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Gold cyanidation
View on WikipediaGold cyanidation (also known as the cyanide process or the MacArthur–Forrest process) is a hydrometallurgical technique for extracting gold from low-grade ore through conversion to a water-soluble coordination complex. It is the most commonly used leaching process for gold extraction.[1] Cyanidation is also widely used in silver extraction, usually after froth flotation.[2]
Production of reagents for mineral processing to recover gold represents 70% of cyanide consumption globally. While other metals, such as copper, zinc, and silver, are also recovered using cyanide, gold remains the primary driver of this technology. [1] The highly toxic nature of cyanide has led to controversy regarding its use in gold mining, with it being banned in some parts of the world. However, when used with appropriate safety measures, cyanide can be safely employed in gold extraction processes.[3] One critical factor in its safe use is maintaining an alkaline pH level above 10.5, which is typically controlled using lime in industrial-scale operations. Lime plays an essential role in gold processing, ensuring that the pH remains at the correct level to mitigate risks associated with cyanide use.[4]
History
[edit]In 1783, Carl Wilhelm Scheele discovered that gold dissolved in aqueous solutions of cyanide. Through the work of Bagration (1844), Elsner (1846), and Faraday (1847), it was determined that each gold atom required two cyanide ions, i.e. the stoichiometry of the soluble compound.
Industrial process
[edit]
The expansion of gold mining in the Rand of South Africa began to slow down in the 1880s, as the new deposits found tended to contain pyritic ore. The gold could not be extracted from this compound with any of the then available chemical processes or technologies.[5] In 1887, John Stewart MacArthur, working in collaboration with brothers Robert and William Forrest for the Tennant Company in Glasgow, Scotland, developed the MacArthur–Forrest process for the extraction of gold from gold ores. Several patents were issued in the same year.[6] By suspending the crushed ore in a cyanide solution, a separation of up to 96 percent pure gold was achieved.[7] The process was first used on the Rand in 1890 and, despite operational imperfections, led to a boom of investment as larger gold mines were opened up.[8][5]
By 1891, Nebraska pharmacist Gilbert S. Peyton had refined the process at his Mercur Mine in Utah, "the first mining plant in the United States to make a commercial success of the cyanide process on gold ores."[9][10] In 1896, Bodländer confirmed that oxygen was necessary for the process, something that had been doubted by MacArthur, and discovered that hydrogen peroxide was formed as an intermediate.[8] Around 1900, the American metallurgist Charles Washington Merrill (1869–1956) and his engineer Thomas Bennett Crowe improved the treatment of the cyanide leachate, by using vacuum and zinc dust. Their process is the Merrill–Crowe process.[11]
Chemical reactions
[edit]

The chemical reaction for the dissolution of gold, the "Elsner equation", follows:
- 4 Au + 8 NaCN + O2 + 2 H2O → 4 Na[Au(CN)2] + 4 NaOH
Potassium cyanide and calcium cyanide are sometimes used in place of sodium cyanide.
Gold is one of the few metals that dissolves in the presence of cyanide ions and oxygen. The soluble gold species is dicyanoaurate.[13] from which it can be recovered by adsorption onto activated carbon.[14]
Application
[edit]The ore is comminuted using grinding machinery. Depending on the ore, it is sometimes further concentrated by froth flotation or by centrifugal (gravity) concentration. Water is added to produce a slurry or pulp. The basic ore slurry can be combined with a solution of sodium cyanide or potassium cyanide; many operations use calcium cyanide, which is more cost effective.
To prevent the creation of toxic hydrogen cyanide during processing, slaked lime (calcium hydroxide) or soda (sodium hydroxide) is added to the extracting solution to ensure that the acidity during cyanidation is maintained over pH 10.5 - strongly basic. Lead nitrate can improve gold leaching speed and quantity recovered, particularly in processing partially oxidized ores.
Effect of dissolved oxygen
[edit]Oxygen is one of the reagents consumed during cyanidation, accepting the electrons from the gold, and a deficiency in dissolved oxygen slows leaching rate. Air or pure oxygen gas can be purged through the pulp to maximize the dissolved oxygen concentration. Intimate oxygen-pulp contactors are used to increase the partial pressure of the oxygen in contact with the solution, thus raising the dissolved oxygen concentration much higher than the saturation level at atmospheric pressure. Oxygen can also be added by dosing the pulp with hydrogen peroxide solution.
Pre-aeration and ore washing
[edit]In some ores, particularly those that are partially sulfidized, aeration (prior to the introduction of cyanide) of the ore in water at high pH can render elements such as iron and sulfur less reactive to cyanide, therefore making the gold cyanidation process more efficient. Specifically, the oxidation of iron to iron (III) oxide and subsequent precipitation as iron hydroxide minimizes loss of cyanide from the formation of ferrous cyanide complexes. The oxidation of sulfur compounds to sulfate ions avoids the consumption of cyanide to thiocyanate (SCN−) byproduct.
Recovery of gold from cyanide solutions
[edit]In order of decreasing economic efficiency, the common processes for recovery of the solubilized gold from solution are (certain processes may be precluded from use by technical factors):
Cyanide remediation processes
[edit]The cyanide remaining in tails streams from gold plants is potentially hazardous. Therefore, some operations process the cyanide-containing waste streams in a detoxification step. This step lowers the concentrations of these cyanide compounds. The INCO-licensed process and the Caro's acid process oxidise the cyanide to cyanate, which is not as toxic as the cyanide ion, and which can then react to form carbonates and ammonia: [15]
- CN−
+ [O] → OCN− - OCN−
+ 2 H
2O → HCO−
3 + NH
3
The Inco process can typically lower cyanide concentrations to below 50 mg/L, whereas the Caro's acid process can lower cyanide levels to between 10 and 50 mg/L, with the lower concentrations achievable in solution streams rather than slurries. Caro's acid – peroxomonosulfuric acid (H2SO5) - converts cyanide to cyanate. Cyanate then hydrolyses to ammonium and carbonate ions. The Caro's acid process is able to achieve discharge levels of Weak Acid Dissociable" (WAD) cyanide below 50 mg/L, which is generally suitable for discharge to tailings. Hydrogen peroxide and basic chlorination can also be used to oxidize cyanide, although these approaches are less common. Typically, this process blows compressed air through the tailings while adding sodium metabisulfite, which releases SO2. Lime is added to maintain the pH at around 8.5, and copper sulfate is added as a catalyst if there is insufficient copper in the ore extract. This procedure can reduce concentrations of WAD cyanide to below the 10 ppm mandated by the EU's Mining Waste Directive. This level compares to the 66-81 ppm free cyanide and 500-1000 ppm total cyanide in the pond at Baia Mare.[16] Remaining free cyanide degrades in the pond, while cyanate ions hydrolyse to ammonium. Studies show that residual cyanide trapped in the gold-mine tailings causes persistent release of toxic metals (e.g. mercury ) into the groundwater and surface water systems.[17][18]
Effects on the environment
[edit]
Despite being used in 90% of gold production:[19] gold cyanidation is controversial due to the toxic nature of cyanide. Although aqueous solutions of cyanide degrade rapidly in sunlight, the less-toxic products, such as cyanates and thiocyanates, may persist for some years. Many such infamous disasters have killed few people — humans can be warned not to drink or go near polluted water, but cyanide spills can have a devastating effect on rivers, sometimes killing everything for several miles downstream. The cyanide could be washed out of river systems and, as long as organisms can migrate from unpolluted areas upstream, affected areas can soon be repopulated. Longer term impact and accumulation of cyanide in riparian or limnological benthos and environmental fate is less clear. According to Romanian authorities, in the Someș river below Baia Mare, the planktons returned to 60% of normal within 16 days of the spill; the numbers were not confirmed by Hungary or Yugoslavia.[16] Other infamous cyanide spills include:
| Year | Mine | Country | Incident |
|---|---|---|---|
| 1985–1991 | Summitville | US | Leakage from leach pad |
| 1980s–present | Ok Tedi | Papua New Guinea | Unrestrained waste discharge |
| 1995 | Omai | Guyana | Collapse of tailings dam |
| 1998 | Kumtor | Kyrgyzstan | Truck drove over bridge |
| 2000 | Baia Mare | Romania | Collapse of containment dam (see 2000 Baia Mare cyanide spill) |
| 2000 | Tolukuma | Papua New Guinea | Helicopter dropped crate into rainforest[20] |
| 2018 | San Dimas | Mexico | Truck leaked 200 liters of cyanide solution into the Piaxtla River in Durango[21] |
| 2024 | Eagle Mine | Canada (Yukon) | Heap Leach failure, cyanide spill into surrounding waterways, ecological damage and company bankruptcy |
Such spills have prompted fierce protests at new mines that involve use of cyanide, such as Roşia Montană in Romania, Lake Cowal in Australia, Pascua Lama in Chile, and Bukit Koman in Malaysia.
Alternatives to cyanide
[edit]Although cyanide is cheap, effective, and biodegradable, its high toxicity and increasingly poor impact on a mine's political and social license to operate, has incentivized alternative methods for extracting gold. Other extractants have been examined including thiosulfate (S2O32−), thiourea (SC(NH2)2), iodine/iodide, ammonia, liquid mercury, and alpha-cyclodextrin. Challenges include reagent cost and the efficiency of gold recovery, although some chlorination process using sodium hypochlorite (household bleach) have shown promise in terms of reagent regeneration. These technologies are at a pre-commercialisation stage and compare favourably to equivalent cyanidation methods, including gold recovery percentage. Thiourea has been implemented commercially for ores containing stibnite.[22] Yet another alternative to cyanidation is the family of glycine-based lixiviants.[23]
Legislation
[edit]The US states of Montana[24] and Wisconsin,[25] the Czech Republic,[26] Hungary,[27] have banned cyanide mining. The European Commission rejected a proposal for such a ban, noting that existing regulations (see below) provide adequate environmental and health protection.[28] Several attempts to ban gold cyanidation in Romania were rejected by the Romanian Parliament. There are currently protests in Romania calling for a ban on the use of cyanide in mining (see 2013 Romanian protests against the Roșia Montană Project).
In the EU, industrial use of hazardous chemicals is controlled by the so-called Seveso II Directive (Directive 96/82/EC,[29] which replaced the original Seveso Directive (82/501/EEC[30] brought in after the 1976 dioxin disaster. "Free cyanide and any compound capable of releasing free cyanide in solution" are further controlled by being on List I of the Groundwater Directive (Directive 80/68/EEC)[31] which bans any discharge of a size which might cause deterioration in the quality of the groundwater at the time or in the future. The Groundwater Directive was largely replaced in 2000 by the Water Framework Directive (2000/60/EC).[32]
In response to the 2000 Baia Mare cyanide spill, the European Parliament and the Council adopted Directive 2006/21/EC on the management of waste from extractive industries.[33] Article 13(6) requires "the concentration of weak acid dissociable cyanide in the pond is reduced to the lowest possible level using best available techniques", and at most all mines started after 1 May 2008 may not discharge waste containing over 10ppm WAD cyanide, mines built or permitted before that date are allowed no more than 50ppm initially, dropping to 25ppm in 2013 and 10ppm by 2018.
Under Article 14, companies must also put in place financial guarantees to ensure clean-up after the mine has finished. This in particular may affect smaller companies wanting to build gold mines in the EU, as they are less likely to have the financial strength to give these kinds of guarantees.
The industry has come up with a voluntary "Cyanide Code"[34] that aims to reduce environmental impacts with third party audits of a company's cyanide management.
References
[edit]- ^ a b Gail, Ernst; Gos, Stephen; Kulzer, Rupprecht; Lorösch, Jürgen; Rubo, Andreas; Sauer, Manfred; Kellens, Raf; Reddy, Jay; Steier, Norbert; Hasenpusch, Wolfgang (2011). "Cyano Compounds, Inorganic". Ullmann's Encyclopedia of Industrial Chemistry. doi:10.1002/14356007.a08_159.pub3. ISBN 978-3-527-30385-4.
- ^ Etris, S. F. (2010). "Silver and Silver Alloys". Kirk-Othmer Encyclopedia of Chemical Technology. pp. 1–43. doi:10.1002/0471238961.1909122205201809.a01.pub3. ISBN 978-0471238966.
- ^ "Cyanide Management" (PDF). Australian Government.
- ^ Du Plessis, C. A.; Lambert, H.; Gärtner, R. S.; Ingram, K.; Slabbert, W.; Eksteen, J. J. (2021). "Lime use in gold processing – A review". Minerals Engineering. 174 107231. Bibcode:2021MiEng.17407231D. doi:10.1016/j.mineng.2021.107231. S2CID 240128866.
- ^ a b Gray, J. A.; McLachlen, J. (Jun 1933). "A history of the introduction of the MacArthur-Forrest cyanide process to the Witwatersrand goldfields". Journal of the Southern African Institute of Mining and Metallurgy. 33 (12): 375–397. hdl:10520/AJA0038223X_5033.
- ^ US 403202, MacArthur, John Stewart; Forrest, William & Forrest Robert, Robert, "Process of Obtaining Gold and Silver from Ores", published 1889-05-14
- ^ "Methods to recover Gold II". 2013-05-14.
- ^ a b Habashi, Fathi Recent Advances in Gold Metallurgy Archived 2008-03-30 at the Wayback Machine
- ^ The alumni quarterly and fortnightly notes. University of Illinois. January 1, 1921. Retrieved May 1, 2016.
- ^ "Mercur, UT". Retrieved May 1, 2016.
- ^ Adams, Mike D. (2005-12-02). Advances in Gold Ore Processing. Elsevier. pp. XXXVII–XLII. ISBN 978-0-444-51730-2. ISSN 0167-4528.
- ^ Greenwood, N. N. & Earnshaw, A. (1997). Chemistry of the Elements (2nd ed.), Oxford:Butterworth-Heinemann. ISBN 0-7506-3365-4.
- ^ "Technical Bulletin 1" (PDF). Multi Mix Systems. Archived from the original (PDF) on 2009-10-23.
- ^ "The absorption of gold cyanide onto activated carbon. I. The kinetics of absorption from pulps". Journal of the Southern African Institute of Mining and Metallurgy. 84 (2): 50–54. February 1984. hdl:10520/AJA0038223X_1427.
- ^ Teixeira, Luiz Alberto Cesar; Montalvo, Javier Paul; Yokoyama, Andia, Lídia; da Fonseca Araújo, Fabiana Valéria; Sarmiento, Cristian Marquez (2013). "Oxidation of cyanide in effluents by Caro's Acid". Minerals Engineering. 45: 81–87. Bibcode:2013MiEng..45...81T. doi:10.1016/j.mineng.2013.01.008. Retrieved 2 May 2021.
{{cite journal}}: CS1 maint: multiple names: authors list (link) - ^ a b UNEP/OCHA Environment Unit "UN assessment mission – Cyanide Spill at Baia Mare, March 2000".
- ^ Maprani, Antu C.; Al, Tom A.; MacQuarrie, Kerry T.; Dalziel, John A.; Shaw, Sean A.; Yeats, Phillip A. (2005). "Determination of Mercury Evasion in a Contaminated Headwater Stream". Environmental Science & Technology. 39 (6): 1679–1687. Bibcode:2005EnST...39.1679M. doi:10.1021/es048962j. PMID 15819225.
- ^ Al, Tom A.; Leybourne, Matthew I.; Maprani, Antu C.; MacQuarrie, Kerry T.; Dalziel, John A.; Fox, Don; Yeats, Phillip A. (2006). "Effects of acid-sulfate weathering and cyanide-containing gold tailings on the transport and fate of mercury and other metals in Gossan Creek: Murray Brook mine, New Brunswick, Canada". Applied Geochemistry. 21 (11): 1969–1985. Bibcode:2006ApGC...21.1969A. doi:10.1016/j.apgeochem.2006.08.013.
- ^ "Long Term persistence of cyanide species in mine waste environments", B. Yarar, Colorado School of Mines, Tailings and Mine Waste '02, Swets & Zeitlinger, ISBN 90-5809-353-0, pp. 197 (Google Books).
- ^ BBC News, BBC: "Cyanide seeps into PNG rivers", March 23, 2000.
- ^ Wilson, T. E. La politica es la politica: "After cyanide spill, can First Majestic clean up its act?" April 21, 2018.
- ^ La Brooy, S.R.; Linge, H.G.; Walker, G.S. (1994). "Review of gold extraction from ores". Minerals Engineering. 7 (10): 1213–1241. Bibcode:1994MiEng...7.1213L. doi:10.1016/0892-6875(94)90114-7.
- ^ "Glycine lixiviants". Mining and Process Solutions. Retrieved 23 April 2021.
- ^ The Citizens Initiative banning of cyanide mining in the State of Montana, US Archived October 21, 2007, at the Wayback Machine
- ^ 2001 Senate Bill 160 Archived 2006-10-10 at the Wayback Machine regarding the use of cyanide in mining.
- ^ "Czech Senate bans use of cyanide in gold mining". Nl.newsbank.com. 2000-08-10. Retrieved 2013-01-03.
- ^ Zöld siker: törvényi tilalom a cianidos bányászatra! Archived July 21, 2011, at the Wayback Machine
- ^ International Mining - European Commission rejects proposed ban on using cyanide in extractivism|extractive industry, July, 2010
- ^ Council Directive 96/82/EC of 9 December 1996 on the control of major-accident hazards involving dangerous substances. For the modifications see the consolidated version.
- ^ Council Directive 82/501/EEC of 24 June 1982 on the major-accident hazards of certain industrial activities. Not in force.
- ^ Council Directive 80/68/EEC of 17 December 1979 on the protection of groundwater against pollution caused by certain dangerous substances. Not in force.
- ^ Directive 2000/60/EC of the European Parliament and of the Council of 23 October 2000 establishing a framework for Community action in the field of water policy (the Water Framework Directive). For the modifications see the consolidated version.
- ^ Directive 2006/21/EC of the European Parliament and of the Council of 15 March 2006 on the management of waste from extractive industries. For the modifications see the consolidated version.
- ^ ICMI cyanidecode.org International Cyanide Management Code For The Manufacture, Transport, and Use of Cyanide In The Production of Gold
External links
[edit]- Efforts at a cleaner process
- Yestech A different commercial method that does not use toxic cyanide
- Cyanide Uncertainties (PDF)
- How gold is extracted by cyanidation process
Gold cyanidation
View on GrokipediaHistory
Early discoveries and patents
The solubility of gold in aqueous cyanide solutions was first experimentally demonstrated in the early 19th century, with chemists such as F. W. Elsner confirming in 1846 that gold dissolves in potassium cyanide under oxidizing conditions to form the soluble complex [Au(CN)₂]⁻.[8] However, these observations did not lead to a practical extraction method due to the slow dissolution kinetics and lack of efficient recovery techniques. Practical development began in the 1880s amid declining yields from traditional mercury amalgamation in gold mining, particularly in regions like New Zealand and South Africa.[9] Scottish chemist John Stewart MacArthur, collaborating with brothers Dr. Robert Williams Forrest and William Forrest, conducted systematic experiments in Glasgow starting around 1884 to address these limitations. Their approach involved treating finely crushed gold-bearing ore with dilute alkaline cyanide solutions (typically 0.1-0.3% sodium or potassium cyanide) under aerobic conditions to dissolve gold selectively, followed by precipitation using zinc shavings in the MacArthur-Forrest process. This innovation achieved extraction efficiencies up to 90% from refractory ores previously uneconomical.[10][11] MacArthur filed for patents in 1887, securing British Patent No. 14,174 on October 7, 1887, titled "Process of Obtaining Gold and Silver from Ores," which described the core method of cyanidation leaching and zinc precipitation. Equivalent patents were granted internationally, including U.S. Patent 403,202 in 1889, validating the process's novelty despite prior art claims. These patents spurred rapid adoption, with the first commercial plant operational at the Crown Mines in Johannesburg, [South Africa](/page/South Africa), by 1890, though legal challenges like the 1896 "Great Cyanide Case" tested their validity against earlier cyanide uses in plating and minor extractions.[8][3]
Industrial adoption and scaling
The MacArthur-Forrest cyanide process saw its first commercial implementation in late 1890 at a plant operated by the Gold Recovery Syndicate in the Witwatersrand region of South Africa, where it treated approximately 10,000 tons of gold-bearing tailings per month.[12] This initial application targeted milling residues that prior methods, such as chlorination, had failed to process efficiently due to the refractory nature of unoxidized pyritic ores prevalent in the deep-level reefs.[12] Recovery rates improved markedly, from around 50-60% under traditional amalgamation and roasting techniques to over 90%, as the process dissolved gold into soluble aurocyanide complexes amenable to zinc precipitation.[9] Rapid scaling followed in the Witwatersrand Basin, where the process averted industry stagnation by enabling the economic extraction from lower-grade and deeper ores that milling alone could not sustain.[12] By 1892, multiple Rand mines had installed cyanide plants, transitioning from batch to continuous vat leaching operations that handled thousands of tons daily; this expansion correlated with a rebound in Transvaal gold output, rising from roughly 1.2 million ounces in 1890 to over 3 million ounces annually by the early 1900s.[9] Innovations such as filter presses for slurry dewatering and agitation tanks for faster dissolution further facilitated larger-scale throughput, reducing processing times from weeks to days and minimizing cyanide consumption through optimized solution strengths (typically 0.05-0.1% NaCN).[13] Global adoption accelerated in the decade following, with Australia's first commercial cyanide plant commencing operations in 1892 at the Excelsior Mill in Charters Towers, Queensland, where it similarly boosted yields from refractory quartz ores.[14] By 1900, the technology had diffused to North American operations, including early adaptations in Utah's Mercur district, marking the onset of widespread hydrometallurgical dominance over pyrometallurgical alternatives.[15] Scaling continued through the early 20th century with plant capacities expanding to process millions of tons yearly, underpinned by supply chain developments for bulk sodium cyanide production and engineering refinements like multi-stage countercurrent leaching to enhance efficiency and reduce reagent costs.[16] This proliferation transformed gold mining from labor-intensive, high-grade exploitation to industrialized, low-grade ore treatment, sustaining output amid depleting surface deposits.[9]Chemical Principles
Core reactions in gold dissolution
The dissolution of gold in aerated alkaline cyanide solutions forms the water-soluble dicyanoaurate(I) anion, enabling selective extraction from ores. The overall stoichiometry, known as Elsner's equation, is represented as: This reaction consumes one mole of oxygen and two moles of water per four moles of gold dissolved, producing four moles of hydroxide ions that maintain the solution's alkalinity.[17][18][19] The process operates electrochemically on the gold surface, where anodic oxidation of gold couples with cathodic reduction of dissolved oxygen. The anodic half-reaction involves gold complexation by cyanide: The cathodic half-reaction is: Four anodic reactions balance with two cathodic reactions to yield the net Elsner stoichiometry, with the mixed potential at the interface driving dissolution under diffusion control by oxygen or cyanide supply.[17][20][21] This mechanism explains the dependence on solution aeration and cyanide concentration, as oxygen acts solely as the oxidant without direct participation in gold complexation.[22][23]Influencing factors like oxygen and pH
Oxygen serves as an essential oxidant in the cyanidation process, facilitating the dissolution of gold through the reaction 4 Au + 8 CN⁻ + O₂ + 2 H₂O → 4 [Au(CN)₂]⁻ + 4 OH⁻, where its consumption directly limits the rate of gold leaching in oxygen-deficient conditions.[24] Insufficient dissolved oxygen (DO) levels below 4 mg/L can significantly constrain gold extraction kinetics, while maintaining higher concentrations, such as 5–6 mg/L or up to 12 ppm via enhancements like hydrogen peroxide addition, accelerates dissolution and reduces cyanide requirements.[25][26][27] In practice, pre-oxidation of sulfide-bearing ores with pure oxygen mitigates inhibitory effects from minerals like pyrite, enabling more efficient subsequent cyanidation by oxidizing reactive species beforehand.[28] The pH of the leaching solution profoundly influences cyanide speciation and process efficacy, with alkaline conditions (typically pH 10–11) favoring the predominance of free cyanide ions (CN⁻) over volatile hydrogen cyanide (HCN), thereby minimizing toxic gas evolution and cyanide loss.[29][30] At pH values above 10.5, gold dissolution rates improve due to reduced OH⁻ adsorption on gold surfaces and lower cyanide consumption, often achieved by adding lime (Ca(OH)₂) to buffer against acidification from ore reactions.[29][30] Deviations to lower pH increase HCN formation, elevating cyanide consumption by the pulp and risks from gaseous emissions, though atmospheric losses remain relatively stable; conversely, excessively high pH may inhibit leaching through surface passivation.[31][32] These factors interact synergistically, as oxygen addition during cyanidation can generate local pH increases via hydroxide production, necessitating pH monitoring and adjustment to sustain optimal CN⁻/O₂ ratios for maximal gold recovery.[33][34] In refractory ores, elevated DO combined with controlled pH during pre-oxidation phases has been shown to enhance overall extraction by countering sulfide passivation.[28]Process Description
Ore preparation and cyanidation leaching
Ore preparation begins with primary crushing of run-of-mine gold ore using jaw or gyratory crushers to reduce particle size to approximately 100-200 mm, followed by secondary and tertiary crushing with cone or impact crushers to achieve a size of 5-20 mm. [35] This comminution exposes gold particles encapsulated within the ore matrix, enhancing subsequent liberation. [36] Grinding then occurs in ball or SAG mills, typically reducing the ore to a fine pulp with 80% passing 75-150 μm (P80), depending on ore type and gold particle size distribution, to maximize surface area for cyanide contact while balancing energy costs and over-grinding risks. [37] [38] Slurry density is adjusted to 30-50% solids post-grinding, often via classification with hydrocyclones to recycle oversize material. [39] Cyanidation leaching involves forming a pulp from the prepared ore and adding a dilute alkaline sodium cyanide (NaCN) solution, typically 0.01-0.05% w/v cyanide concentration, in agitated tanks or vats. [36] The process relies on the Elsner equation, where gold dissolves as Au(CN)₂⁻ in the presence of oxygen: 4Au + 8NaCN + O₂ + 2H₂O → 4Na[Au(CN)₂] + 4NaOH. [40] Leaching occurs under controlled conditions: pH 10-11 maintained with lime to prevent cyanide decomposition to toxic HCN gas, dissolved oxygen levels of 5-10 ppm via air sparging or pure oxygen injection, and temperatures of 20-50°C to optimize kinetics without excessive reagent loss. [1] Retention times vary from 12-72 hours in multi-stage counter-current tanks, achieving 80-95% gold extraction for free-milling ores, with pulp agitation ensuring uniform contact. [41] Lead nitrate or other accelerators may be added to mitigate passivation by sulfides, while copper and other impurities can consume cyanide, necessitating higher dosages or pre-treatments. [42] The resulting pregnant leach solution (PLS) contains solubilized gold, separated from barren tailings via thickening and filtration. [43]Gold recovery from pregnant solutions
The pregnant solution in gold cyanidation, also known as the leachate or eluate, contains dissolved gold primarily in the form of the aurocyanide complex [Au(CN)2]-, typically at concentrations of 0.001 to 0.01 g/L gold, alongside silver and impurities like copper and iron cyanides.[44] Recovery from this solution aims to selectively extract and concentrate the gold for final refining, with overall recovery efficiencies often exceeding 95% in optimized operations.[45] The two predominant industrial methods are adsorption onto activated carbon and zinc cementation via the Merrill-Crowe process, chosen based on solution clarity, impurity levels, and silver content. ![Dicyanoaurate(I)][inline] Activated carbon adsorption, employed in carbon-in-pulp (CIP) and carbon-in-leach (CIL) variants, is the most widely used technique due to its selectivity for the gold-cyanide complex over base metal cyanides. In CIP, the pregnant pulp from leaching is contacted countercurrently with granular activated carbon (typically coconut shell-based, 6x12 or 8x16 mesh size) in a series of agitated tanks or columns, where gold loading capacities reach 1,000 to 4,000 g/t carbon under alkaline conditions (pH 10-11).[45] The loaded carbon is then separated, screened, and subjected to elution using hot (110-140°C) caustic cyanide solution under pressure (Zadra or AARL processes), desorbing over 95% of the gold; the resulting rich eluate undergoes electrowinning in stainless steel wool cathodes at 2-4 V and 50-100 A/m² to deposit high-purity gold (99.5%+).[45] CIL integrates adsorption during leaching, reducing equipment needs but risking higher carbon abrasion. This method dominates heap leach and agitated tank operations for low-grade ores, though carbon fouling by organics or silica can lower efficiency, necessitating regeneration via acid washing or thermal reactivation at 650-750°C. The Merrill-Crowe process, favored for pregnant solutions with low suspended solids (<10 ppm after clarification) and high silver-to-gold ratios, involves zinc dust cementation following solution deaeration to prevent zinc passivation. The clarified, oxygen-depleted solution (DO <0.5 ppm) is reacted with fine zinc powder (95% <10 μm) at 20-50 g/m³ dosage in agitated vessels, displacing gold via the redox reaction: Zn + 2[Au(CN)2]- → 2Au + [Zn(CN)4]2-, yielding a doré precipitate of 90%+ precious metals.[46] Filtration through precoat pressure filters (e.g., leaf or plate-and-frame) recovers the precipitate, which is then retorted to remove mercury and fluxed for smelting into bullion. Barren solution is sampled via a continuous automatic system using a solenoid valve controlled by a timer for periodic aliquots; operators inspect for clarity to detect filtration issues; composite samples are taken proportional to flow or time.[47] This method achieves >99% recovery for silver-rich solutions but is less selective for high-copper liquors, requiring prior cementation or solvent extraction to avoid zinc overconsumption (up to 1.2-1.5 times stoichiometric).[46] Vacuum deaeration towers ensure process reliability, minimizing oxygen interference that could reduce yields by 5-10%.[44] Alternative or supplementary techniques include ion-exchange resins for selective gold loading in copper-contaminated solutions and direct electrowinning for high-grade eluates (>1 g/L Au), though these are less common due to higher energy costs or lower selectivity. Post-recovery barren solutions are typically recycled to leaching after cyanide detoxification via oxidation (e.g., SO2/air or hydrogen peroxide) to below 50 ppm free cyanide, supporting closed-circuit efficiency.[44] Overall, method selection balances capital costs, with carbon systems suiting turbid pulps and Merrill-Crowe clearer flowsheets, contributing to global gold production where cyanidation recovers over 90% of mined gold.[45]Industrial Applications and Variations
Heap leaching versus tank leaching
Heap leaching involves stacking crushed ore on impermeable pads and percolating a dilute cyanide solution through the heap to dissolve gold, with the pregnant solution collected at the base for further processing.[48] This method suits low-grade ores, typically with head grades below 1-2 g/t Au, as it minimizes preprocessing costs by using coarser particle sizes, often 5-20 mm.[49] In contrast, tank leaching, also known as agitation leaching, requires grinding ore to finer sizes, usually below 75-150 μm, and mixing it into a slurry in agitated tanks where cyanide solution contacts the ore under mechanical stirring to enhance dissolution kinetics.[48][45] The primary distinction lies in ore preparation and contact efficiency: heap leaching relies on gravity percolation, which limits solution channeling and uneven wetting, leading to recovery rates of 50-85% for gold, averaging around 70% in operating facilities.[48][49] Tank leaching achieves higher recoveries of 85-95% due to intimate mixing and better control of variables like oxygen supply and pH, making it preferable for higher-grade ores or those requiring finer liberation.[48][50] However, heap leaching offers lower capital and operating costs, with expenses per ounce of gold as low as $500-800, compared to $900-1,500 for tank-based methods, primarily because it avoids energy-intensive grinding and agitation.[51][52]| Aspect | Heap Leaching | Tank Leaching |
|---|---|---|
| Ore Grade Suitability | Low-grade (<1-2 g/t Au) | Higher-grade or complex ores |
| Particle Size | Coarse (5-20 mm) | Fine (<75-150 μm) |
| Recovery Rate | 50-85% (avg. 70%) | 85-95% |
| Processing Time | Months (slower kinetics) | Days to weeks (faster) |
| Capital Cost | Lower (no mills/tanks) | Higher (grinding mills, agitators) |
| Operating Cost | $500-800/oz Au | $900-1,500/oz Au |
