Mirah Gold Project Operating Manual KBK

MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA
OPERATING MANUAL
1.0 INTRODUCTION
The Mirah Plant is a Gold, Silver and Copper recovery plant incorporating the
following:
Crushing
Milling
Classification
Leaching
Adsorption
Elution
Electrowinning
Smelting
Cyanide Recovery
Tailings Disposal
Reagent Mixing/Supply Services
It is designed for a nominal throughput rate of 700,000 tonnes per annum of soft ore,
or 650,000 TPA of hard ore.
The Plant Operating Manual is written as guide to operators and other personnel of
the plant in order to successfully operate the plant facilities. The manual should be
used in conjunction with other information not included but supplied separately to the
Client. This includes vendors manuals, engineering drawings, PLC programs, etc.
The manual is divided into three volumes. Volume 1 has the three main Sections
being: Plant Description, Plant Operating Procedures and Maintenance. Each of
these is then divided into smaller specific plant areas or equipment types to enables
quick reference to each Section. Volume 1 contains information in general that has
been prepared specifically for this manual. Volume 2 and 3 contain information that
was prepared during the design of the plant and facilities. Volume 2 contains design
documents and Volume 3 design drawings and information relating to the drawings.
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2.0 PLANT DESCRIPTION
2.1 Overview
The Mirah gold ore treatment plant consists of the following major process areas:
Area 15 - Crushing
Area 25 - Milling
Area 40 - Leaching/Adsorption
Area 45 - Gold Recovery
Area 46 - Reagents
Area 48 - Cyanide Recovery
Area 50 - Services Water
Area 51 - Services Power
Area 53 - Services Air and Diesel
This Section describes the process route, equipment and operation of all equipment.
2.2 Design Summary
The plant is designed for a nominal throughput of 700,000 tap. Due to variations in
ore hardness the SAG mill has been sized to treat the hardest component of the
Lebar and Kuning ores Kuning hard ore at a rate of 650,000 TPA. Milling capacities
for the softer ores (i.e.: Lebar hard and soft and Kuning soft ore) will be 700,000 tap.
The required leach residence time for the Lebar ore is lower than required for the
Kuning ores. The leach circuit has been designed for 33.5 hours residence time for
Lebar hard ore at 700,000 tpa. At the lower throughput of 650,000 tpa for Kuning ore,
the leach residence time is 36.1 hours.
All of the equipment selected is designed at a capacity of 700,000 tpa.
2.3 Comminution
Reference Drawing: 4272-00-F-001 Crushing and Milling
Coarse ore can be either directly tipped or fed by front end loader into a 100 t
capacity ROM bin 15BIN01. A grizzly (15SCS01) with a spacing of 500 mm has been
provided to reject excessively coarse rocks which may block the coarse ore bin,
apron feeder or jaw crusher. This aperture is variable. Ore is withdrawn from the
coarse ore bin by a 1200 mm wide x 6500 mm long apron feeder, 15FDA01, fitted
with a variable speed hydraulic drive. Ore discharging from the apron feeder drops
into a single toggle jaw crusher (15CRJ01) and then onto the mill feed conveyor
(15CVR01). The mill feed conveyor delivers ore into the SAG mill (25MLS01).
The Mirah comminution circuit consists of an open circuit 850 mm x 1100 mm (34 x
44) single toggle jaw crusher 15CRJ01, powered by a 110 kW motor and a 4.7 m
diameter x 7.8 m long fixed speed grate discharge SAG mill, 25MLS01, powered by a
2500 kW drive and rotating at 76% critical speed. The mill operates in closed circuit
with a bank of 5 x 300 mm hydrocyclone classifiers, 25CYC01/05.
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The design size reductions are as follows:
ROM ore feed mm max < 750

Jaw crusher product size, mm P80 = 110
Leach feed sizing, micron P80 = 75
The mill has been sized to grind Kuning hard ore from a feed size of F 80=110 mm to a
product size of P80=75 microns at a throughput of 650,000 tpa. The ball charge
required to achieve this is 11% by volume @28% mill load. The motor has been sized
to accommodate a ball charge of 12% by volume @ a mill load of 35%.
Mill feed rate is measured by a single idler weightometer, 15WIB01, calibrated for a
tonnage range of 0 to 100 t/h. A control loop will automatically adjust the feed rate of
the primary apron feeder, 15FDA01, to maintain a consistent feed rate to the milling
circuit.
Quicklime is added to the mill feed conveyor, 15CVR01, from a 6 t lime hopper,
46BIN04, using a variable speed belt feeder, 46FDB01. This is to modify the slurry
pH to 10.0-10.5 to minimise the consumption of cyanide and the generation of highly
toxic hydrogen cyanide gas (HCN) in the atmosphere above the leach and adsorption
tanks and around the carbon safety screen. The belt feeder speed is adjusted
manually.
Dust suppression facilities are provided for the ROM bin, 15BIN01, using a spray bar
over the bin. A dust extraction system (15DEX01) is provided for the mill feed
conveyor, 15CVR01, and the primary jaw crusher, 15CRJ01.
PLC sequences are provided for starting and stopping the crusher, apron feeder, lime
feeder and mill feed conveyor. The sequences are initiated via a group start push
button (see Section 4.1).
A spillage pump, 25PPS01, is provided to remove spillage from under the mill and
cyclone tower.
Ball charging is conducted using the ball kibble, 25KBL01, and the kibble hoist,
25HST01, located beside the mill feed conveyor and the SAG mill. Balls are hoisted
up to above the ball charging chute, 25CHU17, where they are fed into the mill.
2.4 Classification and Screening
Reference Drawing: 4272-00-F-001 Crushing and Milling
The SAG mill discharge passes through a 12 mm aperture trammel to remove mill
scats. The undersize is pumped by either of two 8 x 6 centrifugal pumps,
25PPC01/02, with 110 kW drives to the classification cyclones (25CYC01/05). A
common variable speed drive, 25VSD01, and sump level probes are provided for
control of the level in the mill discharge sump in order to stabilize the feed to the
cyclones. Trommel oversize reports to a scats bin.
The cyclone cluster consists of a bank of 5 x 300 mm hydrocyclones.
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Cyclone underflow, at approximately 70% solids, gravitates to the SAG mill feed
chute while cyclone overflow at a design density of 40% solids gravitates to a 1200
mm x 3600 mm, 0.6 mm aperture vibrating trash screen, 25SCV01. Plastic, oversize
rock, wood, blasting wire and other trash in the slurry is removed by the trash screen
before it enters the cyanide leach circuit. The trash screen undersize discharges to
the leach tank or can be diverted to the 1st adsorption tank.
2.5 Leach and Adsorption
Reference Drawing: 4272-00-F-002 Leach and CIL
The cyanide leach and carbon adsorption circuit consists of seven tanks arranged as
one leach, 40TNK01, and six adsorption tanks, 40TNK02/07. Total leach and
adsorption time is approximately 33.5 hours, for softer ores and 36.1 hours for
Kuning hard ore based on an average slurry density of 40% solids.
Sodium cyanide solution can be added to either the leach or 1st adsorption tank.
Test work indicates that relatively high cyanide concentrations (approximately 0.1%)
will be required for optimum silver recovery. Although this will result in higher residual
cyanide levels in the CIL tailings, the cyanide will be recovered in the cyanide
recovery facility.
A continuous launder with a slope of 1.5 is used for slurry transfer. The leach tank
has a diameter of 12.5 m. All the six adsorption tanks have a diameter of 9.5 m.
Design tank volumes are as follows:
Utilised Utilised
Tank Duty Height Volume
m m
40TNK01 L1 12.1 1,473
40TNK02 A1 10.3 730
40TNK03 A2 10.0 709
40TNK04 A3 9.7 688
40TNK05 A4 9.4 667
40TNK06 A5 9.1 645
40TNK07 A6 8.8 624
Total Volume 5,536
A system of plugs and slide-gates is provided for bypassing individual tanks for
maintenance purposes. More than one tank may be bypassed, but this is not
recommended, as precious metal recovery may be adversely affected.
The leach tank is fitted with a 55 kW mechanical agitator (40AGT01) and each of the
adsorption tanks is fitted with a 45 kW mechanical agitator, 40AGT02/07. Each
agitator consists of dual down pumping impellers.
Oxygen is necessary for the leaching of gold by cyanide. Although metallurgical test
work did not indicate Lebar and Kuning ores to have a significant oxygen demand,
aeration sparging is provided in both the leach tank and the first two adsorption
tanks. The design aeration rate is 1.5 Nm/t ore per hour. This is equivalent to a flow
rate at 48 Nm/h of air per tank. All the agitators are supplied with rotary couplings for
air sparging and the air flow rate to each tank is measured by a rota meter.
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A meter will be provided in tank 40TNK01 for monitoring slurry pH. pH is maintained
at 10.0-10.5 to minimise cyanide consumption and prevent high concentrations of
toxic hydrogen cyanide gas (HCN) in the leach, adsorption and tails screen areas.
This is controlled by changing the addition of lime to the mill (see Section 2.3).
Provision has been made for a future leach tank if more residence time is required.
Carbon is moved counter current to the pulp flow at a design rate of 10 tpd. Transfer
pumps, 40PPS15/19, are provided in 40TNK03 to 07 for movement of carbon from
vessels A6 to A1 (40TNK07 to 02) and a loaded carbon pump, 40PPS02, is provided
in tank A1(40TNK02) for transfer of carbon to the 1.2 m x 2.4 m vibrating loaded
carbon screen, 40SCV03, ahead of the carbon elution column. The loaded carbon
screen has an aperture of 0.8 mm.
Carbon is moved batch wise from tank to tank over a 12 hour period. When carbon
is being transferred the volumetric concentration of carbon in the tanks should be
monitored to ensure the required carbon profile is maintained in each tank. The
design concentration of carbon is 15 g/l.
Mechanically swept carbon retention screens, 40SCC02/07, are provided in the

adsorption tanks. Davit hoists, 40HST02/07, are provided for lifting the screens from
the tanks for maintenance purposes. All screen components in contact with slurry are
fabricated from stainless steel and the screen is fabricated from 0.7 mm x 7.0 mm
slotted stainless steel mesh.
The leach and adsorption circuit is largely manually controlled. There are few
interlocks with other areas of the plant, and none which will trip the mill feed, crushing
and conveying system. Some of the more significant control features are listed below
Agitators are started and stopped manually at field pushbutton stations;

drive status and motor current is monitored through the plant control
system
Carbon advance is controlled manually by the leach area operator, based
on field observations of carbon concentrations in the adsorption tanks
The loaded carbon transfer pump, 40PPS02, is started manually but will
stop automatically when the elution column feed hopper is full of carbon
and a high level switch is actuated
Leach air flow rates are controlled manually. A rota meter is provided for
measurement of air addition to each leach tank
Leach and adsorption tank bypassing and drainage require a series of
manual operations. No automatic facilities are provided
A carbon safety screen, 40SCV04, is provided on the tail of the adsorption train to
remove any carbon which may escape from the circuit. The screen is a 1.2 m x 3.6 m
vibratory screen with 0.6 mm polyurethane deck. Any carbon oversize is kept for later
treatment to prevent gold losses.
Operational procedures for this area are described in more detail in Section 3.4.
The spillage pump, 40PPS03, is provided for the leach and adsorption area for the
clean-up of slurry in the bunded area.
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2.6 Gold Recovery
Reference Drawings: 4272-00-F-003 Elution

4272-00-F-005 Gold Recovery
The gold recovery area comprises facilities for carbon elution, carbon regeneration,
electrowinning, bullion smelting and handling and the provision of the reagents
necessary for the carbon elution process.
Elution of gold and silver from the loaded carbon is achieved using a modified Anglo
American Research Laboratory (AARL) method, (a split elution). The major
advantage of a split elution is an improvement in electrowinning efficiency. Loaded
carbon is transferred from the first adsorption tank, 40TNK02, to the elution column,
feed hopper 45BIN03, via the loaded carbon screen, 40SCV03. The recovery area is
designed to treat two 5 tonnes batches of carbon loaded to 9,000 g/t Au + Ag a day,
i.e. A total of 10 tonnes of loaded carbon per day.
Since Regeneration is not required on all the carbon, 5 tonnes of eluted carbon per
day is regenerated in a horizontal carbon regeneration kiln, 45KLN01, and returned
to the last adsorption tank, 40TNK07, and 5 tonnes of eluted carbon per day is
returned from the elution column directly to the last adsorption tank, bypassing
carbon regeneration.
PLC sequences are provided for carrying out several of the gold recovery activities.
These sequences are initiated via the CITECT operator interface computer.
Sequences include:
AARL carbon elution

Transfer of spent electrolyte to cyanide mixing or leaching
Transfer of carbon to regeneration or directly to the last adsorption tank
The regeneration kiln is controlled from a separate PLC control panel located
adjacent to the kiln.
Operations such as electrowinning, cathode handling and bullion smelting are

manually controlled and operated, with some remote monitoring and interlocking
provided for system protection.
Operational procedures for this area are described in more detail in Section 3.5 to
3.7.
2.6.1 Loaded Carbon Recovery
Slurry containing loaded carbon is drawn from the first adsorption tank, 40TNK02, by
a submersible slurry pump, 40PPS03. The slurry discharges onto a 1.2 m x 2.0 m
vibrating loaded carbon screen, (40SCV03) fitted with 0.8 mm aperture
polypropylene screen panels. The slurry passes through the screen and discharges
back to the first or second adsorption tank. The carbon passes over the screen and is
washed by water sprays.
The washed carbon discharges into the screen oversize chute, from which it falls into
the elution column feed hopper, 45BIN03, and is transferred into the elution column
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(45ELU01) as required. Excess water in the carbon drains from the elution column
onto the floor below the column then drains to the CIL area sump pump.
2.6.2 Elution
The elution column, 45ELU01, is a rubber lined pressure vessel with torispherical
ends. The effective volume of the elution column is nominally 12.2 m, allowing for
the containment of 5.0 tonnes of carbon along with some excess volume which
prevents overfilling and allows for solution disengagement. The column and
associated piping is lagged and clad to minimise heat losses.
At the base of the column is the elution column distributor, 45DBR06. The various
solutions used in the elution process enter the column via an inlet manifold. The
column distributor allows water to drain from the column while the column is being
filled with carbon and allows the various solutions to be injected and distributed into
the column during the elution process.
Solution heating for the elution process is achieved by a closed circuit heating
system. This comprises an 1800 kW diesel fired heater, heat exchangers and a
thermal oil circulation pump.
Thermal oil, a high flash point heat transfer fluid, is circulated through the heater
system, 45HTR01, and the primary heat exchange, 45HEX01, by the thermal oil
pump, 45PPC07. Heat is transferred from the thermal oil to the elution feed solution.
The gold is eluted from the carbon at a temperature of 110 C. The primary heat
exchanger is of the plate and frame type.
Waste heat is recovered from the hot solution discharging from the elution column by
a reclaim heat exchanger, 45HEX02, which is also of the plate and frame type. The
recovered heat is transferred to fresh incoming solution prior to final heating of the
solution in the primary heat exchanger.
The elution process is based on the Anglo American Research Laboratories (AARL)
system, using a five step cycle to firstly remove contaminants then elute the gold
from the carbon. These steps include:
Step 1 Acid injection to remove calcium, magnesium, copper, zinc, silica and
some organics from the carbon
Step 2 Hot water rinse to complete the removal of acid and preheat the carbon
bed
Step 3 Caustic-cyanide pre-soak to chemically prepare the carbon for gold

elution
Step 4 Hot water elution to desorb or elute gold from the carbon into a
concentrated volume from which the gold can be recovered by electrode
position
Step 5 Water cooling to terminate the elution process and cool the carbon
sufficiently to allow safe transfer out of the elution column
As the elution is a split elution procedure, during step 4 lean elute is first pumped
through the column from the lean elute tank, 45TNK34, and exits the column to either
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of the electrolyte tank, 45TNK08/09. During the second half of step 4, fresh elution
water from 45TNK10 is pumped through the column then back to the lean eluate
tank, 45TNK34, in preparation for the next elution cycle.
The carbon elution process is fully automated. The elution sequence is initiated from
the CITECT operator interface computer.
The gold rich electrolyte or eluate at approximately 70 C is stored in one of two

electrolyte tanks, 45TNK08/09. Each tank feeds a separate electrowinning circuit.
The use of two electrowinning streams allows electrowinning to be conducted
simultaneously to elution. The gold rich liquor is pumped to three electrolytic cells,
48EWC01/03, in parallel, each containing 10 stainless steel cathodes. The gold and
silver is deposited electrolytically onto the cathode.
Various clean-up pumps are provided for spillages in the elution area. The elution
area sump pump, 45PPS07, covers the elution area. All spillages report to the first
adsorption tank, 40TNK02. An electrolyte sump pump, 45PPS08, is provided to direct
spillage from either electrolyte tank to the first adsorption tank, 40TNK02, or either
electrolyte tank, 45TNK08/09. This is manually set.
An extraction fan, 45FAN01, provided for the electrowinning cells to remove harmful
gases including hydrogen and ammonia from the cells to atmosphere. This fan
should always run while the cells are in operation.
Provision for two additional future cells has been made in the design.
2.6.3 Bullion Processing
On a periodic basis the gold sludge is washed from the cathodes with a high
pressure water spray (45PPC41) either in the cells or on a work table. All slimes from
the cells or the table are fed into the slime filter feed sump, 45SMP04. A pump,
45PPC40, feeds the sludge through a plate and frame filter, 45FTP01 and filtrate is
recirculated back to the sump. Overflow from the sump as well as any other spillage
in the area is pumped by the gold room clean-up pump, 45PPS09, to the electrolyte
spillage pump, 45PPS08, for removal.
Filtered sludge cake is then dried in a drying furnace, 45FRN01, at 150 C. The dried
cake is mixed with fluxing agents and placed in the smelting furnace, 45FRN02.
Bullion is poured into moulds. The ingots are removed from the mould, cleaned up,
weighted, stamped and stored in a safe ready for despatch from the site. The slag is
allowed to cool, before being stored for filter retreatment.
2.6.4 Elution Chemicals
The caustic cyanide pre-soak solution added in Stage 3 of the elution cycle consists
of 2% caustic soda and 2% sodium cyanide. Sodium hydroxide is fed to the caustic
cyanide tank, 45TNK17, from the caustic storage tank, 46TNK22 using the caustic
header tank, 46TNK19. Sodium cyanide is also fed to the caustic cyanide tank from
the cyanide storage tank, 46TNK14, from a header tank, 46TNK17.
Details of reagents are discussed in Section 2.11.
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2.6.5. Eluted Carbon Transfer
Transfer of eluted carbon from the elution column, 45ELU01, is performed

hydraulically. Carbon can be transferred to either the regeneration kiln feed storage
hopper, 45BIN02, via a Dutch State Mines (DSM) dewatering screen, 45SCS08, or
sent directly to the last adsorption tank, 45TNK07. Carbon is transferred under
pressure supplied by water.
The carbon transport process is controlled by a PLC sequences initiated from the
CITECT operator interface computer.
2.6.6. Carbon Regeneration
Five tonnes per day of eluted carbon is transferred to the regeneration kiln feed
storage hopper, 45BIN02, from the elution column. The carbon is hydraulically
transferred from the elution column to a dewatering screen fitted with a 0.7 mm
wedge wire screen panel. From the screen the carbon falls into a bin with sufficient
volume to accommodate 5 tonnes of carbon. A second screen in the base of the
storage hopper effects further dewatering of the carbon.
From the storage hopper the carbon is conveyed by a screw feeder into the
regeneration kiln, 45KLN01, where it is maintained at a temperature of 650 - 700 C
for a period of 20 minutes to burn-off organic foulants absorbed on the carbon and to
reactivate the surface of the carbon to restore its ability to absorb gold from the
leached slurry.
From the kiln the carbon discharges to a quench tank and is conveyed by a screw
feeder, 48FDS02, to the vibrating carbon sizing screen, 45SCV02. From the screen
carbon discharges to the last adsorption tank, 40TNK07, to repeat the gold
adsorption elution regeneration cycle.
The carbon regeneration process is controlled from a separate PLC located adjacent
to the kiln. Important variables including regeneration temperature, fault alarm and
system run/stopped status is displayed on the CITECT operator interface computer.
2.7 Cyanide Recovery
Reference Drawings: 4274-00-F-006 Cyanide Adsorption

4274-00-F-007 Resin Elution
4274-00-F-00 Cyanide Recovery System
The cyanide recovery area comprises an adsorption and elution circuit using
Vitrokele resin as the adsorbent. CIP tailings slurry is contacted with the resin in four
agitated adsorption stages. During adsorption any metal complexed or free cyanides
are loaded onto the resin.
Vitrokele Process Chemistry
Vitrokele is supplied as a sulphated resin and is conditioned prior to use dependent

on whether the aim is to recover metal or cyanide or both.
Cyanide removal is of primary concern the Vitrokele is first conditioned by contact

with a copper sulphate solution followed by treatment with sulphuric acid. The copper
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ion remains attached to the resin and is free to bind with free cyanide from the
solution being treated.
Conditioning R-SO42- + CU(CN)43- R-Cu(CN)43- + SO42-
R-CU(CN)43-+ 3/2H2SO4 R-CuCN- + 3HCN + 3/2SO42-

Adsorption R-CU- + 4CN- R-Cu(CN)43-
Elution/ R-Cu(CN)4 + 3/2 H2SO4 R-CuCN- + 3HCN + 3/2SO42-
3-
Regeneration
Cyanide Scrubbing HCN + NaOH NaCN + H2O
Cyanide is stripped from the resin by sulphuric acid and is recovered by neutralising
with sodium hydroxide. No additional regeneration of the Vitrokele resin is necessary
as the copper remains on the resin ready to bind with more cyanide.
For the recovery of metals, no conditioning is required. The resin is contacted with
the process stream to be treated and the adsorbed metals are eluted with zinc
tetracyanide. Regeneration of the resin is performed by contacting with sulphuric
acid.
The adsorption, elution and regeneration proceeds according to the following general
reactions:
Adsorption R-SO42- + Me(CN)43- R-Me(CN)43- + SO42-
Elution R-Me(CN)43- + NaCN R-CN + Me(CN)43-

or R-ME(CN)43- + Zn(CN)42- R-Zn(CN)42-+ Me(CN)43-
Regeneration R-CN + H2SO4 R-SO42- + HCN
or R-Zn(CN)42- + 2H2SO4 R-SO42- + 4HCN + ZnSO4

Because of the nature of the ore type, it is anticipated that though most of the
cyanide exiting the CIP plant will be free cyanide, there is indication that some WAD
cyanide will be present as copper. These WAD cyanides or copper metal complexes,
will load onto the resin and soon over saturate the resin with copper. As the cyanide
levels in tails must be minimised it is important to periodically remove some of the
metals off the resin i.e. metals elution. A metal elution is a fairly rapid procedure
which uses sodium cyanide as the eluant.
Additionally, the resin will scavenge any remaining silver and gold from solution. If not
removed, this would build up a loading on the resin and inadvertently reduce the
loadings of cyanide on the resin. Additionally, both gold and silver are not removed by
sodium cyanide elution. A stronger eluant, zinc tetra cyanide, and a much longer time
(up to 36 hours) is required in this process. Since the level of gold and silver loadings
are low, the elutions only need to be performed on a periodic basis.
The following tables summarises the design capacity of the circuit:
Free Cyanide Copper Silver Gold

pp, NaCN ppm Cu ppm Ag ppm Au
Cyanide Adsorption Feed 750 40 21.5 neg
Cyanide Adsorption Tails <5 <1 0.1 neg
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Resin Loadings kg/t 113 60 10 neg
Cyanide Copper/Metal Silver/Gold

Elution Elution Elution
Operation Basis Continuous Batch Batch
Feed Rate (aver 24h 0.98 (0.09)?
basis)
Eluant H2SO4 NaCN Na2Zn(CN)4
Batch Time (h) N/A 4 36
Batch Frequency (No/Day) N/A 3 1 in 3
Copper is removed from solution as solid copper cyanide using acid precipitation and
filtration. Gold and silver are recovered in an electrowinning cell. Cyanide in strip
solution is recovered by a stripping and scrubbing circuit.
2.7.1 Cyanide Adsorption
CIP tailing slurry is fed to the first of four agitated adsorption tanks, 48TNK25/28. The
nominal slurry residence time in each adsorption tank is 45 minutes, with a total
residence time of 3 h (based on 700,000 tpa throughput).
The resin is retained in the adsorption tank by a mechanically swept retention screen
(interstage screen), 48SC08/11. The pulp and resin are both kept in suspension by
7.5 kW mechanical agitators, 48AGT12/15. These are dual axial flow impellers.
Slurry flows under gravity through each of the tanks. Launders are provided with
bypass to allow tanks to be taken offline for maintenance. The slurry exits the circuit
and is screened by the resin safety screen, 48SCV05, so as to prevent resin leaving
the circuit. This is a 1.2 m x 3.6 m vibrating screen with 0.6 mm aperture. Once
screened, the slurry gravitates to the tailings sump before being pumped to the
tailings dam.
As resin loads with cyanide and metals, the resin is advanced by continuous air lifting
of slurry and contained resin, counter current to the main slurry flow. At the head of
the circuit, slurry containing loaded resin is air lifted across a vibrating loaded resin
wash screen, 48SCV06.
The loaded resin is separated from the slurry and washed before being transported
by water to either the metal or cyanide elution columns using a splitter box,
48BOX01. The box is manually switched between cyanide and metal elutions. A
positioner reports the position of the box to the CITECT interface. A total of 24 t/d of
resin is advanced.
The adsorption circuit is designed to load the resin to 60 kg/t of free cyanides (as
CN-) and 60 kg/t of metal complex cyanides including copper and silver. Elution for
free cyanide base metal complexed cyanides and precious metal complexed
cyanides requires separate procedures. Hence the resin is transported to either the
metals (48COL02) or cyanide (48COL01) elution columns.
2.7.2 Cyanide Elution
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Cyanide elution involvers the continuous elution of loaded resin in the cyanide elution
column, 48COL01.
Resin is laundered from the loaded resin screen, 48SCV06, to the resin dewatering
screen, 48SCS02. Resin is transferred at an average rate of 0.98 t/h. The operating
flow will be less for the majority of time, with occasional surges coming from the
screen during pressure transfers from either the metal or silver elution columns,
48COL02/05.
The dewatering screen, 48SCS02, is an inclined screen with 0.6 mm aperture. The
screen removes the transport water which gravitates to the final adsorption tank,
48TNK28. Resin overflow from the screen drops into the cyanide elution column,
48COL01. The column contains a dry bed of resin above a slightly fluidised bed, a
screened overflow and two distributors. The resin moves evenly through the bed into
the elution air lift, 48ALT05, where it is transported to the last adsorption tank,
48TNK28. At the outlet to this tank, an air disengagement chamber separates the air
which can contain hydrogen cyanide, HCN, a highly toxic gas.
Warning: The cyanide elution procedure generates HCN, a highly toxic gas.
Care must be taken when working in the area particularly while the
elution column is in operation.
Sulphuric acid from the sulphuric acid dilution tank, 48TNK30, is dosed into the
column through the second distributor (mid way up the column). The acid enters at
10% w/v concentration and is quickly diluted to 5% w/v. It slowly seeps up through
the bed eluting cyanide from the resin. This cyanide is present as dissolved HCN gas
in the solution. Acid is consumed in this reaction.
The spent acid overflows through the screen at the top of the column. This screen is
wedge wire piping to enable even collection of spent acid off the column. This then
gravitates into the stripper feed tank, 48TNK39. The pH of the overflow is measured
and is used to control the addition of acid into the column through a flow meter and
variable speed drives on the sulphuric acid eluant pumps, 48PPC22/23. The pH is
kept as high as possible to ensure complete use of acid. This however, must be done
in conjunction with maintaining reasonable elution efficiencies. A pH between 1.5 and
2.0 is used.
Water is added into the first distributor at the base of the column. This water acts to
wash remaining acid from the resin as well as maintain a constant up flow in the
column. The up flow relates to the total flow of both acid and water into the column.
The air lift uses water injection to fluidise the resin and air is to transport the resin to
the last adsorption tank, 48TNK28. The water injection set to minimise water exiting
the column from the water wash, while maintaining enough flow to get resin up the air
lift.
When surges come through into the column, the level of the dry bed rises. This bed
height is measured using an ultrasonic level indicator. The height is used to control
the flow rate of air to the air lifts. On an increase in height the air will increase to
remove resin at a faster rate.
2.7.3. Metals Elution
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OPERATING MANUAL
Metals elution involves the removal of copper and other base metals (excluding silver
and gold) from the resin. This needs to be done on a periodic basis to prevent over
saturation of copper on the resin. If copper leakage from tails occurs, resin needs to
be chute more frequently.
High strength sodium cyanide is required to elute the resin. Cyanide is prepared in
the metal eluant tank 48TNK33, to 10% w/v strength. The elution procedure requires
three steps:
Step 1 Recycled eluant is pumped from the recycle tank, 48TNK38, through the
elution column, 48COL02, to the precipitation tank, 48TNK35.
Step 2 Metal eluant is pumped from the metal eluant tank, 48TNK33, through the
elution column, 48COL02, to the recycle eluant tank, 48TNK38.
Step 3 Water is used to wash remaining cyanide from the column. Water washes
are returned to the second cyanide adsorption stage, 48TNK26.
2.7.4. Copper Precipitation
Each metal elution cycle results in a batch of eluate in the precipitation tank,
48TNK35. Copper is precipitated as copper cyanide (CuCN) by the addition of 98%,
sulphuric acid to solution. The reaction occurs at a pH of 2.0 and acid addition is
controlled to this pH.
To achieve precipitation, the filter feed pump, 48PPC45, pumps the copper eluate to
the precipitation filter. Concentrated sulphuric acid is injected in-line just before an in-
line mixer, 48MXR01. Sulphuric acid addition is controlled by a variable stroke drive
on an electronically actuated diaphragm acid feed pump, 48PPD05, and is ratiod to
the filter feed flow rate and controlled to pH 2.0.
Warning: The mixing of these fluids generates heat and HCN, a highly toxic
gas. Care must be taken when working in the area particularly
while the precipitation process is occurring.
The now precipitated solids and liquid are pumped through a pulse tube filter,
48FTP09. The filtrate is transferred to the stripper feed tank, 48TNK39. Once the
entire contents of the precipitation tank, 48TNK35, have been precipitated and
filtered, the filter then goes into a wash cycle. The wash cycle involves water flush
followed by an air flush to remove any remaining toxic material in the filter cake. The
filter is drained and water washes go to the stripper feed surge tank, 48TNK39, and
air flushes go to the cyanide stripping column, 48COL04.
A discharge cycle is performed after filter performance drops below normal filtration
rates. The discharge cycle involves water washing, air washing, draining and then
discharging using an air burst to blow cake off the candles. Discharged cake goes
into a bin under the filter. This bin is then removed manually to be stored and
disposed of.
2.7.5. Silver Elution and Recovery
As sodium cyanide eluant is not a strong enough to remove precious metals in metal
elutions, a second elution procedure is employed. This uses zinc tetracyanide
Na2Zn(CN)4 as the eluant.
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OPERATING MANUAL
Before a silver elution, a metal elution is performed on a batch of resin. With all
copper removed, resin is transferred under pressure from the metal elution column,
48COL02, to the silver elution column, 48COL03. The pressure transfer uses water
to transport the resin.
Eluant is prepared in the gold eluant tank, 48TNK36. In a fresh batch, the required
quantity of sodium cyanide as solution is added to the tank. Zinc sulphate, as a
powder, is then added by hand into the tank. Water is then used to make the tank up
to full volume. The agitator, 48AGT19, is then switched on for a period to achieve
mixing of the solution. Zinc sulphate will slowly dissolve and the solution will become
essentially clear. The agitator is then turned off during elution.
A heater, 48HTR02, is used to bring the eluant up to a constant temperature of 40

-50 C. The system must not be raised above 50 C due to the negative effect this
will have on the resin and its properties.
Silver elutions include two steps.
Step 1 Recirculation of the eluant through the silver elution column, the
electrowinning cell, 48EWC07 and back into the gold eluant tank,
48TNK36. This step operates for approximately 36 hours.
Step 2 A water wash is applied to remove any remaining cyanide solution. Water
washes are disposed of in the second adsorption tank, 48TNK26.
On completion of the elution, resin is transferred from the silver elution column to the
loaded resin screen, 48SCV06. This is done by pressure transfer with water.
Electrowinning of gold and silver occurs in the same fashion as the main plant (see
Section 2.6). The cell is located in the gold room.
2.7.6. Cyanide Stripping and Scrubbing
Cyanide stripping is used to remove toxic hydrogen cyanide, HCN, from various
streams which are created in the resin elution processes. Scrubbing involves
absorbing the gas from the air stream using caustic soda. Both are performed in
packed towers using polypropylene packing to increase the liquid/gas contact area
for the transfer to occur.
Liquors to be stripped are fed into the stripper feed surge tank, 48TNK39. These are
pumped into the stripper using variable speed drives pumps, 48PPC47/48, to the
spray bar at the top of the stripping column, 48COL04.
These liquors are then discharged from the stripping column to tailings using the
stripping column pumps, 48PPC41/42.
Air is drawn through both columns using the cyanide recovery fan, 48FAN02. This air
is drawn from the atmosphere at the stripping column and the vents of various
vessels and tanks which contain toxic material. The air is discharged to atmosphere
from a 15 m high stack after exiting the scrubbing column.
The scrubbing column, 48COL05, uses the cyanide scrubbing column pump,
48PPC43/44, to recirculate solution to the distributor at the top of the column. A pH
probe in the scrubbing caustic column monitors in the pH column. As the pH falls,
365880219.doc 14
OPERATING MANUAL
caustic is injected into the scrubber. pH should be maintained at approximately 12.0.

Higher than this value will result in low concentration cyanide being produced and
inefficient caustic use. Lower than this results in a more unstable system.
The level in the scrubber sumps is maintained using a bleed off from the distribution
line. This bleed off contains recovered cyanide which goes back to the cyanide
storage tank, 46TNK14.
2.8 Tailings Disposal
Reference Drawings: 4274-00-F-004 Water and Services

4274-00-F-006 Cyanide Adsorption
After the last stage in cyanide adsorption, 48TNK28, slurry passes over the resin
safety screen, 48SCV05. The safety screen is a vibratory screen which has an
aperture to 0.6 mm and will pick up any resin passing out the adsorption circuit.
Oversize will fall into the resin bin, 48BIN05.
The undersize from the screen then enters the tails sump. Other waste streams from
the process are also combined in this sump.
Tailings are pumped to the tailings dam using variable speed 30 kW drive pumps,
48PPC19/20. The VSD is controlled to a level set point in the sump.
When the tails pumps shut down, process water is used to flush the sump.
2.9 Water Systems
Reference Drawing: 4274-00-F-004 Water and Services
There are six water systems associated with the Mirah Gold process plant.
Raw water
Tailings dam decant water
Process Water
Fire water
Potable water
Safety shower water
2.9.1. Raw Water Systems
Raw water is obtained from a river located nearby to the process plant. Raw water is
used for:
Mine dust control

Sprays for dust control at the coarse ore bin
Sprays for the trash, tails and carbon recovery screens
Service points for clean up around the plant
Gold elution circuit
Cyanide recovery circuit
Make-up to the process water pond
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OPERATING MANUAL
Two centrifugal pumps, 50TNK31/32, pump water from the river to the raw water
tank. 50TNK21. Raw water is reticulated around the plant by two centrifugal pumps,
50PPC24/25, (rated at 80 m3/h each) located at the raw water tank. The overflow
from the raw water tank reports to the process water pond, 50DAM01. An outlet is
installed on the tank for the fire water system.
2.9.2. Tailings Dam Decant Water System
Water is recovered by the decant water pump, 50PPC49. This has a capacity of
approximately 180 m3/h. The pump is mounted on a pontoon and delivers water via
polyethylene pipe to the process water dam, 50DAM0.
The decant water pump is started and stopped locally. Throughout the shift the
operator should observe that return water is discharging into the process water pond.
The pond is to be checked once each shift to determine the water level in the pond.
The tailings dam, 50DAM02, should also be inspected to ensure the pond area
around the tailings decant pontoon is free of slimes to ensure the decant water is
clear. Slimes in the decant water will accumulate in the process water pond and may
result in scaling in pipelines, blocking of spray nozzles and the problem of having to
deslime the process water dam.
Valving is provided on the decant water pump manifold to flush tailings from the
tailings distribution pipelines when tailings emplacement is changed from one side of
the dam to the other. Care is required to ensure the flushing water isolation valves
are closed when not in use to prevent tailings entering the decant water pipelines.
2.9.3. Process Water System
Raw water and tailings dam return water discharge into the process water pond,
50DAM01. This HDPE lined pond is designed to contain a utilized volume of 1400
m. This volume is equivalent t0 12 hours milling at design tonnage.
When the plant is shutdown the decant water pumps must be turned off to prevent
the process water overflowing. This is important as the decant water contains
residual cyanide, lime and gold from continued leaching of residual gold in the
tailings dam. Two process water pumps each with suction tanks are provided for
delivery of process water to the milling circuit.
The process water pumps, 50PPC27/28, have a design maximum capacity of 200
m/hour at a head of 50 m. This will be sufficient for milling of up to 87.5 t/h of ore
(700 Kt/a) at a leach feed density of 40% solids with excess water available for clean-
up. The process water is distributed to the mill feed chute and mill discharge hopper.
A pipeline also delivers process water to the tailings pump sump for flushing out the
tailings pipeline when the plant is shut down. The process water pumps are started
locally at the pump station. Status indication (run/stopped/faulted) is provided on the
CITECT Operator Interface.
2.9.4. Fire Water System
A diesel driven pump, 50PPC26, capable of delivering 60 m/h at a head of 40 m is

provided for fire water pumping. The fire water pump has a fuel tank with capacity for
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OPERATING MANUAL
3 hours operations and will continue pumping until the level in the raw water tank is
exhausted.
A battery charger is provided to ensure the battery on the fire water pump engine
remains charged at all times. The pump should be a test-run for 1 hour each week
and the fuel tank should be topped up.
The fire water pump discharges water into the plant raw water pipeline for fire fighting
in the process area. The fire water pump status (run/stopped/faulted) is monitored on
the CITECT operator interface computer.
2.9.5. Potable Water System
Potable water is made using raw water supply and treating it in the water treatment
plant, 50CJL01. This is a filtration and sterilization plant. The treatment plant can
process up to 12 m/h. A supply of caustic is needed for pH adjustments. The potable
water will be stored in a 25 m galvanized steel tank, 50TNK18.
Potable water will be used for:

Drinking fountains around the plant, offices and workshops
Safety shower/eyewash stations
Ablutions
General uses in the laboratory, workshops and power station
Depending on the quality of the raw water supply potable water may also be used in
the gold elution circuit.
Warning: As with other safety warnings only taps clearly marked Potable
Water should be used for drinking purposes. Water from all other
taps must be assumed unfit for human consumption and/or to be
contaminated with cyanide.
Two pumps, 50PPC29/30, are provided for distribution of potable water around the
site and to the camp.
The status of the potable water pumps (run/stopped/faulted) is monitored on the

2.9.6. Safety Shower Water System
Safety showers are provided at strategic positions around the plant:

Hydrochloric acid storage area
Sulphuric acid storage area
Caustic cyanide mix tank area
Cyanide pump area
Cyanide mix tank area/caustic mix tank area
Lime feeder area
Leach tank
Cyanide recovery
Copper precipitation area
Metal/Silver elution area
Cyanide elution column
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OPERATING MANUAL
Laboratory
Water supply to the safety shower is from potable water pumps, 50PPC29/30. A 1 m
head tank is also provided to ensure water supply to the safety showers when
electrical power is not available. All safety shower piping is insulated to prevent
scalding when a safety shower is turned on. Since water from the showers and
eyewash will come in contact with eyes and skin it is important that the showers and
eyewash is kept clean. The operation of the showers should also be tested regularly.
2.10 Air System
Warning: Compressed air can be extremely dangerous if abused, do not use

for cleaning dust from clothing. Do not direct air jets towards any
part of the body. Wear eye and ear protections and clear the area
when purging air lines.
Three air systems are provided in the process plant area:

General plant air
Aeration air
Instrument air
2.10.1 General Plant Air
Compressed air at a pressure of 750 kPa is provided by two 37 kW rotary air screw
compressors, 53CMP01/02. The compressors deliver 380 m/h each and can be
operated on a Lead/Lag basis whereby the standby compressor starts automatically
if demand exceeds the capacity of the duty compressors.
The compressors are started and stopped locally and should be swapped over on a
planned basis to ensure even wear rates. The compressors have ample capacity for
the estimated air usage and it should be possible to meet the entire plant demand
with only a single unit on line. The major uses of compressed air are:
Leach aeration (135 m/h)
Resin air lift (35 Nm/h per air lift)
Mill lubrication systems (15 m/h)
Instrument air system (10 m/h max)
Compressed air service outlets are provided at various points around the process
plant for maintenance tools. This is particularly important for mill reline maintenance.
The compressors are started and stopped locally and the status (run/stopped/faulted)
is monitored on the CITECT operator interface computer. A pressure switch is
provided on the air receiver discharge pipeline to warn of low plant air pressure. Low
pressure will initiate a trip of the carbon elution, carbon transfer, cyanide mixing and
caustic cyanide mixing sequences.
Compressed air from the compressors is piped to a 2.2 m capacity plant air receiver,
53RCP01. Moisture contained in the compressed air accumulates in the receiver and
is vented via an automatic blow-down valve. From the receiver all of the compressed
air flows through two coalescent air/oil separators, 53FTP07/08, to reduce the oil
content of the air. The separators will coalesce all oil droplets greater than 1 micron
size. Removal of oil from plant air is important since it is used for aeration in the
leach tanks. Oil in the air would contaminate the carbon thus reducing its capacity for
365880219.doc 18
OPERATING MANUAL
loading gold. The oil can only be removed and adsorption properties of the carbon
restored by heating the carbon in the regeneration kiln.
2.10.2 Low Pressure Air
Oxygen is required for the dissolution of gold by sodium cyanide:
4Au + 8NaCN + 2H2O + O2 4NaAu(CN)2 + 4NaOH
Some ores contain minerals such as pyrrhotite, clays and organic species which
consume oxygen in the leach solution, thus limiting the leaching of gold. The oxygen
content of the slurry is also affected by the slurry temperatures and salinity. Although
test work for Mirah ores did not indicate the ore to have a high oxygen demand,
aeration is supplied to leach tank 40TNK01 and adsorption tanks 40TNK02/03 to
ensure a maximum rate of gold dissolution. The design is based on an aeration rate
of 1.5 Nm/h/t ore. This equates to a flow rate of 48 m/h into each of the tanks.
A rotameter is provided for monitoring and controlling the flow rate of air into each
leach vessels.
2.10.3 Instrument Air
A 23 m/h capacity instrument air dryer, 53DRY01, and an instrument air receiver,
53RCP03, are provided for supply of super low moisture compressed air to the
sequence valves in the plant. The dryer operates by cooling the air in order to lower
the dew point, thus precipitating moisture from the air. The air supplied to the
sequence control valves needs to be free of moisture and oil to ensure reliable valve
operation and low valve maintenance costs. The instrument air dryer is started
locally. There is no indication on the CITECT operator interface computer of the air
dryer status (running/stopped/faulted). After passing through the dryer the instrument
air is stored in a 0.5 m air receiver. A non return valve is installed between the dryer
and receiver to prevent back flow of air from the instrument air system into the
general plant air system.
2.11 Reagent Systems
The chemicals used in the Mirah process plant are:

Quicklime (CaO)
Sodium cyanide (NaCN)
Sodium hydroxide (NaOH)
Hydrochloric acid (HCl)
Sulphuric acid (H2SO4)
Zinc sulphate (ZnSO4)
Copper sulphate (first fill only)
Fluxing agents for gold smelting including :
- Borax (Na2B4O7) anhydrous
- Boric acid (H3BO3)
- Silica flour (SiO2)
- Sodium Nitrate (NaNO3)
Various chemicals associated with solution, solids and carbon analysis in the
laboratory and plant filtration room
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OPERATING MANUAL
2.11.1 Quicklime
Quicklime Handling System
Warning: Quicklime will cause irritation and burns to skin, eyes and mucous
membranes in the nose and throat. Always wear eye protection,
rubber gloves, protective clothing and respirator when working with
quicklime. Quicklime powder should be washed from the skin as
quickly as possible with copious quantities of water. If irritation
continues seek first aid attention.
The Role of Quicklime in Gold Extraction
Quicklime is used for pH control in the leach and adsorption Section. Cyanide which
is used to dissolve the gold from the ore exists in solution as either CN - or as HCN,
dissolved hydrogen cyanide. The relative amounts of these two species in solution
depends on the pH of the system. HCN is a highly toxic gas and is easily lost from
the slurry due to the action of the tank agitators and when the tailings slurry
discharges to the carbon safety screen.
High levels of HCN in the atmosphere result in both a hazardous work environment
and increased cyanide consumption rate.
To both minimize cyanide usage and ensure a safe working environment the pH in
the leach and adsorption circuit should be maintained in the range 10.0 to 10.5.
Operation at higher pH values will result in excessively high lime usage with little
additional benefit in terms of either plant safety or reduced cyanide usage rates.
Quicklime Addition
Quicklime will be supplied to the site in 1000 kg bags and will be stored in a shed.
Based on test work lime consumption is 2 kg/t. Therefore lime usage at a design
milling rate of 87.5 tph will be 175 kg/h.
Quicklime is fed from a hopper, 46BIN04, to a belt feeder, 46FDB01.
The belt feeder has a manually operated variable speed drive.
2.11.2 Cyanide
Warning: Sodium Cyanide is highly toxic if ingested. It also forms highly toxic
hydrogen cyanide gas which can result in rapid death. Cyanide
solutions are also alkaline which can cause irritation and burns to
skin and eyes. Protective clothing must be worn when handling
cyanide. A carbon filter or external air supply respirator must be
worn when mixing cyanide. If cyanide is ingested or if exposed to
high concentrations of hydrogen cyanide gas first aid attention must
be available. All personal should be familiar with the first aid
procedures for cyanide poisoning and the required equipment
should be regularly inspected and tested by the designated first-aid
officer. Operators should endeavour to minimize working in areas
where high hydrogen cyanide concentrations are likely to occur,
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OPERATING MANUAL
particularly around the cyanide recovery plant and tails pump sump.
Hydrogen cyanide can also accumulate above the surface of the
leach and adsorption tanks so care is required when working below
the level of floor grating. When working in these areas when the
plant is operating carbon filter respirators should be worn as a
safety precaution. When entering enclosed tanks the site Closed
Vessel Safety Procedures must be followed.
Roll of Cyanide in Gold Extraction
The role of cyanide in the gold extraction process is to dissolve the gold in the ore to
form a stable gold cyanide complex. The gold is then adsorbed onto carbon from
which it is subsequently stripped and recovered by electrowinning and smelting to
yield gold bullion ingots.
Cyanide Mixing
The cyanide mixing facility consists of a monorail and dual speed hoist, 46HST08, to
lift the 1 t Bulka bag of briquetted cyanide to an enclosed bag breaker 46BRR01.
From the bag breaker the briquettes fall into the mix tank, 46TNK13, which is
agitated by a 1.1 kW turbine agitator, 46AGT01.
The cyanide mix tank has a utilised volume of 17 m. This is sufficient for mixing
three bags of cyanide to make 15 m solution of approximately 20% w/v NaCN.
Cyanide can be mixed using either spent electrolyte or raw water. When using raw
water caustic should be added to the mix tank to ensure a high level of protective
alkalinity before adding the cyanide (Caustic will be pumped via the caustic transfer
pump and is necessary to ensure hydrogen cyanide is not formed when the cyanide
briquettes are added to the raw water)
Level probes are installed in the mix tank to control the addition of either raw water or
spent electrolyte to the tank. The filling of the mix tank is affected via a control
sequence initiated from a local control panel.
After mixing, the cyanide solution is dumped into the cyanide storage tank, 46TNK14,
via a manual 100 mm butterfly valve.
The cyanide addition rate is anticipated to be 2.4 kg/t. At design milling rate of 87.5
t/h leach cyanide addition will be 5063 kg/d. An additional 142 kg will be consumed
for each carbon elution. Cyanide will be recovered from the cyanide recovery plant at
a net recovery of 1.18 kg/t or 2478 kg/d. Total usage will thus be approximately 2541
kg/d. A mix batch (3000 kg) will thus be sufficient for 1.2 days operation.
Cyanide Storage and Dosing
The cyanide holding tank, 46TNK14, has a utilised volume of 55 m. At design

throughput the storage tank has a storage capacity equivalent to 4.4 days milling.
The bund around the tank has sufficient volume to contain the complete volume of
the holding tank. The cyanide feed pumps, 46PPC11/12, are mounted on elevated
plinths to ensure the pumps are not submerged in the event of the bund filling with
cyanide solution.
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OPERATING MANUAL
Two centrifugal pumps transfer cyanide to the header tank, 46TNK17, one duty, one
standby. The header tank distributes cyanide to the leach tank, 40TNK01, to the
caustic cyanide tanks, 45TNK11, and to the metal eluant tank, 45TNK33. Overflow is
returned to the storage tank.
Cyanide to leach is controlled using a manual valve to limit the dosing rate into the
leach tank. The flow is a measured using a rotometer. At a leach addition of 2.25 kg/l
and 20% w/v and at design tonnages of 87.5 tph, this flow will typically be 16 l/min.
Cyanide for the caustic cyanide tank requires 142 kg/batch. This is 710 l/batch.
Cyanide to the metal eluant tank, 48TNK33, is used to make up metal eluant to 10%
w/v strength. It is critical that the strength of eluant is between 9.5% and 11%. Lower
concentrates will affect elution efficiencies. Higher concentrations will affect reagent
usage. At design flows, typical metal elutions need to be performed 3 times a day as
5 m batches i.e. 50 kg of cyanide per batch. This comes to 250 l/batch.
2.11.3 Sodium Hydroxide (Caustic Soda)
Warning: Sodium Hydroxide (caustic soda) solutions are corrosive and will
cause burns to skin and eyes unless removed immediately. If
splashed with caustic solution wash it off with copious amounts of
clean fresh water, and then seek first aid attention. When flake
caustic is dissolved in water a large quantity of heat is evolved. This
could result in boiling. The mix tank agitator should be running
when adding flake caustic to the caustic mix tank. Always wear
gloves and eye protection when handling both liquid and flake
caustic.
Sodium hydroxide has three uses at the Mirah gold project:

1. pH protection to minimize the generation of HCN gas during cyanide mixing.
2. To assist in the elution of gold from loaded carbon and to ensure sufficient
conductivity in the electrolyte to maximize electrowinning efficiency.
3. To absorb HCN gas that is generated in the cyanide recovery process.
Caustic Mixing
The caustic mixing facility consists of a monorail and dual speed hoist, 46HST09, to
lift the 500 kg bulka bags of flake caustic soda to an enclosed bag breaker,
46BBR02. From the bag breaker the flake falls into the agitated mixing tank,
46TNK15, which is agitated by a 1.1 kW turbine agitator, 46AGT11.
The caustic mix/storage tank has a utilized volume of 17 m. This is sufficient for
mixing 8 x 500 kg bags of caustic flake to make a solution of approximately 23% w/v
NaOH. Raw water is used to dilute the caustic soda.
Level probes are installed in the mix tank to control the addition of raw water into the
tank. The filling of the mix tank is affected via a control sequence initiated from the
After mixing, the caustic solution is dumped into the caustic storage tank, 46TNK22,
via a manual valve.
The consumption of caustic soda in each application is anticipated as follows:
365880219.doc 22
OPERATING MANUAL
50 kg per cyanide mix

142 kg per gold elution
3360 kg per day for cyanide recovery
Total usage will be approximately 3694 kg/day; therefore a mix batch (4000 kg) will
be sufficient for 1 day.
Caustic Storage and Dosing
The caustic holding tank, 46TNK22, has a utilised volume of 55 m. At design

throughput the storage tank will have a capacity equivalent to 3.2 days milling. The
bund around the tank has sufficient volume to contain the complete volume of the
holding tank. The caustic feed pumps, 46PPC14/15, are mounted on elevated plinths
to ensure the pumps are not submerged in the event of the bund filling with cyanide
solution.
Two centrifugal pumps, 46PPC14/15, are provided for transfer of caustic to the
header tank, 46TNK19. The header tank distributes the caustic to the cyanide
scrubber, 48COL05, to electrowinning electrolyte tanks, 45TNK08/09, and to the
caustic cyanide tank, 45TNK11. Overflow is returned to the storage tank.
Caustic to the cyanide scrubber is used to provide caustic for adsorption of HCN from
the cyanide stripper, 48COL04. Caustic addition is controlled using a fully modulating
value linked to a pH meter in the scrubber (see Section 2.7.6). Typical consumption
is 11 l/min.
Caustic to the electrolyte tank is used to increase the conductivity of electrolyte to

improve current densities in the electrowinning cells, 45EWC01/06. Performance is a
problem if the current drawn by a rectifier is still low while the voltage is above 3V.
Every elution needs to make up a tank of caustic cyanide eluant. Each batch requires
680 l.
Caustic for cyanide mixing is drawn directly off a line connected to the discharge of
the caustic feed pumps.
2.11.4 Hydrochloric Acid (HCl)
Warning: Hydrochloric acid is a highly corrosive liquid. Should skin contact be

made, burns will occur unless it is removed immediately. If splashed
with hydrochloric acid wash it away with copious quantities of clean
fresh water. Always wear safety goggles and face shield, PVC
gauntlets, PVC apron and chemically resistant safety boots when
working on acid systems. Hydrochloric acid vapours can cause
irritation to the nose, throat and lungs. Ensure adequate ventilation
in all working areas. When hydrochloric acid is added to water a
large amount of heat is released. This can cause a splashing hazard.
Always add acid to water, never add water to concentrated acid.
Hydrochloric acid for the Mirah project is delivered to site as part of general freight
consignments in 220 litre plastic drums. Acid is pumped from containers by one of
two air actuated diaphragm pumps (46PPC07/08) into a 2.5 m acid storage vessel.
Dosing into the elution is done with a small peristaltic pump, 48PPD13, with a manual
365880219.doc 23
OPERATING MANUAL
variable speed drive. For a solution acid concentration of 3% HCl and pre-soak
volume of 7.2 m, acid consumption will be approximately 620 l/elution cycle.
2.11.5 Sulphuric Acid (H2SO4)
Warning: Sulphuric Acid is a highly corrosive liquid. Should skin contact be

made, burns will occur unless it is removed immediately. If splashed
with sulphuric acid wash it away with copious quantities of clean
fresh water. Always wear safety goggles and face shield, PCL
gauntlets, PCL apron and chemically resistant safety boots when
working on high concentration (>20% w/w) acid systems. When
working on lower concentration systems a minimum of safety
goggles, PCL gloves and chemically resistant safety boots are
required. Sulphuric acid vapours can cause severe irritation, lung
damage and other complications. Sulphuric acid is not very volatile
and therefore workplace exposures are primarily mists and aerosols
which can be avoided with adequate ventilation. When sulphuric
acid is added to water a large amount of heat is released. This can
cause a splashing hazard. Always add acid to water, never add water
to concentrated acid.
Sulphuric acid is delivered to site as 98% w/w liquid in 220 l drums. While
concentrated acid is highly corrosive to human contact, it remains passive to mild
steel while above 90% w/w. If plastics are used in concentrated acid environments,
manufacturers approval should be sought.
Containers will be located at the bund near the concentrated sulphuric acid tank,
48TNK29. Containers are emptied using an air operated diaphragm drum pump,
48PPS06. The pump will empty the tank contents in under 10 minutes. At design flow
4.4 tpd of acid is required. Therefore 20 x 220 l drums are used per day of milling.
The concentrated acid tank, 48TNK29, stores a total of 20 m (37 t) of acid at 98%
w/w. This relates to a capacity of 8.3 days milling operation at design flow rates.
Acid is consumed in:

Cyanide elution at 1.47 kg/t of resin
Copper precipitation at 431 kg/batch
For use in cyanide elution the acid is first diluted to 10% w/v in the sulphuric acid
dilution tank, 48TNK30. Upon a low level being reached in the dilution tank, the
sulphuric acid pump, 48PPD04, pumps acid to the tank from the storage tank. Raw
water is added on a ratio basis into the dilution tank to make up to 10% w/v. Both the
pump and raw water addition is stopped upon a high level being reached.
The dilution tank has a 6 h capacity at design flows. All diluted acid is used by the
cyanide elution column, 48COL01.
Concentrated acid is also used in the precipitation of copper in the metal elution of
resin (see Section 2.7.4). The line pumps the acid at 70 m pressure to the in-line
mixer. The pump, 48PPD05, is a double diaphragm pump and a pressure relief valve
and line has been provided for safety.
2.11.6 Other Chemicals
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OPERATING MANUAL
Details of chemicals which are used for specialist purposes around the plant have
material and safety data sheets attached.
These are stored in dry form around the plant.
3.0 PLANT OPERATING PROCEDURES
3.1 Introduction
The following notes are provided as a guide only to the operation and control of the
process plant. During commissioning and subsequent operation of the facility it may
be necessary to vary the operation and control of the process plant to improve plant
365880219.doc 25
OPERATING MANUAL
performance. It is the Owners responsibility to ensure that all personnel are familiar
with the operation and control of the process plant.
The operation and control of the process plant is described by plant areas generally
in the order of the piping and instrumentation diagrams.
This Section details the operations that are required by the operator mainly in the
field to start-up and shut down the plant.
For details of equipment interlocks, control loops and start and stop sequences, see
Section 4.
Proper start-up of the process plant involves careful co-ordination of control room
start-up and field procedures. Prior to start-up of the process plant a number of pre-
start checks are required.
The following description assumes the plant is operated under the supervision of all
control interlocks.
Warning: Many operations on the process plant have been automated and
equipment may start or stop without prior warning. It is the
operators responsibility to ensure the safety of all personnel
working on the plant and that all personnel understand the
automatic nature of the operation.
3.2 General
Start-up Procedures
The following is a list of start-up checks that are made for all plant areas:
Ensure that the power isolators in the MCC are on
Ensure all thermal overloads are reset in the MCC
Ensure all local stop buttons are in the out position
All selector switches are set to the normal position in the plant control system
for equipment to be started
Start the compressors and air systems
Start water systems
3.3 Crushing, Milling and Classification
Reference drawings: 4274-00-J-001 Crushing and Grinding
Warning: Crushers and conveyors are dangerous items of equipment and

should, at all times, be operated with guards in place.
It is the operators responsibility to ensure that equipment is safe
before starting up, and thus extra checks are required before
operating equipment:
Check no person is working inside the guarded area
Check all guards are installed
Check no tools or material are left on top or underside of
conveyor belts after maintenance
One of the main causes of serious accidents in metallurgical
plants is associated with conveyor belts.
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OPERATING MANUAL
The crushing circuit consists of a primary jaw crusher, feeder and conveyor feeding
into the mail. The milling circuit consists of a SAG mill in closed circuit with cyclones.
Start-up Procedure
Ensure raw water is available and all necessary isolation valves to the dust
scrubber and sprays are open
On the plant control system check that all belt-drift, pull wire, blocked chute
and under speed fault indications are off
Start the crushing system from the plant control system
Start the lime belt feeder to add lime on to the mill feed conveyor. Check the
speed setting on the VSD and adjust if necessary to achieve correct dosing
rates
Inform the truck driver or front-end loader operator that the crushing plant is
ready to receive ore
Ensure raw water is available and the isolation valves to the mill gearboxes
are open
Check the isolation valves on the instrument air line to the air actuated valves
are open and instrument air is available
Make sure the correct number of duty cyclones are available and the feed
valves to the cyclones are open. Normally five cyclones are used
Ensure plant air is available and the isolation valves to the lubrication systems
are open
Ensure the process water valves are in the correct position and that process
water is available
Check the duty Mill Discharge Pump dump and water flushing valves are
closed and open the pump suction valve
Check the standby Mill Discharge Pump suction valve is closed and the dump
valve is open. This allows a visual check that the tech-Taylor valve is
functioning properly when the plant is operating and prevents the sanding-up
of the standby pump
Check the following PID controller is in automatic mode and has the correct
set point :
- LIC2500 Mill sump level controller
Ensure all plant equipment in other areas down stream from the milling circuit
that are required are operational
Start the duty Mill Discharge Pump at the local station
Start the mill circuit from the plant control system
Inform the FEL operator and crusher operator to commence feeding ore to
the plant
Shut Down Procedure
This procedure assumes that the plant is stopped in an orderly fashion leaving all
equipment ready for a normal start-up
Inform the FEL or dump truck operators to stop feeding ore to the plant
Continue operation of the crusher until the level in the ROM bin has dropped
so as to just cover the feeder. This procedure is recommended to allow easier
start-up after a prolonged shutdown
365880219.doc 27
OPERATING MANUAL
Do not empty the bin entirely, this will lead to excessive dusting when the next
load is tipped and may cause damage to the Crusher Feeder
Stop the crushing and conveying equipment from the plant control system. In
the event of a emergency it is possible to stop the plant immediately using the
emergency stop button. This should not be used for routine shutting down of
the plant as it may prevent or delay the plant from starting again as some
equipment may have to be cleared of ore to prevent overloading of the
equipment on start-up
Stop the feeder and allow the Mill Feed Conveyor to empty of ore
Allow the mills to grind out the excess ore
Stop the mill circuit from the plant control system
Close the process water isolation valves
Allow the Mill Discharge Pump to clear the Mill Discharge Sump of slurry then
stop the Mill Discharge Pump
Close the Mill Discharge Pump suction valve and open the dump valve on the
pump. Flush the pump with water if necessary
All other valves may be left in the operating position for when the milling circuit is to
be restarted.
3.4 Leach, CIP and Cyanide Adsorption
Reference Drawings: 4274-00-J-002 Leach and CIL

4274-00-J-006 Cyanide Adsorption
The leach, CIL and cyanide adsorption circuit consists of 11 tanks of various sizes.
The cyanide adsorption circuit may be bypassed in the event that low cyanides in CIL
tails are treated. It is possible to bypass any tank in the circuit. The following
description is for the circuits operating normally with all tanks in use.
3.4.1 Circuit Operation
Start-up Procedure
Ensure the correct number of spigots are open at the tailings dams for the
expected flow rate
Start the tank agitators. Normally these will always be left operating
Start the interstage screens
Check that cyanide is available and all isolation valves are open. Check the
cyanide isolation valves to the first CIL Tank is closed
Check the following controller is in the automatic mode and has the correct
set point :
- Tailings Sump level controller (LIC4801)
Check that instrument air is available and the isolation valves to the air
actuated valves are open
Check the standby Tailings Pump suction valve is closed and the dump valve
is open
Check the dump and water flushing valves on the duty Tailings Pump is
closed
Ensure gland water is available and open the isolation valve to the duty
Tailings Pump and close the valve to the standby pump
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OPERATING MANUAL
Ensure process water is available and start the duty Tailings Pump. Open the
process water isolation valve to the Tailings Sump if required
Start the Resin Safety Screen and open the water isolation valve to the
screen sprays
Start the Carbon Safety Screen and open the water isolation valve to the
screen sprays
Check the launder spades and plugs are in the correct locations
Check the low pressure leach air valves are set correctly and that isolation
valves are open flow rate. Open the isolation valve to the agitator shaft and
ensure the correct flow rate is being achieved
Start the Trash Screen and open the water isolation valve to the screen
sprays
Start feeding the circuit with slurry
Ensure cyanide and lime are being dosed to the circuit and the correct
process readings are achieved
Close the process water isolation valve to the Tailings Sump, if it has been
opened, once slurry flow is established to the Tailings Sump
Shutdown Procedure
The plant the shutdown procedure for these circuits is in the approximate reverse
order of the starting procedure
Stop the slurry feed to the Trash Screen

Close the water isolation valve to the Trash Screen sprays and stop the
screen
Allow the tank circuit slurry levels to drain down. Open the water valve to the
Tailings Sump if required to maintain the sump level
When the slurry flow has ceased stop the leach air and the cyanide flows to
the circuits
Stop the interstage screens
Close the isolation valve to the Carbon Safety Screen and Resin Safety
Screen sprays and stop the screens
With the Tailings Pump operating flush the tailings pipeline with process
water. This may take 15 to 20 minutes depending on the flow rate and the
position of the outlets in the tailings dam. When complete close the process
water isolation valve to the Tailings Sump and stop the Tailings Pump.
Close the gland water isolation valve to the Tailings Pump
Close the Tailings Pump suction valve and open the dump valve to drain the
pump
All other valves may be left in the operating position and agitators left running for
when the plant is restarted.
3.4.2 Carbon Transfer
The carbon transfer operates on a batch basis moving carbon up the CIP train. To
initiate the transfer the procedure is as follows:
Start-up Procedure
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OPERATING MANUAL
Check the carbon concentration in each of the adsorption tanks. Check that
each of the transfer DSMs is clear of blockages
Start each of the transfer pumps are required to move carbon up the circuit.
Carbon should be moved sequentially up the circuit to avoid short circuiting.
Carbon should not be moved from two adjacent tanks at the same time but
from alternate tanks, i.e. move carbon from tanks 7, 5 and 3 first, then from
tanks 6 and 4. Carbon in the first CIL tank is moved to the loaded carbon
screen. The carbon concentration in the first CIL tank should be greater than
30 g/l before transferring loaded carbon.
Continue to monitor the carbon concentrations through the tank to prevent
imbalance in the circuit
Shutdown Procedure
Switch off each of the carbon transfer pumps are require
3.4.3 Resin Transfer
Resin transfer between each of the carbon adsorption tanks operates on a

continuous basis. To initiate the transfer, the procedure is as follows:
Start-up Procedure
Check that the low pressure air systems if running and all isolation valves to
the cyanide recovery plant are open
Check instrument air is available and the isolation valve to the cyanide elution
column is open
Check that the cyanide elution column has available surge capacity for
receiving resin. Ensure that the column is on standby for use
Set the resin splitter box to send resin to cyanide elution
Check that the correct undersize pan discharge valve on the loaded resin
wash screen is open to the correct tank
Start the loaded resin wash screen and open the isolation valve to the water
sprays
Start the resin trash screen and open the isolation valve to the water sprays
Start the fine resin screen and open the isolation valve to the water sprays
Open the air isolation valve to each of the air lifts beginning with the lowest
tank first. Adjust if necessary the air flow to achieve correct resin flow
Open the adsorption air lift actuated valve
Adjust the flow of water into the resin splitter box to achieve flow of resin
along the launder. This should be set to allow flow of resin without
overloading the dewatering screen above the cyanide elution column.
3.5 Carbon Advance and Elution

4274-00-J-003 Gold Recovery Sheet 1
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OPERATING MANUAL
The carbon desorption circuit operates on a batch basis from carbon recovered from
the first CIL tank.
3.5.1 Carbon Transfer to The Elution Circuit
To fill the Elution Column Feed Hopper:
Start-up Procedure
Start the Loaded Carbon Screen and open the process water isolation valve
to the screen sprays
Start the Carbon Recovery Pump and ensure the carbon is flowing into the
Elution Column Feed Hopper
Start the floor sump pump to recover the solution that drains from the Elution
Column as required
Shutdown Procedure
Close the process water isolation valve to the Loaded Carbon Screen sprays
and stop the screen
Hose any residual carbon from the Loaded Carbon Screen Chute into the
Elution Column Feed Hopper
To fill the Elution Column with carbon the procedure is as follows:
Start-up Procedure
Check instrument air is available and the isolation valves to the three
automated valves at the top of the Elution Column are open
Open the drain on the bottom of the Elution Column and close the column
solution inlet and carbon outlet isolation valves
At the top of the Elution Column open the carbon inlet isolation valve and
close all the other solution outlet valves. The valves are automated and this is
performed from the plant control system
Check the return slurry isolation valve to the first CIL Tank on the Loaded
Carbon Screen Undersize Chute is open and the isolation valve to the Leach
Tank is closed
Shutdown Procedure
When the column is full of carbon a high level switch closes the Carbon Inlet Valve.
Allow the Elution Column to drain completely of solution then close the drain
valve at the base of the Elution Column
Carbon can now be advanced through the CIL tanks by using the airlifts in sequence
or all together as directed by operations.
3.5.2 Carbon Elution
The carbon in the Elution Column is eluted free of precious metals by the following
sequence of events:
Start-up Procedure
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OPERATING MANUAL
Check the following temperature set points are correct in the plant control
system :
- TS14540 Eluate Temperature Set Point 1
- TS24540 Eluate Temperature Set Point 2
- TSH4540 Eluate Discharge High Temperature Set Point
Check instrument air is available and all the isolation valves to the air
actuated valves in the circuit are open
Check all the automated valves and equipment are in the remote mode on the
plant control system
Check the flow controller (FIC4502) is in the automated mode and has the
correct set point
Check the Elution Heater Controller is in the automatic mode
Check that there is diesel in the header tank, the isolation valve on the diesel
supply line is open and the Diesel Reticulation Pumps are running
Check the raw water isolation valve to the base of the elution column is
closed and the isolating valves to the Caustic Cyanide Mix Tank and the
Elution Water Tank are open. Ensure the tanks are full
Open the isolation valve on the cyanide pipeline to the Caustic Cyanide Mix
Tank. Ensure cyanide and caustic solutions are available i.e. header tanks full
and duty feed pumps are running
Check the suction manual isolation valves on the Caustic Cyanide Pump and
the Elution Water Pump are open
Check there is sufficient hydrochloric acid in the Acid Storage Tank. If there is
not transfer more acid using the Acid Transfer Pump provided
Check the drain valves on the Hydrochloric Acid Dosing Pump are closed.
Open the manual suction and discharge isolation valves on the pump.
Check the isolation valves to all the pressure gauges and the pressure
transmitter (PIT4503) in the circuit are open.
Check the heat exchanger flushing valves are closed. Ensure the heat
exchanger isolation valves are open
Open the solution isolation valve on the Elution Column inlet
Ensure the Electrolyte Filter drain valves are closed
Warning: Note if it is necessary to inspect these filters during the elution

cycle care must be taken as they will contain hot caustic/cyanide
solutions.
Check the isolation valve on the Thermal Oil Circulation Pump suction is open
Check there is sufficient thermal oil in the Thermal Oil Head Tank. If there is
not make-up with the Thermal Oil Drum Pump provided.
Ensure one of the Electrolyte Tanks is empty of solution elution. Refer to the
following tables in Section 4.5 which describes how equipment operates and
which valves open at each stage of the carbon desorption process.
- 4284-45-F-001 Gold Elution Control Sequence
Select the required elution sequence and start the elution from the plant
control system. Ensure the equipment and valves operate as required by the
elution sequence selected.
Shutdown Procedure
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OPERATING MANUAL
At the end of the elution sequence all equipment will be stopped and all valves can
be left in the operating position. However it is advisable to close the diesel isolation
valve to the Elution Heater. After the elution it is normal for the carbon in the Elution
Column to be transferred to the Regeneration Kiln for regeneration of the carbon or
to be transferred to either of the last two CIP tanks. Operations will direct when the
regeneration stage is to be bypassed. There are two manual valves that have to be
set to select the CIP Tank that is to receive the carbon. Normally it is the last CIP
Tank unless this tank is bypassed for maintenance purposes.
3.5.3 Carbon Transfer from the Elution Column to the Regeneration Kiln
To transfer carbon to the Regeneration Kiln and to regenerate the carbon is as

follows:
Start-up Procedure
Open the manual isolation valve on the carbon transfer pipeline to the
Regeneration Kiln and check that the isolation valves to the CIP Tanks are
closed
Open the solution inlet isolation valve at the bottom of the Elution Column and
open the carbon outlet isolation valve which is also on the base of the Elution
Column. Check all other isolation valves on the Elution Column are closed
(manual and automatic)
Check the raw water isolation valve to the Elution Water Tank is open and raw
water is available
Check the suction isolation valve on the Elution Water Pump is open
Check there is instrument air available and the isolation valves to the
following are open :
- Elution water pump discharge valve
- Elution flow control valve
Check the elution flow controller is in automatic mode and has
the correct set point
Place the Elution Water Pump discharge valve (KV4507) in the
manual mode on the plant control system and open the valve
Place the Elution Water Pump in manual mode on the plant
control system and start the pump
Ensure the carbon is being transferred to the Carbon Dewatering Screen above the
Kiln Feed Hopper. It is possible to add more transfer water to the carbon transfer
pipeline by opening the raw water isolation valve at the base of the Elution Column.
Normally this is not required and the transfer of carbon will take approximately one
hour.
Shutdown Procedure
Stop the Elution Water Pump on the plant control system

Close the Elution Water Pump discharge isolation valve from the plant control
system
Close the carbon outlet isolation valve on the base of the Elution Column
Return the elution water pump and elution water pump discharge valve to
normal mode
All other valves may be left in the operating position.
365880219.doc 33
OPERATING MANUAL
3.6 Regeneration

Let the free moisture drain from the transferred carbon in the Kiln Feed Hopper
before regenerating the carbon.
Start-up Procedure
Check that the isolation valve on the diesel supply line is open, there is diesel
in the header tank and the diesel Reticulation Pump is running
Check the drain valve on the Regenerated Carbon Quench Tank is closed
Check the raw water isolation valve on the kiln cooler is open
Check the process water isolation valve to the Regenerated Carbon Quench
Tank is open
Open the process water isolation valve to the Regenerated Carbon Sizing
Screen sprays. Start the Regenerated Carbon Sizing Screen
Check the Carbon Regeneration Kiln temperature is in automated mode and
has the correct temperature setting. Operations will specify the required
regeneration temperature
Open the Kiln Feed Hopper discharge slide gate and start the Carbon
Regeneration Kiln on the local panel
Shutdown Procedure
Stop the Regeneration Kiln from the local panel

Close the process water isolation valve to the Regenerated Carbon Sizing
Screen sprays. Stop the Regenerated Carbon Sizing Screen
Close the isolation valve on diesel supply line
Close the raw water isolation valve to the Regeneration Kiln Quench Tank
The kiln shutdown is automatically controlled. The kiln will continue to run for a period
to time after it has stopped the carbon feed and burners to allow the kiln shell to cool.
3.7 Electrowinning
Reference Drawing: 4274-00-J-004 Gold Recovery Sheet 2
Solution from the carbon elution process is collected in either Electrolyte Tank for
further batch processing in the electrowinning circuit. Processing a batch of
electrolyte solution takes a maximum of 16 hours.
Start-up Procedure
Check the drain valve on the Electrolyte Circulation Pump is closed and the
suction and discharge isolation valves are open
Ensure the isolation valves for the electrolyte solution to the Leach Tank and
the Cyanide Mixing Tank are closed
365880219.doc 34
OPERATING MANUAL
Check the feed isolation valves to the Electrowinning Cells are open and the
cell drain valves are closed
Start the electrowinning cell exhaust fan
Start the Electrolyte Circulation Pump and ensure the correct solution levels
in the Electrowinning Cells are maintained
Start the rectifiers and ensure the correct amperage is being achieved. If the
amperage is low open the caustic make-up valve to the Electrolyte Tank for a
short period and recheck the correct amperage is achieved
Shutdown Procedure
Barren electrolyte is pumped to the Leach Tank or the Cyanide Mixing Tank on the
completion of electrowinning
Check the Leach Tank or Cyanide Mixing Tank is ready to receive barren
electrolyte solution. Open the corresponding valve to the tank chosen to
receive the solution
Set the flow rate required using the discharge isolation valve on the pump to
drain the Electrolyte Tank
Close the isolation valve to the electrowinning cells
Operations will direct whether any cathodes will be removed from the Electrowinning
Cells. If no cathodes are to be removed the Electrowinning Cells may be left full of
solution in which case the rectifiers must be left on at a reduced amperage to prevent
dissolution of the precious metals. If cathodes are to be removed open the drain
valve on the Electrowinning Cells and stop the rectifiers before removing the
cathodes.
The Cyanide Mixing Tank has less capacity than the Electrolyte tank and on
completion of filling the Cyanide Mixing Tank the low flow alarm will sound. Either
stop the Electrolyte Circulation Pump and wait for the next batch of cyanide to be
mixed or open the isolation valve to the Leach Tank.
When the Electrolyte Tank is empty the Electrolyte Circulation Pump will stop
automatically
Close the isolation valves to the Cyanide Mixing Tank and the Leach Tank
All other valves may be left in the operating position for when the next batch of
solution is to be treated.
Cathodes are washed in situ using the portable high pressure water pump. Slimes
are collected in the slime filter feed sump.
Precious metal sludge in the bottom of the electrowinning cells may be collected by
hand. This will require the cathodes and anodes to be removed to allow access. Raw
water can be piped to the electrowinning cell drain line to assist in the removal of the
precious metal sludge if required. The precious metal sludge recovered is filtered in
the E/W Cell Slimes Filter.
The sludge is removed from the slime filter and placed in the drying oven. The sludge
is then mixed with fluxes and smelted in the Smelting Furnace to produce Dore bars.
365880219.doc 35
OPERATING MANUAL
For the drying and smelting operations refer to the vendor manuals before the
operation of this equipment. When operating the Smelting Furnace the Smelting
Furnace Exhaust Fan must be operating before operating the Smelting Furnace.
The drying operation takes 24 hours and the smelting operation takes 2 to 3 hours.
3.8 Cyanide Elution
Reference Drawing: 4274-00-J-011Resin Elution Sheet 2
Warning: Cyanide Elution generates HCN, hydrogen cyanide, a highly toxic

gas. Care must be taken when working in the area, particularly while the
process is operating.
Start-up Procedure
Check that the HCN monitoring system is fully operational

Start the cyanide and stripping column and ensure that the system is stable.
This is very important for removing any toxic gas and many interlocks on the
column rely on normal operation of this system (see Section 3.11)
Open all liquor isolation valves including the water injection nozzles and the
overflow nozzle around the cyanide elution column
Isolate the discharge knife gate valve at the base of the column
Ensure all samples points are closed and locked (if necessary)
Check that instrument air is available and the isolation valves to the air
Check that dilute acid is available and begin the acid dilution sequence (see
Section 3.12.5)
Fill the column with resin by advancing resin through the circuit
Fill the column with water using the wash water at the base of the column
Once the column is overflowing adjust the water flow to reach operational flow
rate by setting the wash water flow rate controller to automatic
Open the discharge knife gate valve to fill the air lift
Open the water flow to the air lift and adjust the flow rate using manual
diaphragm valve to ensure that the resin will be fluidized for air lifting
Open the isolation air valves and stroke the actuated air valve to a position
which will achieve correct resin movement
Restart the resin flow rate into the column
Trim the water flow rate to the air lift so that the overflow rate is approximately
the same flow rate as when the column resin discharge flow was closed
Set the set points to the following controllers :
- Sulphuric acid flow rate (FIC4840)
- Wash water flow rate (FIC4894)
- pH in overflow (AIC4838)
- Bed level in column (LIC4825)
Start the acid eluant pumps and set the sulphuric acid flow rate controller to
automatic
Check the system to ensure resin flow downwards and an overflow of the
eluate at a flow rate roughly equivalent to both the acid eluant and the water
wash combined. Trim this flow using the set point on the water wash to
achieve the correct total up flow required as set by operations.
Set the level controller on the air valve to automatic
365880219.doc 36
OPERATING MANUAL
Once acid is emerging from the top of the column (indicated by a dramatic
decrease in pH on the overflow) set the pH loop to automatic
Shutdown Procedure
Stop the acid eluant pump and set the controller to manual. Set the pH
controller to manual as well
If the column is to be shutdown for a reasonable length of time, wait for a
period to allow the water to remove and wash out acid and cyanide. The flow
rate of water can be increased to do this if required.
Isolate water to the water injection point at the bottom of the column
Shutdown resin feed to the column
Shut the air valve to the air lift and set the controller to manual. Shut off water
addition into the air lift
Shut the knife gate discharge valve
Shut off the controller to the work wash and isolate the water supply
Warning: The column still contains resin and some Hydrogen Cyanide. To
allow maintenance on the column the column must be washed to
remove all remaining cyanide, before the contents are dumped to
the floor.
3.9 Resin Metal Elution
Reference Drawings: 4274-00-J-009 Resin Elution Sheet 1
3.9.1 Resin Transfer to The Metal Elution Column
To fill the metal elution column with resin the procedure is as follows:
Start-up Procedure
Check the adsorption area spillage pump is on standby

Check instrument air is available and the isolation valves to automated valves
at the top of the column are open
Open the drain on the bottom of the elution column and close the solution
inlet and outlet valves
At the top of the column open the resin inlet isolation valve and close all the
other solution outlet valves
Set the splitter box to send resin to the metal elution column
Use the adsorption area spillage pump to remove solution as necessary
Shutdown Procedure
A level probe in the elution column will indicate when the full level is reached.
Shutdown the column as follows:
Set the splitter box to send resin to the cyanide elution column
Close the resin inlet valve
Allow the column to drain completely of solution then close the drain valve at
the base of the column
365880219.doc 37
OPERATING MANUAL
3.9.2 Metal Elution
The resin in the elution column is eluted free of precious metals by the following
sequence of events:
Start-up Procedure
Check the metal elution sequence for times and flow rates on the plant control
system
Check instrument air is available and all the isolation valves to the air
Check the flow controller (FIC4845) is in automatic
closed and the isolating valves to the metal eluant tank and the recycle eluant
tank are open. Ensure the tanks are full.
Open manual isolation valves on the metal eluant pump and the recycle pump
suctions
Check there is sufficient room in the precipitation tank for a batch of eluate
Check that any isolation valves on pressure gauges and transmitters in the
circuit are open
Close the drain valve on the elution column
Refer to 4274-48-F-001 Metal Elution Sequence for equipment and valve
operation order and times
Start the elution sequence from the plant control system
Shutdown Procedure
At the end of the sequence all equipment will be stopped and all valves can be
left in the operating operation. It is normal for the resin to be returned to cyanide
adsorption. Occasionally, the resin will instead need to be transferred to the silver
elution column for precious metal elutions.
3.9.3 Resin Transfer to Silver Elution
Resin can only be transferred to silver elution via the metal elution column
Start-up Procedure
Check instrument air is available and that isolation valves to actuated valves
are opened
Set the manual valves at the base of the columns so that the resin to silver
elution line is opened and the resin to adsorption line is closed
Open the valves to the silver elution resin inlet and the silver elution drain.
Close all other solution inlet and outlet valves
Open the discharge valve to the metal elution column and the bypass line
(from solution inlet to outlet) valve. Close all other solution inlet and outlet
valves
Open the water inlet and set the flow rate controller to the required set point
into automatic
Check the sight glass on the resin discharge line for adequate flow
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Shutdown Procedure
Once resin transfer is completed (using the sight glass to supply to judge)
stop the raw water to the metal elution column
Close all the inlet and discharge valves to both columns
3.9.4 Silver Elution
The resin in the elution column is eluted free of precious metals by the following
sequence of events:
Start-up Procedure
Check the sequence for times and flow rates on the plant control system
Check instrument ore is available and all the isolation valves to the air
Check the flow controller (FIC4846) is in automatic
closed and the isolating valves to the metal eluant tank and the recycle eluant
tank are open. Ensure the tanks are full
Open suction manual isolation valves on the metal eluant pump and the
recycle pump are open
Check the electrowinning cells to ensure the cathodes are in place and the
cell is ready to operate
Check isolation valves to all the pressure gauges and transmitter in the
circuit, and open them
Close the drain valve on the elution column
Refer to 4274-48-F-002 Silver Elution Sequence for equipment and valve
operation order and times
Start the elution sequence from the plant control system
Start the electrowinning cell at the local panel once it is being filled with eluate
Shutdown Procedure
Once the main elution part of the sequence is complete the cell should be turned
off and drained. Do not leave eluate in cell while it is off as cyanide in the eluate
will leach metal off the cathodes. At the end of the sequence all other equipment
will be stopped and all valves can be left in the operating position. Resin will be
returned to the loaded resin screen.
3.9.5 Resin Transfer to Adsorption
This applies to either metal elution or silver elution transfer back to the adsorption.
Resin can only be transferred to silver elution via the metal elution column.
Start-up Procedure
Check instrument air is available and isolation valves to actuated valves are
opened
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OPERATING MANUAL
Open the manual valve at the base of the columns so that the resin will be
transferred from the correct elution column to cyanide adsorption. Close the
metal elution to silver elution valve and the valve from the other elution
column to cyanide adsorption
Open the discharge valve to the correct elution column and the bypass line
(from solution inlet to outlet) valve. Close all other solution inlet and outlet
valves
Open the water inlet and set the flow rate controller to the required set point
into automatic
Check the sight glass on the resin discharge line for adequate flow
Shutdown Procedure
Once resin transfer is completed (using the sight glass to judge) close the
water line to the metal elution column
Close all the inlet and discharge valves to both columns
3.10 Copper Precipitation
Reference Drawings: 4274-00-J-011Resin Elution Sheet 2

4274-48-F-003 Filtration Control Sequence
Warning: Copper precipitation uses high pressure concentrated sulphuric

acid, a highly corrosive substance, as well as generating heat and
hydrogen cyanide, a highly toxic gas. Care should be taken when
working in the area, particularly while the process is operating.
Copper precipitation is highly automated and divided into two activities filtration and
washing/discharge
3.10.1 Filtration
Start-up Procedure

Check that instrument air is available and that isolation valves on air to
Start the cyanide stripper and scrubber and ensure that this is operating
correctly (see Section 3.11)
Check the times of each stage in the filtration sequence
Set the set points of the following controllers making sure all controllers are
set to automatic :
- Precipitation pH (AIC4878)
Check that plant air is available to the filter air receiver and that the filter air
receiver isolation valves are open. Check that the pressure setting on the
pressure control valve is set correctly.
Open the isolation valve to the air piping around the filter. Check the flow
control valve setting on the filter is correct.
Open the suction and discharge valves to the filter feed pump
Open the suction and discharge valves to the precipitation acid feed pump
Open the isolation valve to the raw water system supply
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OPERATING MANUAL
Check that all equipment and valves involved with the sequence are in
remote
Start the filtration sequence using the plant control system
Shutdown Procedure
The filtration will shutdown itself on a low level being reached in the precipitation
tank. The remainder of the sequence will then be completed
In the event of a premature shutdown being required either:

Stop the sequence at the plant control system
Stop the acid feed pump followed by the filter feed pump
It is advisable that water is run through the filter to wash out acid and cyanide
Warning: The filter at this stage still contains toxic and harmful material and
should under no circumstances be opened without the correct
discharge sequence being followed.
3.10.2 Discharge
Warning: Discharging of cake can release HCN gas if the filter has not been
operated correctly. Precautions should always take place in the form
of personal protection equipment if working in or near the filter and
other personnel should be notified if working in the area.
As the filter has already been operated, it is assumed air, water etc. is available:
Place container at discharge outlet
Open isolation valve at filter discharge
Start the discharge sequence using the plant control system
Shutdown
The sequence once discharge is complete will stop automatically
If premature shutdown is required, follow the sequence steps manually before

discharging cake
3.11 Cyanide Stripping and Scrubbing
Reference Drawings: 4274-00-J-010 Cyanide Recovery System
Cyanide stripping and scrubbing involves the removal of HCN from acid streams and
redissolution as NaCN in a caustic stream.
Start-up Procedure

Check that instrument air is available to all actuated and modulating valves
Check that the caustic header tank is full and the duty caustic feed pump is
operating
Open the isolation valve on the caustic line to the scrubber
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OPERATING MANUAL
Open the isolation valves on the suction and discharge of the duty scrubbing
column pump. Close the suction and discharge valves on the stand by
scrubbing column pump
Open the isolation valves to the pressure transmitters on both columns
Open the suction and discharge valves of the duty stripping column pump.
Close the suction and discharge valves on the stand by stripping column
pump
Open the vent isolation valves feeding into the stripping column
Check that the following controllers are set to automatic and check the set
points :
- Caustic Flow AIC4834
- Recovered Cyanide Flow FIC4864
- Scrubber Level LIC4833
- Stripper Levels LSH/LSL4832
Start the cyanide stripper and scrubber sequence from the plant control
system
Adjust the manual damper at the air inlet to provide back pressure to the vent
lines by closing it until just before the system can be heard labouring
Shutdown
A shutdown sequence is provided by the plant control system which will shutdown
the plant in the correct fashion
In the case of an emergency:

Stop the cyanide recovery fan
3.12 Reagents
On the plant there are a number of reagent systems
Warning: Many reagents used within the plant may be toxic or hazardous. All
chemical should be considered hazardous and treated accordingly.
Adequate protective clothing should be worn when handling all
chemicals. Personal hygiene must be maintained to prevent
accidental poisoning. Smoking or consuming of food in the vicinity
of the reagent areas is strictly prohibited. All operators should
become familiar with and understand the hazards with all the
chemicals used on the plant from the product and safety data sheets
provided in Appendix 1.
3.12.1 Quicklime Lime System
The quicklime addition once initiated will maintain quicklime supplies to the mill
Warning: Lime will cause irritation and burns to skin, eyes and mucous
membranes in the nose and throat. Always wear eye protection,
rubber gloves, protective clothing and respirator when working
with lime. Lime powder should be washed from the skin as quickly
as possible with copious quantities of water. If irritation continues
seek first aid attention.
Start-up Procedure
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Check the content level in the lime hopper for available lime remaining and
make up as required
Start the Lime Feeder from the plant control system or at the MCC
Trim the VSD at the MCC to feed the correct lime dosage on to the belt
Use pH in the leach tanks to confirm dosage. pH should be 10.0 10.5
Shutdown Procedure
Stop the belt feeder at the plant control system
3.12.2 Sodium Cyanide System
Warning: Sodium Cyanide is highly toxic if ingested. It also forms highly toxic
hydrogen cyanide gas which can result in rapid death. Cyanide
solutions are also alkaline which can cause irritation and burns to
the skin and eyes. Protective clothing must be worn when handling
cyanide. A carbon filter or external air supply respirator must be
worn when mixing cyanide. If cyanide is ingested or if exposed to
high concentrations of hydrogen cyanide gas first aid attention must
be available. All personal must be familiar with the first aid
procedures for cyanide poisoning and the required equipment
should be regularly inspected. When entering tanks that have
contained cyanide, proper precautions must be taken against
residual levels of cyanide and the tank detoxified with hypochlorite
or similar.
Raw water or spent electrolyte (if available) is used to make-up 20% w/w cyanide
solution for plant use. If raw water is used then it is necessary to first add sodium
hydroxide solution to the Sodium Cyanide Mixing Tank to reduce the amount and risk
associated with HCN gas formation. If spent electrolyte is used then no sodium
hydroxide is required and the amount of sodium cyanide required to make-up the
20% w/w is reduced.
Mixing Procedure
Check that the storage tank has the capacity to hold a new batch
Check the drain valve on the Sodium Cyanide Mixing tank is closed
Open the manual sodium hydroxide dosing valve to the Sodium Cyanide
Mixing Tank if raw water is being used to mix cyanide. Ensure a high pH is
achieved (greater than pH 11)
Add the raw water or spent electrolyte solution to the Sodium Cyanide Mixing
Tank by opening the automated valve at the local panel
The valve will automatically close on a high level in the mixing tank. The Sodium
Cyanide Mixing Agitator will automatically start as the tank fills.
Add the sodium cyanide to the mixing tank using the Cyanide/Bag Hoist. This
requires the bulk bags to be lowered onto the Sodium Cyanide Bulk Bag
Breaker to burst the bottom of the bag. This may require the bag to be raised
and lowered several times to ensure it empties completely. Make sure the
doors to the bag breaker remain closed during this procedure to prevent
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OPERATING MANUAL
cyanide dust escaping. A number of bulk bags are required to make the
solution up to 20% w/w cyanide.
Leave the batch to mix for a minimum of half an hour
Once completely mixed open the mixing tank discharge valve
Start-up Procedure
Check the suction and discharge isolation valves on the standby Sodium
Cyanide Feed Pump are closed
Check the drain and flushing valves on the duty Cyanide Feed Pump are
closed and open the pump suction and discharge isolation valves
Start the duty Cyanide Feed Pump at the plant control station and ensure flow
returns to the storage tank via the header tank
3.12.3 Sodium Hydroxide System
Warning: Sodium Hydroxide (caustic soda) solutions are corrosive and will
cause burns to skin and eyes unless removed immediately. Is splashed with
caustic solution wash it off with copious amounts of clean fresh water, then
seek first aid attention. When flake caustic is dissolved in water a large
quantity of heat is involved. This could result in boiling. The mix tank agitator
should be running when adding flake caustic to the caustic mix tank. Always
wear gloves and eye protection when handling both liquid and flake caustic.
Raw water is used to make-up 20% w/w caustic solution for plant use.
Mixing Procedure
Check that the storage tank has the capacity to hold a new batch
Check the drain valve on the Caustic Soda Mixing tank is closed
Add the raw water to the Caustic Soda Mixing Tank by opening the automated
valve at the local panel
The valve will automatically close on a high level in the mixing tank. The Caustic
Soda Mixing Agitator will automatically start as the tank fills
Add the caustic soda to the mixing tank using the Caustic Bag Hoist. This
requires the bulk bag to be lowered onto the Caustic Soda Bulk Bag Breaker
to burst the bottom of the bag. This may require the bag to be raised and
lowered several times to ensure it empties completely. Make sure the doors to
the bag breaker remain closed during this procedure to prevent caustic dust
escaping. A number of bulk bags are required to make the solution up to 20%
w/w caustic
Leave the batch to mix for a minimum of half an hour
Once completely mixed open the mixing tank discharge valve
Start-up Procedure
Check the suction and discharge isolation valves on the standby Caustic
Soda Feed Pump are closed
Check the drain and flushing valves on the duty Caustic Soda Feed Pump are
closed and open the pump suction and discharge isolation valves
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Start the duty Caustic Feed Pump at the plant control station and ensure flow
returns to the storage tank via the header tank
3.12.4 Hydrochloric Acid
Warning: Hydrochloric acid is a highly corrosive liquid. Should skin contact be

made, burns will occur unless it is removed immediately. If splashed with
hydrochloric acid wash it away with copious quantities of clean fresh water.
Always wear safety goggles and face shield, PVC gauntlets, PVC apron and
chemically resistant safety boots when working on acid systems. Hydrochloric
acid vapours can cause irritation to the nose, throat and lungs. Ensure
adequate ventilation in all working areas. When hydrochloric acid is added to
water a large amount of heat is released. This can cause a splashing hazard.
Always add acid to water, never add water to concentrated acid.
Hydrochloric acid is used only by the carbon elution sequence. To allow start-up and
shutdown of the acid the following procedural guidelines are given:
Start-up Procedure
Using sight glass to check level in acid tank

Add acid using drum pumps if required
Open suction and discharge valves to the hydrochloric acid dosing pump
Put the pump in the appropriate mode in the plant control system ready for
use
Shutdown Procedure
Stop the pump or take it out of automatic mode
Valves can be left in their current positions unless isolation is required
3.12.5 Sulphuric Acid
Warning: Sulphuric Acid is a highly corrosive liquid. Should skin contact be

made, burns will occur unless it is removed immediately. If splashed with
sulphuric acid wash it away with copious quantities of clean fresh water.
Always wear safety goggles and face shield, PCL gauntlets, PCL apron and
chemically resistant safety boots when working on high concentration (> 20%
w/w) acid systems. When working on lower concentration systems a minimum
of safety goggles, PCL gloves and chemically resistant safety boots are
required. Sulphuric acid vapours can cause severe irritation, lung damage and
other complications. Sulphuric acid is not very volatile and therefore
workplace exposures are primarily mists and aerosols which can be avoided
with adequate ventilation. When sulphuric acid is added to water a large
amount of heat is released. This can cause a splashing hazard. Always add
acid to water, never add water to concentrated acid.
Sulphuric acid is used by the precipitation of copper and in cyanide elution. Copper
precipitation requires concentrated sulphuric acid only. Cyanide elution also includes
a dilution procedure into the dilution tank. The acid dilution procedure is covered
here.
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OPERATING MANUAL
Acid Dilution Start-up
Check the sight glass at the concentrated sulphuric acid tank for the tank
level. Add acid using the acid drum pump as required. Note that this should
be monitored regularly
Open the isolation valves to the concentrated sulphuric acid feed pump on
both the suction and discharge
Check that instrument air is available to instruments and control valves
Open the raw water isolation valve to allow the required flow rate to the
dilution tank
Start the acid dilution sequence from the plant control system
Acid Dilution Shutdown
Stop the acid dilution sequence from the plant control system
Close the isolation valves on the concentrate sulphuric acid feed pump
suction and discharge
When the acid dilution tank is empty a low level alarm will sound to warn that more
solution is required to be mixed.
3.13 Water Systems
Reference Drawings: 4274-00-J-008 Water Services
Warning: Water should only be consumed from taps clearly marked Potable
Water. Water from all other taps must be assumed unfit for human
consumption.
In general the water systems must be in operation before other Sections of the plant
can be operated.
3.13.1 Raw Water Bore System
The bore supply pumps are located at the river, 2 km from the main plant.
Start-up Procedure
Ensure isolation valves around duty pump are open and standby pumps are
closed
Ensure the isolation valves to the pressure switch and gauge, bleed line and
main plant are all open
Start the pump from the local start/stop station
Shutdown
Stop the pumps from the local start/stop station
3.13.2 Decant Water System
A tailings decant pump is located on a pontoon at the Tailings dam
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OPERATING MANUAL
Start-up Procedure
Fill the priming tank with water

Ensure the Decant Water Pump discharge valve is opened, the tailings pipe
distribution valves are isolated and the process water pond feed valve is
opened
Start the Reclaim Water Pump from the local start/stop station
Monitor the level in the process water pond to prevent overfilling
If reclaim water is used to flush tailing lines, open and close the appropriate valves to
suit.
Shutdown Procedure
Stop the Decant Water Pump from the local start/stop station. The pump
discharge isolation valve may be left in the operating position for when the
pump is required to be used again
3.13.3 Process Water System
A duty and stand by Process Water Pumps are supplied. Only one pump is required
to operate.
Start-up Procedure
Check the discharge isolation valve is closed on the stand by Process Water
Pump
Check the drain valve is closed and open the suction and discharge isolation
valves on the duty Process Water Pump
Check all the valves in the process water discharge system are in the correct
position i.e. no service point valves have been accidentally left open
Fill the priming tank with water
Start the duty Process Water Pump from the plant control system and check
flow is established
The duty Process Water Pump will stop on a low flow in the discharge line.
Shutdown Procedure
Stop the Process Water Pump from the plant control system
All valves may be left in the operating position for when the plant is restarted except
where they can cause major discharges on opening e.g. a service point.
3.13.4 Raw Water System
A duty and stand by Raw Water Pump are located at the Raw Water Tank and only
one pump is required for normal operation of the plant. An additional fire water pump
is provided on diesel backup to provide fire water on power failure.
Start-up Procedure
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OPERATING MANUAL
Check the suction and discharge valve is closed on the standby Raw Water
Pump
Check the drain valve is closed and open the suction and discharge isolation
valves on the duty Raw Water Pump
Check all the valves in the raw water piping system are in correct position i.e.
no service point valves have been accidentally left open
Start the duty Raw Water Pump from the plant control system and check flow
is established
The duty Raw Water Pump will be stopped on a low level in the Raw Water Tank but
in normal operation of the plant this will only occur if the bore supply pumps are not
operating.
Shutdown Procedure
Stop the Raw Water Pump from the plant control system
Close the suction and discharge isolation valves on the Raw Water Pump
All other valves may be left in the operating position.
3.13.5 Potable Water System
The potable water system is in two parts. The first part takes raw water and treats the
water to produce potable water suitable for human consumption. The water treatment
package is vendor supplied. Refer to the vendor manual for the operation of this part
of the potable water system.
The second part of the potable water system takes potable water from the Potable
Water Tank and distributes it throughout the site as required. There is a duty and
stand by Potable Water Pump installed.
Start-up Procedure
Check the discharge isolation valve is closed on the standby Potable Water
Pump
Check the suction and discharge isolation valves are open on the duty
Potable Water Pump
Start the duty Potable Water Pump from the local control station
The Potable Water Pumps also supplies water to the safety shower system. Also
check the isolation valves to the safety shower system, to the Safety Shower Head
Tank and the Safety Shower Head Tank discharge and to the Safety Showers are
open.
Shutdown Procedure
Stop the Potable Water Pump at the local control station
All valves may be left in operating position
3.14 Fuels Diesel
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OPERATING MANUAL
Warning: Diesel fuels are flammable and as such adequate precautions should
be taken against fire. Refer to the product and safety data sheets in
Appendix 1.
There are two bulk storage tanks in a bunded area located near to the diesel power
plant. Diesel is fed to the power plant and the main plant by duty and standby Diesel
Reticulation Pumps. Diesel is unloaded from tankers by the Diesel Unloading Pump.
Diesel for vehicles is from either the heavy vehicle or light vehicle bowser. This has a
take off from the main reticulation line.
Start-up Procedure
Check the discharge isolation valve is closed on the standby Diesel

Reticulation Pump
Check the suction and discharge valves are open on the duty Diesel
Reticulation Pump
Start the duty pump from the local control panel
Shutdown Procedure
Stop the duty Diesel Reticulation Pump

Close the discharge and suction valves
Diesel unloading is required when a tanker arrives
Start-up Procedure
Select storage tank to transfer diesel to open inlet valve and ensure inlet
valve on other tank is closed
Connect tanker to Offloading Pump with hose
Open Offloading Pump suction and discharge
Start pump and transfer diesel from the tanker into storage tank
Shutdown Procedure
Stop pump when tanker is empty. Close all the valves and disconnect the
hose from the tanker
3.15 Air Systems
There are a number of different air systems on the plant and generally these systems
are the first to be started after a total plant shutdown
Warning: Compressed air can cause serious injury if used incorrectly and it is
the operators responsibility to ensure the safety of all personnel
when using the compressed air systems on the plant.
Do not use frayed, damaged or deteriorated hoses. Always store hoses

properly and away from heat sources or direct sunlight, A hose failure can
cause injury
Use only the correct type and size of hose and fittings and connections. Use
clamps of robust construction especially made for compressed air
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OPERATING MANUAL
Use eye protection, if using compressed air for cleaning down equipment. Do
so with extreme caution, take care not to blow dirt at people or into machinery
When blowing through a hose or air line, ensure that the open end is held
securely. A free end will whip and can cause injury. Open the supply air cock
carefully and ensure that any ejected particles will be restrained. A blocked
hose can become a compressed air gun
Never apply compressed air to the skin or direct it at a person. Even air at low
pressure can cause serious injury. Never use a compressed air hose to clean
dirt from clothing
Do not use air directly from a compressor for breathing purposes, for example
charging air cylinders, unless the system has been specifically designed for
such a purpose and breathing air filters and regulators are fitted
3.15.1 Plant Air System
Start-up Procedure
Check all service point valves are closed

Check the isolation valves to the air receivers open
Check the Plant Air Filter bypass isolation valve is closed and open the feed
and discharge isolation valves to the Plant Air Filter
Check the isolation valves to the instrument air system are closed
Open the Plant Air Compressor isolation valves
Check the lead/lag operation switches are set correctly on the compressors
Start the compressors from the local station and ensure the correct system
pressure is achieved
The two compressors will operate on a lead/lag basis whereby the lead compressor
selected will endeavour to satisfy demand. The lagging compressor will remain idle
unless the demand exceeds the capacity of the lead compressor selected in which
case the lagging compressor will automatically start to satisfy the increased demand.
If demand is low both compressors may shutdown until required again.
Shutdown Procedure
Stop both compressors and close the discharge isolation valves
All other valves may be left in the operating position for when the system is restarted.
3.15.2 Instrument Air System
Start-up Procedure
Check the instrument air dryer isolation valves are open and the bypass valve
is closed
Switch the air dryer on at the local panel
Open all the isolation valves in the instrument air system and ensure the
correct operating pressure is established
Shutdown Procedure
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OPERATING MANUAL
The instrument air system is shutdown automatically when the plant air system is
shutdown. All valves may be left in the operating position for when the plant is
restarted.
Warning: Both the plant air and instrument air systems retain compressed air
even after the Plant Air Compressors have been shutdown.
3.16 Plant Control Description
The plant control system uses CITECT as the operator interface with an underlying
PLC which controls the inputs and outputs to and from the plant. Without the CITECT
interface the plant can and will continue to operate all equipment, interlocks and
sequences though the operator will not be able to interface with the system.
This Section is provided to describe the use of the plant control system. Details can
be found in the PLC program documentation and CITECT documentation. It is
assumed that the reader has a working knowledge of operation within CITECT.
3.16.1 CITECT Start-up/Shutdown
CITECT should be running at all times during normal operation. To initiate CITECT:
Check that the PLC communications cable is connected to the operator

interface PCs
Switch on the operator interface PCs
Wait for the CITECT opening screen to start (after the operating system has
been initiated)
Click on the start button
Enter the appropriate login name and password (see security below for more
details)
The main menu screen will appear. The operator should then navigate
through the system as required
Only a person of Engineer or Manager Authority can shutdown CITECT properly.
Warning: Do not turn the computer directly off. Windows 95 TM and CITECTTM
both require a controlled shutdown. Failure to do could cause
corruption of databases used by the control system and cause
problems with normal operation.
The shutdown CITECT:
Initiate shutdown from the Engineering Menu on the Main Menu page
Follow instructions to shutdown system
Shutdown Windows 95
Shut off computer
3.16.2 Navigation
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OPERATING MANUAL
The operator interface uses a main menu with a series of options to allow the
operator to move between pages. Pages include mimics (graphical representations
of the plant), sequence summaries, group status, trends, controllers and other
utilities. These pages are arranged into Sections including:
Crushing and Milling

Leach and CIL
Gold Recovery
Cyanide Recovery
Reagents
Services
Engineering
The operator can select from the pages by clicking on the appropriate button. To
return to the main menu at any time the user needs to press F1 key. PgUp and PgDn
keys as well as icons on the left of the screen can also be used to move between
pages.
The alarms page can be accessed through the clock icon at the top right of the
screen. While the clock is flashing red, an alarm is unacknowledged. Alarms can be
acknowledged from the alarms summary page.
The following list describes the function of various buttons at the main menu:
MIMICS: Contained graphical images of the plant for a specific area and
use colours to display equipment status and instrument
readings and the alarms.
Group Status: Includes a listing of all equipment for the specific Section and
the status of equipment
Trends: Displays a customizable trend page of relevant analogues for a

particular Section
Controllers: Allows the operator to look at controller status, set point,

outputs and process variables for a Section
Login: Allows new user login
Logoff: Allows user logoff
Alarm Set Points: Displays all analogues alarm set points for the plant
PLC Hardware: A mimic of the PLC and its status
Utilities: Various utility programs available to the engineer or manager

only
Shutdown: Allows controlled shutdown of CITECT engineer or manager

only
3.16.3 Equipment Control Menu
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OPERATING MANUAL
Equipment control menus are pop ups to equipment items that allow the user to
control the equipment in question. These control menus are typical brought up by
clicking a small button next to the equipment in question. They include a combination
of a series of buttons as well as a series of feedback indications.
The control menus contain generic items for every equipment item. The following is a
description of each of the buttons in the menu:
Start/Open: Will start a drive/valve if in normal mode
Stop/Close: Will stop a drive/valve if in normal mode
Normal: Will put a drive in normal/remote mode. Local start controls are
disabled (local stops are still enabled) and PLC interlocks are
enabled. A green indicator next to the button will be lit if the
equipment is in normal mode
Maintenance: Will put a drive into local mode. Local controls only will start or
stop a drive. Only hardwired interlocks are available. A blue
indicator next to the button will be lit if the equipment is in
maintenance mode
Close: The close button will remove the control menu from the screen.
This is recommended as soon as the control is finished with. Too
many popup windows will prevent other windows from opening
The following is a description of each of the indicators in the menu and if in the active
position, what they mean:
Ready: Drive/valve is in ready mode and can be operated by the use
Fault: The drive/valve is faulted at the MCC. This could be a thermal

overload or a control circuit breaker being open
LOS: Locked on stop field stop button is locked in the off position and
must be reset
Failed: An operation such as an open or start signal has been given and
the drive/valve has not responded correctly
Run/Open: A drive is running or a valve is in the open position
Open Limit: The open limit switch on a valve is activated
Close Limit: The close limit switch on a valve is activated
Interlock: The equipment has a software (PLC) or hardwired interlock in

place preventing operation
3.16.4 Process Mimics
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Various process mimics are given for each Section. A copy of those are included in
Appendix 4.
Non controlled equipment appears as a dull coloured item drawn as a graphic on the
screen. Controlled equipment is brightly coloured, the colour indicating the mode the
equipment is operating in. The following is a description of the colours and
corresponding modes for controlled equipment.
Yellow: Ready normal mode
Green: Running/open normal mode
Blue: Ready maintenance mode
Flashing Blue: Running/open maintenance mode
Red: Fault acknowledged
Flashing Red: Fault unacknowledged
Flashing Yellow: Loss of communication with PLC
3.16.5 Alarms
Alarms are generated when conditions which are unacceptable to normal plant
operation are experienced. An audible alarm in the control room will sound until a
particular alarm is acknowledged or conditions return to normal.
The alarms page can be accessed from any CITECT page by clicking on the alarm
clock icon. The icon will flash red if there are unacknowledged alarms. Once the icon
is clicked, the alarms summary page will be displayed. Alarms are listed in order of
the latest to the earliest. Each line contains the alarm tag, alarm description, the time
at which the alarm was triggered and the time at which it is acknowledged. Each line
is colour coded as follows:
Red Flashing: Unacknowledged current alarm
Red: Acknowledged current alarm
Grey Flashing: Unacknowledged reset alarm
Grey: Acknowledged reset alarm (only shown on the alarms

summary page)
The mimics also contain animated calls which will flash red (unacknowledged) or stay
red (acknowledged) when an alarm is triggered.
A printer device will print out each of the alarms as they happen giving the operators
a second source apart from the main terminal screens.
3.16.6 Trends and Controllers
365880219.doc 54
OPERATING MANUAL
A trend page has been set up for each Section of the plant. The trend page contains
the most relevant variables presented in graphical form against time. The page is
fully configurable allowing the operator to add more process variables, change scales
and look at plant history. Up to three months of data is stored by the system.
Controllers are presented on similar pages. Graphical trends show the appropriate
set point, process variable and output for het controller in question. Operators can
configure the PID constants and time the loops on this screen.
3.16.7 Security
Logins for various user levels have been provided to prevent unauthorized changes
to the control system. The following is a list of the user levels which can be assigned
and the functions of each level:
Operator: Can access all pages except utilities and PLC hardware, start and
stop all equipment. Can not change any alarm set points, sequence
variables or controller settings. Can not perform a shutdown.
Supervisor: Has all operator privileges. Can also access PLC hardware pages and
change most alarm set points, sequence variables or controller
settings. Can not perform a shutdown.
Engineer: Has all privileges. Can perform a shutdown. Can access CITECT
utilities.
Manager: Has all privileges. Can perform a shutdown. Can not access CITECT
utilities.
3.16.8 PLC Program
The PLC program is fully documented in the PLC Program Manual. This is a
reference only and personnel strictly trained to use the PLC should only need access
to this document.
The PLC controls all inputs and outputs from the plant as well as sequences and
interlocks. The plant can not run in normal mode without the PLC.
4.0 PROCESS CONTROL FUNCTIONAL DESCRIPTION
4.1 General
365880219.doc 55
OPERATING MANUAL
Refer to the Control System Philosophy of detailed information for PLC/Citect

maintenance
VDU Alarms
Refer to the P&ID drawing, schematic diagrams and control panel general
arrangements
VDU Trending
All PID Control Loops have a permanent trend page. All other Analogue signals are
trended via user configurable trend pages. The user configurable trend pages enable
any analogue signal to be displayed as a trend. When a signal is selected for
trending, an historical trend of events can be displayed for dates prior to the time of
initiating the selection. The server had disk drive has the capacity to store all trends
for a minimum of three months. The Citect operating system will alert the user when
the hard disk is full, and the oldest files can be selectively saved on floppy disk or
deleted to allow space on the hard disk for new trend data.
VDU Indication
All process variables are displayed adjacent to the applicable equipment symbol on
the VDU graphic display. Where multiple process variables relate to a single item of
equipment then these may be displayed on a pull-down summary display due to
space limitations on the main display.
Interlocks
The plant is designed to operate in remote (normal) control via the PLC. In this
mode, equipment can only start in the correct sequence and all equipment is
interlocked with the necessary process operated switches and instrumentation.
The selection of operation via the Local Control Station (Field Station) is done via the
VDU (Citect) display. This should only be done at the request of authorized
personnel.
The mode selection choices on the VDU screen are:

Normal - Remote operation via the VDU screen (PLC/Citect)
Maintenance - Local operation via the Local Control Station
(stop/start station)
Important: Operation of equipment via the Local Control Station should only
take place for maintenance purposes. There are no process interlocks in
maintenance mode and in the case of most equipment such as pumps there
are no machine protection interlocks (i.e. Low Pressure/Flow switches)
Large equipment such as Mills and Crushers have machine protection interlocks in
both modes (Maintenance and Normal)
The Local Stop Buttons and devices affecting personal safety operate at all times (in
any mode).
365880219.doc 56
OPERATING MANUAL
The Interlock Section for each area description is intended to provide information
regarding the order in which equipment should run. In some cases manually
operated equipment which is not PLC controlled or hardwire interlocked has been
included to indicate the correct operational procedure.
Controls
The control system is designed for all control by the plant operator to take place via
the VDU (Citect) screen.
Operator Interface VDU screens are located in the following area:

Main Plant Control Room (Leaching Area) - 2 screens
A Local Control Panel is located in the Primary Crushing area with the basic functions
and displays necessary for the Primary Crushing operator to monitor and intervene
where fully automatic operation is not practical due to such factors as blockages or
inconsistent ore properties.
The Primary Crushing Control Panel is interfaced with the PLC system and therefore
all Process interlocks and machine interlocks are fully operational when equipment is
started and stopped from this panel.
In general any other control stations are small panels which are not used for normal
plant operation i.e. grease test stations.
Alarms
When a fault occurs with any item of equipment, the graphical representation of the
item will flash (change colour in repetition) on the VDU screen in addition to an
audible alarm in the plant area.
The flashing equipment can be selected to activate a drive status page which
indicates the status of the drive (i.e. drive faulted) and includes the status of any
devices directly related to the drive (i.e. belt drift switch, stop button).
The status of all field devices can be viewed on the Citect screen.
System Start
For a system start in any area of the plant, all drives should be selected to Normal
mode.
All drives should be shown as Ready on the screen. A drive is Ready when the
Mimic Symbol is Yellow.
When the start is first initiated, the drive light turns from Yellow to Flashing Green.
For all drives there is a run-up timer to allow time for feedback from the field wiring
indicating that the drive has reached the running condition.
For most drives the run-up timer is set for a short duration 5 seconds (nominal)
which allows enough time for the electrical contactor for the motor to close and the
Citect/PLC system to register the closed condition.
365880219.doc 57
OPERATING MANUAL
For some drives the run-up timer is set for a longer duration to allow time for other
conditions to be met. For example, the electrical circuits for conveyors incorporate a
start warning siren with a 10 second time delay before the motor contactor actually
closes. In addition, more time is required for the conveyor to accelerate to full speed
before the under speed detection logic is enabled. The run-up time (drive flashing
green on the VDU screen) for a conveyor is 20 seconds (nominal).
If the drive starts successfully the colour of the drive will remain solid Green.
If the drive fails to start (when run-up time has expired) or a fault occurs after starting,
the drive will flash Red in an alarm condition.
The drive will continue to flash Red until the alarm is accepted. When the alarms
accepted the drive will remain solid Red colour while the fault condition still exists.
If the fault condition no longer exists, then the drive will turn Yellow Ready.
For certain fault conditions, the drive will turn Yellow after it is reset but will still fail
when a re-start is attempted. This is because there is no steady state information
available to the PLC when the drive is not running to indicate that the fault still exists.
Examples are:
Drive Under speed - the PLC determines the time elapsed between
pulses from a field mounted proximity sensor
MCC hardwire fault - the PLC detects that the run-up timer has expired
(i.e. contactor pull-in but the motor contactor has not closed
Coil has failed)
The cause of the drive faults (as above) are available on the VDU screen for the
operator to view prior to the alarm being reset.
An alarm log is also available to indicate all alarms which have occurred.
4.2 Crushing
Reference Drawings: 4274-00-J-001
Interlocks (Normal Mode)
The following table indicates the condition which must be met prior to the operation of
the drives/valves listed:
NI No Interlocks
SI Standard Conveyor Interlocks Belt Drift, Under speed, Blocked
Chute
15FDA01 15CRJ01 running, TAHH1504, LAL1504, LAH1503, PAL1504

15CRJ01 15CVR01 running (20 sec delay)
15DEX01 NI
15CVR01 SI, 25MLS01 running
46FDB01 15FDA01 running
365880219.doc 58
OPERATING MANUAL
FV1502 NI
Controls
WIC1505 Mill feed rate control loop
The loop controls the feed rate of the ore to the SAG mill (25MLS01). The loop set
point is operator imputed and is adjusted to maintain mill load volume. The loop uses
a belt weightometer (15WIB01) to measure feed rate and adjusts the apron feeder
(15FDA01) speed to maintain the ore tonnage at the inputted set point. The loop also
displays the cumulative tonnage milled.
46FDB01 Lime Feeder
The lime addition rate to the mill is manually controlled by adjusting the speed of the
feeder.
Alarms
The following conditions are measured and alarm levels displayed:
LAH 1503 High level in crusher feed

TAHH 1504 High-high temperature in apron feeder drive
LAL 1504 Low level (oil) in apron feeder drive
PAL 1504A Low pressure (oil) in apron feeder drive
WAH/WAL 1505 High/low tonnage on conveyor 15CVR01
Start Sequence
The crusher system starts in the following sequence:
15DEX01
15CVR01 SAG mill must be running
15CRJ01 (20 sec delay)
15FDA01 (30 sec delay)
46FDB01
Stop Sequence (Normal)
The system is stopped in reverse order to standby:
46FDB01
15FDA01
15CRJ01 (30 sec delay)
15CUR01 (10 sec delay)
15DEX01 (2 min delay)
4.3 Milling
Reference Drawing: 4274-00-J-001
365880219.doc 59
OPERATING MANUAL
Interlocks
The table below indicates the conditions which must be met prior to the operation of
the drives.
NI No interlocks
25MLS01 25PPC01 or 25PPC02 running, mill lube system running TAH2513,

TAH2514, TAH2515, TAH2516, TAH2517
25PPC01/02 LALL2500
25PPS01 NI
Controls
LIC2500 Mill sump level control
The loop controls the level of slurry in the mill discharge sump (25SMP01). The level
set point is operated inputted. Sump level is controlled by adjustment of the speed of
the mill discharge pumps (25PPC01/02).
25MLS01 SAG mill
The SAG mill has a number of control and monitoring loops for the mill lubrication
system. For detail refer to vendor data.
Alarms
The following conditions are monitored and alarm condition displayed:
WAH/WAH/WAL2512 Mill load

LAH/WAL2500 Mill discharge sump level
TAH2513 Feed trunnion bearing temperature
TAH2514 Discharge trunnion bearing temperature
TAH2515 DE pinion bearing temperature
TAH2516 NDE pinion bearing temperature
TAH2517 Gear box oil temperature
Start Sequence
The mill system will start in the following sequence:
25PPC01 or 25PPC02
25MLS01
The milling area is shutdown in the reverse order to start-up:
25MLS01
25PPC01 or 25PPC02 (10 min delay)
4.4 Leaching/Adsorption
365880219.doc 60
OPERATING MANUAL
The following table indicates the conditions which must be met prior to the operation
of the drives:
40AGT01-07 NI
40PPS02 40SCV03 running, LAH4549
40PPS15-19 NI
25SCV01 NI
40SCV03 NI
40SCV04 NI
40PPS03 NI
40SSC02-07 NI
Controls
This area is manually operated and has no control loops installed. AIT4000 is a
monitoring loop which measures and displays the pH of the leach tank.
Alarms
The following conditions are measured and alarm levels displayed:
AAH/AAL Leach tank pH
Start Sequence
No sequence
Stop Sequence
No sequence
4.5 Gold Recovery

4274-00-J-003
4274-00-J-005
of the drives listed.
4.5.1 Elution
45AG709 LAL4501
45PPC01 LAL4501, 4SPPC02/46PPD13 not running
KV4506 open
365880219.doc 61
OPERATING MANUAL
KV4507/KV4511 closed
PAH/PAHH4503, FAH4533
45PPC02 45PPC01 not running, KV4507/KV4502/KV4510, KV4546 or
KV4547 open
KV4506/KV4508 closed, LSLL4515
PAH4503, FAH4533
45PPS07 NI
46PPS20 48PPC19 or 48PPC20 running
46PPD07/08 NI
46PPD13 45OOC02 running
KV4507/ZKV4511/KV4512 open
KV4506/KV4513 closed
FAL4502
45PPD03 NI
45HTR01 45PDC01 or 45PPC02 running, 45PPC07 running
FAL4538, TAH4540, LAL4536, TAH4539
45PPC07 NI
KV4502 NI
KV4508 KV4509 open, ZSC4548 closed
KV4509 NI
KV4510 NI
KV4511 KV4510 open
KV4512 KV4513 closed
KV4506 KV4507 closed, KV4512 or KV4513 open, KV4510 open,
KV4508 closed
KV4507 KV4506 closed, KV4510 open
KV4501 LAH4501
KV4545 LAH4544
KV4560 LAH4501
KV4561 LAH4501
ZSC4548 LAH4549, KV4508 closed
Controls
LIT4501 Caustic cyanide make-up
Level control loop that controls the addition of water to the caustic cyanide tank
through control valve KV4501
FIC4502 Elution column flow control
The loop controls the flow of eluant to the elution column by controlling valve
KV4502. A flow set point is operator-entered and flow is measured by a magnetic
flow meter FE4502.
TIC4520 Heater Temperature Control
Eluant solution temperature is controlled to a set point by controlling the heat input of
the elution heater 45HTR01. The solution temperature is measured by TE4540 and
the heater burner output adjusted accordingly.
365880219.doc 62
OPERATING MANUAL
Alarms
The following conditions are measured and alarms displayed:
LAH/LAL4501 Caustic cyanide mixing tank level

LAL4515 Elution water tank level low
LAL/LAH4544 Lean eluate tank level
FAL/FAH4502 Elution column flow rate
PAHH/PAH4503 Elution column feed pressure high
LAH4549 Elution column feed hopper level high
LAH4534 Elution column level high
FAH4533 Pressure relief line flow
FAH4532 Contaminated HCl line flow
TAH4539 Oil temperature high
TAH4540 Oil heater temperature high
LAL4536 Thermal oil heat tank level low
FAL4538 Oil flow low
Start Sequence
The entire elution sequence is detailing in drawing 4274-45-F-001
The stop sequence is detailed in drawing 4274-45-F-001
4.5.2 Carbon Regeneration
Interlocks (Normal)
The following table indicates the interlocks which must be met prior to the operation
of the drive/value listed:
45KLN01 45FDS02 running, 45SCV02 running, LAH4005

45FDS02 45SCV02 running
45SCV02 NI
Controls
A vendor supported control panel is included with the kiln. This controls the operation
of the kiln.
Alarms
The following conditions are measured and alarms displayed
LAH4005 Kiln feed hopper level low
Start Sequence
45SCV02
45FDS02
365880219.doc 63
OPERATING MANUAL
45KLN01
45KLN01 Burner stop cool down before drive stop

45FDS02
45SCV02 (30 sec delay)
4.5.3 Electrowinning
Interlocks (Normal)
The following table indicates the interlocks which must be met prior to the operation
on the drives/valves listed:
NI = No Interlocks
45PPC05 LAL4541, LAH4556, 45PPC08 running

45PPC06 LAL4542, LAH4557, 45PPC09 running
45PPS08 NI
45PPS09 NI
45PPC41 NI
45PPC40 NI
45PPC08 LAH4441, KV4552 or KV4553 open
45PPC09 LAH4542, KV4554 or KV4555 open
45FAN01 NI
45FAN02 NI
45FAN03-04 NI
45FTP01 NI
45FRN01 NI
45FRN02 NI
KV4550 KV4551 closed, LAH4541
KV4551 KV4550 closed, LAH4542
Controls
There are no control loops within electrowinning.
Alarms
The following conditions are measured and alarms are displayed:
LAL/LAH4541 Electrolyte tank No. 1 level

LAL/LAH4542 Electrolyte tank No. 2 level
LAH4556 Electrolyte return sump A level high
LAH4557 Electrolyte return sump B level high
Start Sequence
365880219.doc 64
OPERATING MANUAL
User selectable sequence Electrowinning A or Electrowinning B
A 45PPC08
KV4552 note: KV4553 is user selectable
45PPC05
B 45PPC09
KV4554 note: KV4555 is user selectable
45PPC06
Stop Sequence
The stop sequence is dependent on the electrowinning stream selected, A or B
A 45PPC05
KV4552/4553
45PPC08
B 45PPC09
KV4554/4555
45PPC06
4.6 Cyanide Recovery
Reference Drawings: 4274-00-J-006 Cyanide Adsorption

4274-00-J-009 Resin Elution Sheet 1 of 2
4274-00-J-010 Cyanide Recovery System
4274-00-J-011Resin Elution Sheet 2 of 2
Interlocks (Electrical)
The cyanide recovery fan 48FAN02 is hardwire interlocked to the cyanide

scrubbing column pumps 48PPC43/44
This fan will not start unless either of 48PPC43 or 44 are running first
The precipitation aid feed pump 48PPD05 is provided with a hardwired
interlock to prevent it form running unless the filter feed pump is running first
of the drive/valve listed. For convenience the interlocks are grouped according to
P&ID.
4274-00-J-006 Cyanide Adsorption
48PPC19/20 LSL4801
48PPS11 No Interlocks
48SCV05 No Interlocks
48SSC08 No Interlocks
365880219.doc 65
OPERATING MANUAL
48AGT12 No Interlocks
KV4861 LAH4801
KV4874 ZS4870 to loaded resin position
KV4875 48SCV06 running and not LAH4825
4274-00-J-009 Resin Elution Sheet 1 of 2
48AGT17 not LSL4828

48AGT19 not LSL4829
48AGT20 not LSL4827
48HTR02 not LSLL4829, not TSH4857
48PPC35 not LSLL4828, 48PPC46 stopped
48PPC36 not LSLL4829, KV4807 closed
48PPC46 not LSLL4827, 48PPC35 stopped (KV4803??)
48REC07 No Interlocks
FV4845 No Interlocks
KV4803 No Interlocks
KV4804 LAH4827
KV4806 LSH4826
KV4813 48PPC36 stopped
KV4816 not LSH4828
KV4818 not LSH4867, KV4803 closed and 48PPC46, 48PPC35
stopped
KV4820 48PPC35 and 48PPC46 stopped
KV4822 LAH4829
KV4848 Not LSH4847, KV4807 closed and 48PPC36 stopped
KV4871 not LSH4828
KV4872 not LSH4829
KV4873 not LSH4829
4274-00-J-010 Cyanide Recovery System
48AGT16 not LSL4831

48FAN02 not ASLL4834, not ASHH4835, 48PPC43/44 running
365880219.doc 66
OPERATING MANUAL
(electrical), KV4863 and KV4862(1) open, not LSH4884

48PPC22/23 not LSLL4831, not LSHH4882 and not ASL4838
48PPC41/42 not LSL4832, not LSH4801
48PPC43/44 not LSL4833
48PPD04 not LSL4844, not LSH4831, KV4892 operational(2)
48PPD05 not LSL4844, not FAL4877, not TSH4879, not ASL4878,

not PSH4880, KV4865 open, 48PPC45 running
AV4834 not LSH4884, not LSH4884, not LSH4833 (ASH4834?)

IV4864 48PPC43/44 running(3), not LSH4604
KV4862 48FAN02 running(1)
KV4863 48PPC43/44 running
KV4892 not LSH4831
Notes:
(1)
A delay on the interlock between 48FAN02 and KV4862 exists to enable
successful start-up of both items
(2)
The timer to switch KV4892 on and off must be operational
(3)
A 30s delay is applied to the interlock on start-up of 48PPC43/44
4274-00-J-011Resin Elution Sheet 2 of 2
48AGT18 LSL4826
48PPC45 not LSLL4826, KV4814 open, KV4812 open
48PPC47/48 not LSL4830, not LSHH4832, not LSH4883, 48FAN02 running
LV4825 not LAL4825
KV4811 not KV4812
KV4812 not KV4811
KV4814 No interlocks
KV4815 KV4814, KV4865, KV4812 closed
KV4865 48PPC45 running
KV4889 48PPC45 stopped
KV4886 not LAL4825
Controls
Cyanide Adsorption
LIC4801 A PID loop to control the flow rate of tailings from the sump 48SMP03, to
maintain sump level. An output low is required to prevent the pumps, 48PPC19/20,
from operating below the slurry critical speed.
365880219.doc 67
OPERATING MANUAL
Resin Elution
FIC4845 A PID loop to control the flow rate of eluant or water into the metal elution
column 48COL02 from a set point, set by either the operator or the metal elution
sequence
FIC4846 A PID loop to control the flow rate of eluant or water into the silver elution
column 48COL03 from a set point, set by either the operator or the silver elution
sequence
TSL/TSH4857 An on/off control switch from the current temperature in the gold
eluant tank, 48TNK36, to the gold eluant heater 48HTR02. The set point will typically
be 50 C
LIC4825 A PID loop to control the flow rate of air in the eluted resin air lift 48ALT05
with the resin bed level in the cyanide elution column 48COL01. An output low and
high is required to place limits on the flow of air in the air lift
FIC4840 A PID loop to control the flow VSD on the acid eluant pumps 48PPC22/23.
The acid flow maintains the elution efficiency of the column. An output high and low
will prevent excess acid to the column. The set point will typically be 2.5 3.0
m/h ???
AIC4838 A cascading PID loop to control the set point on FIC4840 to a set point pH
on the dilute sulphuric acid overflow from the cyanide elution column 48COL01. The
set point will typically be pH = 2.0
LIC4830 A PID loop to control the VSD on the stripper feed pumps 48PPC47/48 to
achieve a level in the stripper feed tank 48TNK39. An output low and high is required
to maintain a minimum and maximum flow rate to the stripper 48COL04. The set
point will typically be 2.5 3.5 m/h
FIC4877 A ratio control to control the VSD on the precipitation acid feed pump
48PPD05 to achieve a constant ratio of acid flow to eluate flow in the precipitation
line. The ratio is measured in kg/m and is calculated from the pump speed, eluate
flow rate and acid density. The ratio is typically set by the cascading AIC4878 or
manually at around 65 90 kg/m
AIC4878 A cascading PID loop to control the ratio of acid to eluate in the
precipitation through FFIC4877 in order to achieve a constant pH. An output low and
high is required to maintain a maximum and minimum ratio of acid addition to the
circuit. The set point will typically be pH = 2.0
FIC4894 A PID loop to control the addition of water to the cyanide elution column.
The set point to be maintained is the sum of FIC4840 and FIC4894. This total flow
represents the up flow velocity in the column. An output high and low will prevent
excess and to little water being added into the column. The set point is typically 2.5
m/h
Cyanide Recovery System
LSH/LSL4832 An on/off control switch for the cyanide stripping column pumps
48PPC41/42 which is triggered by the level in the cyanide stripping column sump
48COL04
365880219.doc 68
OPERATING MANUAL
FIC4864 A PID control loop to control the flow rate of recovered cyanide being bled
from the cyanide scrubber 48COL05 through the control of FV4864. The set point is
set by LIC4833
LIC4833 A PID control loop to control the level in the cyanide scrubber 48COL05
by the changing the set point flow rate to controller FIC4864
AIC4834 A PID control loop to control the addition of caustic into the cyanide
scrubber via pH measurement by the use of AV4834
Elution Sequences
Reference Drawings: 4274-48-F-001 Metal elution control sequence

4274-48-F-002 Silver elution control sequence
The above drawings give details of the sequences employed in the batch elution in
the metal elution column 48COL02 and the silver elution column 48COL03. The
eluant makeup procedures are also included.
Filtration Sequence
Reference Drawing: 4274-48-F-003 Filtration control sequence
The above drawing gives details of the sequence used in the precipitation and
filtration batch process.
Dilute Acid Makeup Sequence
The dilute acid makeup sequence must be activated through the control system.
Once activated the following sequence will occur:
LSL4831 will trigger the sequence to start

KV4892 will be operated. This includes actuation from on to off on a timer e.g.
15 s on 15 s off
48PPD04 will run
LSH4831 will trigger the sequence to stop
The sequence is repeated until it is deactivated. Interlocks will not deactivate the
sequence.
Cyanide Stripping and Scrubbing Start-up Sequence
The following sequence describes the start-up of the cyanide recovery package:
48PPC43/44 started
AIC4834 PID controller is activated
After a delay of 20 s KV4863 is open
KV4862 and 48FAN02 are started simultaneously
FIC4864 PID controller is activated
LIC4833 PID controller is activated
LIC4832 On/Off controller is activated
365880219.doc 69
OPERATING MANUAL
If a problem occurs in the sequence the control system will abort the sequence and
drives running, valves open and controllers activated will remain in that state.
Cyanide Stripping and Scrubbing Stop Sequence
The following sequence describes the shutdown of the cyanide recovery package:
LIC4832 On/Off controller is deactivated

LIC4833 PID controller is deactivated
FIC4864 PID controller is activated
KV4862 and 48FAN02 are stopped simultaneously
KV4863 is closed
After a delay of 20 s, AIC4834 PID controller is deactivated
48PPC43/44 stopped
If a problem occurs in the sequence the control system will abort the sequence and
drives running, valves open and controllers activated will remain in that state.
4.7 Reagents
The following table lists the conditions which must be met before the drives/valves
will operate:
45PPC14 not LSLL4601

46PPS10 NI
46AGT11 not LAL4619
45CPL02 LE4614, 46AGT11 running
46AGT10 not LAL4618
46CPL01 LE4603, 46AGT10 running
KV4614 LE4614
KV4603 LE4603
KV4616 not LSH4603
Controls
The reagent make-up area for caustic and cyanide is supplied with local panels for
control of the reagent make-up.
Each local control panel controls the addition of water to the make-up tank prior to
the addition of either solid caustic or cyanide.
Alarms
LAL4916 Caustic mixing tank level low

LAL/LAH4601 Caustic storage tank level
365880219.doc 70
OPERATING MANUAL
LAL4618 Cyanide mixing tank level low

LAL/LAH4604 Cyanide storage tank level
Start Sequence
Caustic make-up initiated from local control panel

KV4616
46AGT11 (on reaching level set point)
Cyanide make-up initiated from local control panel

KV4603
46AGT10 (on reaching level set point)
Caustic dosing
46PPC14 or 46PPC15
Cyanide dosing
46PPC11 pr 46PPC12
Stop Sequence
KV4603 on reaching high level

46AGT10 on reaching low level
KV4614 on reaching high level
46AGT11 on reaching low level
4.8 Services

4274-00-J-008
The following table lists the condition which must be met for the valves/drives listed
to operate:
NI = No Interlocks
Air Systems
53CMP01 NI
53CMP02 NI
53DRY01 NI
Diesel Supply
53PPC33 NI
53PPC34 NI
53PPC51 NI
Water Supply
50CJL01 NI
50PPC29 NI
50PPC30 NI
50PPC31 PSL5007
365880219.doc 71
OPERATING MANUAL
50PPC32 PSL5007
50PPC49 FSL5013
50PPC27 FAL5015
50PPC28 FAL5015
50PPC26 NI
50PPC24 LALL5008
50PPC25 LALL5008
Controls
There are no control loops within the services area. A local panel for control of the fire
water pump is provided.
Alarms
The following conditions are measured and alarms displayed
Air System
None
Diesel System
None
Water System
LAL/LALL5001 Potable water tank level low
LAH/LALL5008 Raw water tank level
PAL5007 Raw water low pressure
FAL5013 Decant water low flow
FAL5015 Process water low flow
LAL5006 Safety shower header tank level low
Start Sequence
Air System
None
Diesel System
None
Water System
None
Stop Sequence
None
5.0 MAINTENANCE
All equipment on the processing plant has been supplied by vendors. For the
instructions for the operation and maintenance of individual items of equipment refer
to the manuals and information supplied by the vendors. Refer to Section 5.1 for the
vendor data register and if more information is required contact the vendor. Refer to
Section 5.2 for the vendor contact information.
5.1 Vendor Data Register
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OPERATING MANUAL
The following table is a summary of vendor documents and information that form part
of this operations manual but have been provided by equipment suppliers under
separate cover.
The summary is ordered by the vendor name and the type of document and the
following abbreviations have been used for each document type
DGN Drawings
DS Data Sheet
EL Equipment List
IL Instrument List
ITP Inspection Test Plan
MN Manual
ODOC Other Document
SPEC Specification
5.2 Vendor Contact Information
Attached is a list of supplier contact information including supplier addresses, phone

and fax numbers and contact names. Included in the list is the type of equipment
purchased and the purchase order number.
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OPERATING MANUAL
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OPERATING MANUAL
365880219.doc 75

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MIRAH GOLD PROJECT PT KASONGAN BUMI KENCANA

2.0 PLANT DESCRIPTION

2.2 Design Summary

All of the equipment selected is designed at a capacity of 700,000 tpa.

Reference Drawing: 4272-00-F-001 Crushing and Milling

The design size reductions are as follows:

ROM ore feed mm max < 750

2.4 Classification and Screening

Reference Drawing: 4272-00-F-001 Crushing and Milling

The cyclone cluster consists of a bank of 5 x 300 mm hydrocyclones.

2.5 Leach and Adsorption

Reference Drawing: 4272-00-F-002 Leach and CIL

Mechanically swept carbon retention screens, 40SCC02/07, are provided in the

Agitators are started and stopped manually at field pushbutton stations;

2.6 Gold Recovery

Reference Drawings: 4272-00-F-003 Elution

AARL carbon elution

Operations such as electrowinning, cathode handling and bullion smelting are

2.6.1 Loaded Carbon Recovery

Step 3 Caustic-cyanide pre-soak to chemically prepare the carbon for gold

The gold rich electrolyte or eluate at approximately 70 C is stored in one of two

2.6.3 Bullion Processing

2.6.4 Elution Chemicals

Details of reagents are discussed in Section 2.11.

2.6.5. Eluted Carbon Transfer

Transfer of eluted carbon from the elution column, 45ELU01, is performed

2.6.6. Carbon Regeneration

2.7 Cyanide Recovery

Reference Drawings: 4274-00-F-006 Cyanide Adsorption

Vitrokele Process Chemistry

Vitrokele is supplied as a sulphated resin and is conditioned prior to use dependent

Cyanide removal is of primary concern the Vitrokele is first conditioned by contact

Conditioning R-SO42- + CU(CN)43- R-Cu(CN)43- + SO42-

R-CU(CN)43-+ 3/2H2SO4 R-CuCN- + 3HCN + 3/2SO42-

Cyanide Scrubbing HCN + NaOH NaCN + H2O

Adsorption R-SO42- + Me(CN)43- R-Me(CN)43- + SO42-

Elution R-Me(CN)43- + NaCN R-CN + Me(CN)43-

Regeneration R-CN + H2SO4 R-SO42- + HCN

or R-Zn(CN)42- + 2H2SO4 R-SO42- + 4HCN + ZnSO4

The following tables summarises the design capacity of the circuit:

Free Cyanide Copper Silver Gold

Resin Loadings kg/t 113 60 10 neg

Cyanide Copper/Metal Silver/Gold

2.7.1 Cyanide Adsorption

2.7.2 Cyanide Elution

2.7.3. Metals Elution

2.7.4. Copper Precipitation

A heater, 48HTR02, is used to bring the eluant up to a constant temperature of 40

Silver elutions include two steps.

2.7.6. Cyanide Stripping and Scrubbing

caustic is injected into the scrubber. pH should be maintained at approximately 12.0.

2.8 Tailings Disposal

Reference Drawings: 4274-00-F-004 Water and Services

2.9 Water Systems

Reference Drawing: 4274-00-F-004 Water and Services

2.9.1. Raw Water Systems

Mine dust control

2.9.2. Tailings Dam Decant Water System

2.9.3. Process Water System

2.9.4. Fire Water System

A diesel driven pump, 50PPC26, capable of delivering 60 m/h at a head of 40 m is

2.9.5. Potable Water System

Potable water will be used for:

The status of the potable water pumps (run/stopped/faulted) is monitored on the