ofrest the activated carbon is
the variables in the adsorpÍion section: (a) Gold
transferred from the fifth tank to the fourth. This procedure
concentration in the liquid phase; (b) Carbon gold
content.
is repeated for the other tanks until the loaded activated
carbon be transferred from the first tank towards the
elution stage. After one hour of rest the transfer cycle is
In this study the following strategies of carbon transfer in
repeated.
the adsorption circuit are simulated for 37 hours, and after
the metallurgical performance indices calculated and
. Strategy #4: This strategy is similar Ío sÍrategy 2,
analyzed:
but the activated carbon transfer from the sixth to the fifth
o tank, the fifth to the fourth tank, the fourth to the third
Strategy #l: After five hours of rest (without
tank, and the third to the second tank are synchronized.
carbon transfer), the loaded activated carbon is transferrsd
After one hour ofrest the transfer cycle is repeated.
from the first tank to the elution stage for one hour, and
after another hour of rest the activated carbon is
o Strategy #5: This strategy is similar to strategies 2
and 4 but the activated carbon transfer from the seventh to
transferred from the second tank to the first. This

136
the sixth tank, the sixth to the fifth tank, the fifth to the indicates a continuously accumulation in the activated
fourth tank, the fourth to the third tank, and the third to the carbon. This is assessed by the amount of gold
second tank are synchronized. After one hour of rest the accumulated in the circuit (MAuAcc, see Eq.24).
transfer cycle is repeated. In this case study the most important performance indices
o Strategy #6: This strategy is similar to strategies 2, are the amount of gold recovered (MAuRecCb), the
4, and 5, but the addition of new activated carbon in the amount of gold loss in the liquid (Mauloliq), and the
seventh taú, and the transfer of the seventh to the sixth amount of gold held in the circuit (MauAcc). By analyzing
tank, the sixth to the fifth tank, the fifth to the fourth tank, these indices one note that for strategy #l the gold
the fourth to the third tank, and the third to the second tank recovered is very low, the gold loss very strong and an
are sl,nchronized. After one hour of rest the transfer cycle important accumulation happens; on the other hand, for
is repeated. strategy #7 rhe gold recovered is high, the gold loss very
o Strategy #7: This strategy is similar to strategies 2, weak and the gold accumulation is smaller than in
4,5, and 6, but the addition of new activated carbon in the strategy #1. These results indicate that strategy #l could
seventh tank, and the transfer of the seventh to the sixth not be recommended and strategy #2, and its variants,
tank, the sixth to the fifth tank, the fifth to the fourth tank, would be the most recommended
the fourth to the third tank, the third to the second tank, Carbon transfer pumps slmchronized (strategies 4, 5, 6,'7,
and the second to the first tank are synchronized. After one and 8) may give better results than the sequential strategy
hour ofrest the transfer cycle is repeated. when the amount of carbon loaded in the first tanks is high
o Strategy #8: This strategy is similar to strategies 2, (see strategies 2 and 4,5 and 6); however, the performance
4,5,6, andT but the addition of new activated carbon in of the process in the case of all pumps are transferring the
the seventh tank, and all transfer pumps are synchronized. carbon simultaneously (strategy #8) is as bad as strategy
After one hour ofrest the transfer cycle is repeated. #1 because the residence time of the carbon in the reach
The results of the metallurgical performance indices (see solution in the first tanks is very small. These results are in
Eqs. 20 to 26) calculated from the circuit simulated results agreement with previous simulation studies performed for
for 37 hours of operation for each strategy of transfer are CIL and CIP processes.l6
presented at Table 3. The results of the performance Finally, one notes that strategy 6 is the most effective to
indices show that the total amount of gold that fed the decrease the gold losses in the liquid phase, and to
circuit (MAus), the amount of cyanide loss at the exit of increase the gold recovery that gives values larger than
the circuit (MCNLo), and the amount of carbon added to that of strategies I and 2. Note that as one increases the
the adsorption circuit (McbA) are identical in all activated mixing in the circuit, by turn on the transfer pumps
carbon transfer strategie's. Also the amount of gold loss simultaneously, (strategies 4, 5, 6,7, and 8) it seems that
with the ore (MAuLoSol) is viúually independent of the the gold recovery reach a maximum value for strategy 7
strategy because the ore gold content is already very low and thereafter decreases, while the lost of dissolved gold
in the adsorption section. Due the façt lhaÍ the simulation passes by a minimal value for strategy 6 and thereafter
results are not completely in the stable cyclic regime, that increases again.
would be reached after a larger number of transfer cycles
and long simulation time, the unbalanced gold mass

Table 3: Performance indices for different carbon transfer sequence stratepy

Strategy #
0<-l 7<-8 7+-8 (7+-8), (7<-8), (7<-8), 4<-5
7<-8 5+-6
t<*2 6<-7 6<-7
6<-7 (6<-7), (6<-7), (6<-7), (6<-7), 5<-6
Pumping 2<-3 (5+-6), (5<-6), (5<-6), (5<-6), (5<-6), 6<-7
5<-6 7<-8
sequence 3<-4 4<-5 4<-5
(4<-5), (4<-5), (4<-5), (4<-5), (4<-5), 7<-8
4+-5 (3<-4), (3<-4), (3<-4), (3<-4), (3+-4), 3<-4
3<-4 3<-4
5+-6 2<-3 (2<-3) (2<-3) (2<-3) (2<-3), (2<-3), 2<-3
2<-3
6<-7 l<-2 l<-2 t<-2 t<-2 t<-2 (1<-2) (t<-2), t<-2
7+-8 0<-1 0<-1 0<-l 0<-l 0<-l 0<-1 (0+-1) 0+-l
MAuRecCb (kg) 7.469 8.817 8.817 8.820 8.820 8.821 8.828 7.466 8.817
MAuLoLiq (kg) 0.2668 0.2529 0.2541 0.2528 0.2528 0.2520 0.2531 0.2583 0.2554
MAuLoSol (kg) 2.s47 2.546 2.546 2.546 2.546 2.s46 2.547 2.546 2.546
MAuAcc (ke) 38.03 36.70 36.69 36.69 36.69 36.69 36.68 38.04 36.69
MAus(kg) 48.31 48.31 48.31 48.31 48.3t 48.31 48.31 48.31 48.31
MCNLo (t) 6.488 6.488 6.488 6.488 6.488 6.488 6.488 6.488 6.488
MCbA (ke) 634.4 634.4 634.4 634.4 634.4 634.4 634.4 634.4 634.4
MAu6 - Total amount of gold that fed the circuit; MAuRecCb - Amount of gold recovered by activated çarbon at the
exit of the adsorption circuit; MAuLoLiq - Amount of gold loss with the liquid at the adsorption circuit exit;
MAuLoSol - Amount of gold loss with the ore at the adsorption circuit exit; MAuAcc - Amount of gold accumulated in
the circuit; MCbA - Amount of carbon added to the adsorption circuit; MCNLo - Amount of free cyanide loss at the
exit ofthe adsorption circuit.

t37
5. CONCLUSIONS 10. van Deventer, J.S.J., Competitive equilibrium
A dynamic phenomenological model that describes the adsorption of metal cyanides on activated carbon,
gold leaching and the adsorption on activated carbon is Separation Science and Technologt, 1986, 2l(10),1025-
presented. This model can be easily simplified to represent 1037.
the CIL, the CIP, or the leaching process, and it can take 11. Carrier, C.; Hodouin, D.; Courchesne, M., Dynamic
into account more complex rate equations. In this study, simulation of the CIP gold recovery proces$ In:
the model was initially htted to an experimental data set Proceedings of the International Symposium on Gold
for the leaching section cascade ofa plant and after for the Metallurgt, eds. R.S. Salter; D.M. Wyslouzil; G.W.
adsorption section cascade (CIL process) of the same McDonald, Pergamon Press, 1987, 309-325.
plant. The results of calibration are good and describe well 12. Stange, W. ; King, R.P., A population balance
the plant dynamics; also the kinetic parameters found are approach to the modeling of CIP process, In: Proceedings
in agreement with those presented in the literature. The of the 20th International Symposium on the Application of
two sections of the plant were simulated together and Computers and Mathematics in the Mineral Industries,
several carbon transfer strategies were analyzed using as 1987,209-221.
performance indicators, metallurgical indices. In spite the 13. Woollacott, L. ;Stange, W.; King, R.P., Towards
fact that the simulated plant was not completely in the more effective simulation of CIP and CIL processes. 1. A
stable cyclic regime, the simulated results indicate that modelling of adsorption and leaching, Journal of the South
there are strategies more adequate to enhance the gold African Institute of Mining and Metallurgt, 1990,90,275-
recovery in the activate carbon and to reduce the gold 282.
losses in the liquid phase especially that in which an 14. Stange, W. ; King, R.P.; Woollacott, L., Towards
important amount of activated carbon is held in the first more effective simulation of CIP and CIL processes. 2. A
tanks and the contact time between the carbon and the pulp population-balance-based simulation approach, Journal of
is large. the South African Institute of Mining and Metallurgt,
1990,90,307-314.
ACKNOWLEDGMENTS 15. Stange, W.; Woollacott, L.; King, R.P., Towards more
This research was supported by Conselho Nacional de effective simulation of Ctp and CIL processes. 3.
Desenvolvimento Científico e Tecnológlco (CNPq, Brazil) Validation and use of a new simulator, Journal of the
and Federal University of Bahia (UFBa, Brazil). The South African Institute of Mining and Metallurgt, 1990,
author also would like to thank Prof. Daniel Hodouin 90,323-331.
(Laval University, Canada) for useful discussions, and 16. Stange, W., The optimization of the CIP process using
Mrs. Ann Bax (Murdoch University, Australia) for mathematical and economic models, Minerals
providing the experimental data used in this study. Engineering, 1991, 4(12), 127 9-1295.
17. Stange, W. The process design of gold leaching and
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Bulletin,1987, 80, 1 08- 1 14. 18. van Deventer, J.S.J.; Ross, V.E., The dynamic
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3. Yannopoulos, J.C.; The Extractive Metallurgt of Gold, 681.
Van Nostrand Reinhold, 1991. 19. van der Walt, T.J.; van Deventer, J.S.J., Non-ideal
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and gold - a literature survey, Minerals Science and Min er al s E ngine erin g, 1992, 5 (l 0 -I 2), I 40 | - I 420.
Engineering, 1980, l2(2), 85-99. 20. J.H; Barker, I.J.; Swartz, C.L.E.,
Schubert,
5. Bailey, P.R., Application of activated carbon to gold Performance evaluation of a carbon-in-pulp plant by
recovery, In: The Extractive Metallurgt of Gold in South dynamic simulation, Journal of the South African Institute
Africa, Ed. Stanley, G.G., The South African Institute of of Min in g and Met a I lur g,t, 1993, 93 (l I I l2), 293 -299 .
Mining and Metallurgy, 1987, 379-614. 21. van Deventer, J.S.J.; Lorenzen, L.; van der Merwe,
6. Dixon, S., Cho, E.H. and Pitt, C.H., The interactions P.F.; Morrison D.W.; van der Westhuysen; J.P.W., The
between gold cyanide, silver cyanide and high surface area fundamentals of unit operations in CIP plants: A progress
charcoal, AIChE Sympos ium Series, 1978, 7 4(17 3), 75-83. report, Minerals Engineering, 1994, 7 (2-3), 265 -27 8.
7. van Deventer, J.S.J., Kinetic models for the adsorption 22. Liebenberg, S.P.; van Deventer, J.S.J., The dynamic
of gold onto activated carbon, In Proceedings of Mintek simulation of in-pulp sorption processes using the lumping
50: International Conference on Mineral Science and of competitive and fouling phenomena, Minerals
Technologt, South Africa , 1984, 487 -494, Engineering, 1997, 1 0(9), 959-9'7 2.
8. Nicol, M.J; Fleming, C.A.; Cromberge, G., The 23. Liebenberg, S.P.; van Deventer, J.S.J., The realistic
adsorption of gold cyanide onto activated carbon. II: simulation of CIP plants using practical mesures of
Applications of the kinetic model to multistage absorption competitive adsorption and fouling, Proceedings of the XX
circuits, Journal of the South African InsÍitute of Mining International Mineral Processing Conference, Aachen,
and Metallurgt, 1984, 84, 50-54. 1997,381-389.
9. Williams, D.F. and Glasser, D., The modelling and 24. Rogans, E.J.; Maclntosh, A.J.; Morrison, N.;
simulation of processes for the absortion of gold by Schoeman, N.; Carbon-in-pulp and carbon-in-leach
activated charcoal, Journal of the South Aírican Institute adsorpion circuits - Optimization of design using the
of Mining and Metallurgt, 1985, 85(8),237-243. carousel system, In Proceedings of the Canadian Mineral

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P ro c es s ing C onfer enc e, Ottawa, 1998, 639 -663 .
25. Coelzee, J.W.; Gray, D.E., Counter-current vs co- 31. de Andrade Lima, L.R.P., Hodouin, D., A lumped
current flow in carbon-in-pulp adsorption circuits, kinetic model for gold cyanidation, Hydrometallurgt,
Minerals Engineering, 1999, l2(4), 41 5 -422.
26. Rees, K.L.; van Deventer J.S.J.; Dunne, R.C.; Gold
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35. Biegler, L.T.; Westerberg, A.W.; Grossmann, I. E.;
for Chemical Process Design,

APPENDIX
Condensated version of the reactor model (Eqs. 6 to 16), after combine the ordinary differential and the algebraic
equations.3o

(D Holdups:
dMs,
-* =Qs,-, -Qs,+Qsi ,-Qsl
dMl (Ala,b,c)
-o. =QI,, -Ql,+Qli-, -Qli
dMc,
-* =Q"í., -Q"í
(ii) Flowrates :

a'
Ms
=f[a, í
,-Q, *i,
Qs,,.ÉJ Ql ,-, )
(A2a,b)

o, =?(0,,-e,*T.+)
(ii} Flowrates due to the carbon transfer :
Ms.
Q'í= Q,
n
MI ,
(A3a,b,c)
arí= a
n
Mc.
Q.i =, Q,

(i") Concentrations :

dCs, Qs, , (Cs,_, -Cs, )+Qsi*, (Cs,*, -Cs, )

dt Mr, - Rau,

dcli _ Qli_r
(cli_l -Cli )+ell.r (cli*r -Cl,' )'+-----:-RAu.
Ms, Mc,
dt M1, Ml,
- Ml''Rcs.'
(A4a,b,c,d)
dCc, Qcí*, (Cc,*, -Cc, )
+ Rcn,
dt Mc,
dCcn, Ql, , (Ccn, 1 -Ccn, )+Qlir, (Ccrr,*, -Ccn, )
-RcN,
dt Ml'

139
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Eb de -hnekn, 7 a tl da nqvembro ft HIIIS

Local

Hotel JW Marriott
Avenida Atlântica, 2600 - Copacabana - Rio de Janeiro

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Organização
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