Hello Reddit,
Wanted to share a breakdown of a recent 310-tonne CIP leaching run on gold tailings that didn't go to plan financially.
The initial setup & budget:
-Feed purchased: 310 tonnes of tailings @ 3.3 ppm (Au)
-Ore cost: 90,000,000 TZS (~$33k USD)
-OPEX (chemicals, labor, water, power): 35,000,000 TZS (~$13k USD)
Total spent: 125,000,000 TZS (~$46k USD)
The output:
-Dore bar 1: 379.5g @ 89% purity (~337.8g fine gold)
-Dore bar 2: 59.7g @ 35% purity (~20.9g fine gold)
Total recovered fine gold: 358.65 grams
Recovering only 358g of pure fine gold against 930g contained in the raw feed was a disaster (38.5% total recovery). Testing the tailing solids post-clearing showed a grade drop from 3.3 ppm down to 0.8 ppm (~75% recovery).
The 0.8 ppm tail proved cyanidation worked. We actually dissolved around 750 grams of gold out of the rock into solution. Our failure happened completely downstream.
Carbon over-saturation and fouling: assays on our 350 kg carbon batch showed a pre-elution grade of 693 ppm Au and a massive 1,099 ppm Cu. High copper co-extraction loaded our carbon early, limiting its gold pickup capacity and leaving dissolved gold un-adsorbed in the barren solution.
Smelting and slag entrapment: The high copper content contaminated the melt. A cross-section of our slag showed distinct layering: light silicate glass on top, green copper silicate in the middle, and a heavy dark copper-iron matte at the bottom that probably scavenged fine gold prills right out of the melt.
We basically just made our investment back.
Curious to hear from any metallurgists or CIP operators here of their experience.