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KCGM Increases Gold Recovery

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October 6, 2005



Kalgoorlie, Western Australia; In July 2004, Kalgoorlie Consolidated Gold Mines (KCGM) (a 50/50 joint venture between Barrick and Newmont operated by Barrick) commissioned a gravity circuit consisting of five (5) Knelson KC-XD48 Concentrators and a ConSep ACACIA CS6000 concentrate leach reactor. After more than one full year of operation the circuit has demonstrated improvements at KCGM in excess of initial expectation.

 

Fimiston 36' SAG Mill

“Following the introduction of the gravity circuit at KCGM, we have seen the benefits of the circuit exceed design expectations. With ConSep and Knelson’s support we have been able to implement a program of continuous improvement in the gravity circuit, which has continued to generate steady mechanical and process performance gains. Overall the project has been a good success for KCGM” stated KCGM’s Danny Hillier.

 

KCGM is Australia’s largest gold plant, and ranks as the 9th largest gold producer in the world. The plant processes approximately 13.0 million tonnes per annum at a grade of 2.0 to 2.5 g/t Au. The plant recovers approximately 800,000oz per year of gold. The gravity circuit was installed after a detailed study was undertaken to determine the potential benefits for gravity recovery at KCGM. The initial test work to define the benefit of gravity at KCGM consisted on a number of parallel test work programs including:

• GRG test work and Modelling by Knelson Gravity Solutions and ConSep Pty.
• GRG test work and Modelling by the AJ Parker Centre / Andre R LaPlante
• Amtel studies of mineralogy of CIP tails and Rougher Column Tails
• On site test work using a KC-CD12 Knelson Concentrator Pilot Plant
• On site test work using KCGM’s KC-MD3 Laboratory Knelson Concentrator
• JK MLA analysis of the Knelson Concentrates

 

Fimiston Ball Mill One Gravity Tower

The test work revealed that the KCGM mill feed ranged in GRG from 36 to 41% of total gold at a final grind size of 75 microns. The trials of the pilot 12” Knelson on CIP tails revealed 0.2 – 3.6% potential extra recovery could be achieved by the plant, and while highly variable, the average additional recovery predicted by this test work was 1.06%.

 

On the basis of the modelling undertaken in Knelson and the AJ Parker Centre (using Andre R LaPlante), an ideal case gravity circuit configuration was determined. For each of the two Fimiston Ball Milling Circuits the equipment purchased consisted of:

• Two off 300tph KCXD48 Knelson Concentrators
• One off Schenck 5.5 m x 3.1 m vibrating screen
• One off 10/8 Warman Gravity Feed Pump
• One off 3/2 Warman Concentrate Transfer Pump

 

KCGM KCXD48 Installed in Mt. Charlotte circuit

For the Smaller Mt. Charlotte Circuit, the gravity circuit consisted of:

• One off 300tph KCXD48 Knelson Concentrators
• One off Schenck 4.3 m x 2.5 m vibrating screen
• One off 8/6 Warman Gravity Feed Pump
• One off 3/2 Warman Concentrate Transfer Pump

 

KCGM CS6000 ConSep ACACIA Installation

The 10 – 12 tpd of gravity concentrate generated from the Knelson Concentrators is intensively leached within a CS6000 ConSep ACACIA. The ConSep ACACIA design at KCGM included a new reactor geometry. The reactor was also designed to take up to 12 tpd of gravity concentrate, making it the world’s largest ConSep ACACIA intensive cyanidation circuit at the time it was commissioned. The reactor was also designed specifically enable operation at elevated temperatures during the leach cycle. Test work carried out on the gravity concentrates had revealed that the ideal leach conditions for KCGM were to utilize a combination of leach accelerants and an elevated temperature of 55°C. These conditions maximized the recovery of the difficult to leach gold telluride complex, Calaverite (AuTe2). This species is one of the slowest leaching gold components in KCGM’s ore, and is partially gravity recoverable. ConSep has also undertaken a comprehensive post commissioning ‘GRG Accountability’ test work program at KCGM. This test work program has determined the ideal gravity XD48 set-up for maximized gold recovery and is on-going at this time.

 

 

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