Elution Report
Elution Report
I HemedAmriHemed declare that is the original work of my IPT study at JEMA AFRICA Ltd. I
declare that this work has not yet presented at any institute in Tanzania and world wide.
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ACKNOWLEDGEMENT
I would like to thank my chief operator mr Yassin Mlega who has been with me during my IPT
study for the period of two month. Also I would like to thank branch manager of
jemaafricamrJumaLuchele who have been providing support to all IPT student who arrived at
jemaafrica. I would like to appreciate indutrial supervisor mrsese for providing guidelines to
work health and safety during working hours at JEMA AFRICA LTD
I would like to extend my great thanks to all workers at JEMA AFRICA LTD inclungmarkertors,
operators, security men as well as customers who came for gold recovery process .My great
thanks also goes to IPT supervisor ENG. Mtui who came to my IPT study for assessment of what
we have done during our IPT study.Also my great thanks goes to my parent and relatives who
funded me with money and properties to stay health for the whole time of my IPT study. Also I
respect, and obedience during our part time at JEMA AFRICA LTD.
Other great thanks goes to our intitute principle who visited us during our IPT study to evaluate
the challenges that great face the student during their IPT study. There are many challenge that
face the students during their study. Those challenge includes accommodation, food, money,
social interaction, trust, etc. to our fellow female students face sexual corruption in which most
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TABLE OF CONTENTS
ACKNOWLEDGEMENT...............................................................................................................ii
TABLE OF CONTENTS...............................................................................................................iii
LIST OF FIGURES.........................................................................................................................v
ABSTRACT...................................................................................................................................vi
LIST OF ABBREVIATION........................................................................................................viii
CHAPTER ONE..............................................................................................................................1
1.0. INTRODUCTION....................................................................................................................1
CHAPTER TWO.............................................................................................................................3
CHAPTER THREE.......................................................................................................................11
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3.2. Flocculation...........................................................................................................................11
3.3. Decantation.............................................................................................................................12
3.4. Filtration.................................................................................................................................12
CHAPTER FOUR.........................................................................................................................14
4.1. Smelting..................................................................................................................................14
CHAPTER FIVE...........................................................................................................................18
5.1 CONCLUSION........................................................................................................................18
5.2. RECOMMENDATION..........................................................................................................20
REFERENCES..............................................................................................................................21
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LIST OF FIGURES
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ABSTRACT
This report is about the recovery of gold from elution circuit, acid digestion and smelting at
jemaafricaltd . This process beginning from acid wash circle in which the loaded carbon is
cilculated in the column containing acids including dil.hydrochloric acid [3%]. Acid wash circle
help to remove [dissolve] inorganic foulants such as calcium, magnesium, sodium, salts, silica
Another process in the recovery of gold is elution process. In elution process acid washed carbon
is added into elution circuit in which water, caustic soda and carbon are treated under high
complete.
The next stage in the gold recovery is acid digestion in which the steel wool from the cathode
plate is softened with concentrated hydrochloric acid then followed by addition of conc.nitric
acid which digest the steel wool into solution form. The process of acid digestion continues until
the gold concentrate become free from impurities. This process also known purification by acids
The next stage in the recovery of gold is addition of flocculant by causing colloids and other
suspended particles in the liquid containing gold concentrate to aggregate, forming a floc. After
addition of flocculent it took about fifteen minutes for the suspended particles to settle down
The next stage is decantation process in which gold from flocculation is left to settle for about 15
min in the container then water is poured off until gold concentrates is seen. After doing so
filtration process follows in which a piece of cotton cloth and filter with handle are used in
filtration process . The piece of cotton cloths is folded until all water drain off.
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The next step is smelting of gold using gas burner. In this process the gold concentrate folded in
the cotton cloth is first mixed with borax then put into crucible ready for smelting process. After
putting the concentrate into crucible then fire is released from gas burner hit into the mould until
the gold is separated from impurities. The concentrates while in molten state are poured into the
mould to acquire a bar shape. After cooling it is put into the ladle then put into the container
having nitric acid for further purification. The gold bar is hammered to remove impurities
compacted together with gold then washed with soap to remove further impurities. Finally the
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LIST OF ABBREVIATION
LTD…………………………….. Limited
NaOH………………………………Caustic solution
pH………………………………….Positive hydrogen
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CHAPTER ONE
1.0. INTRODUCTION
Jemaafrica LTD is the company associated with gold elution and selling and supply of dosing
chemicals such us sodium cyanide, hydrogen peroxide, nitric acids, Sulphiric acid and carbon
used for gold recovery during leaching gold ore. Chemicals and reagents are being sold to
various part of east africa mainly Tanzania and Burundi. In Tanzania districts such as Kahama,
Geita, Nyamagana in Mwanza region and other places where mining of gold ore take place
The main branch [head quarter] of JEMA AFRICA LTD located in Mwanza region in Tanzania.
It has other branches at Kahama, Geita And Musoma Tanzania. My IPT study was at kahama
branch.
About kahama branch it was established on august 2018 under the leadership of mrsese as
branch manager and mr Yassin Mlenga as chief operator. Currently the branch manager is
MrJumaLuchele , industrial supervisor mrSese and the current chief operator is Mr Yassin
Mlenga
At 2018 Kahama branch started with about five [5] elution column machines where gold elution
takes place. Currently the company have seven [7] elution column machine. About condition of
operation is good due to large number of customers came for recovery of gold from loaded
carbon.
About safety and health are good due to availability of personal protective equipment [PPE] such
as gloves ,goggles safety boot, rainboots, helment and first aid kit and emergency water.
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Alsoabout security also is good due to the presence of security men, CCTV camera and good
Apart from gold elution JEMA A2FRICA LTD possess their own institute called Jema institute
Buzwagi Gold Mine. It’s about one kilometa from Buzwagi gold mine .Jema Africa Limited is
located near shinyangakahama road. Other elution adjacent jemaafrica include chibu elution,
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CHAPTER TWO.
Elution is the process of removing the gold from the loaded carbon. Other names for elution are
stripping or desorption. It involve using high temperature and pressure and treating the loaded
carbon with concentrated cyanide,caustic solution followed by elution with potable water, the
gold cyanide complex can be induced to desorb from the carbon and return to solution.
The main factor that makes desorption or stripping of gold is high temperature. If the
temperature of the solution and carbon mixture is increased the will readily desorb from the
carbon into the solution. Temperature is therefore the most important variable in the elution
process and temperature of[100 °C-120 °C] Are neccesaryto achieve optimum elution
perfomance. Other requirements of the elution process are high cyanide concentration, high
caustic concentration, low ionic strength of the solution[i.e. low level of salts in the water],
optimum flow rate rate of solution through the carbon, low gold concentration in the solution.
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Figure 1: Zadra elution plant
2.2 Zadra process description
At Jema Africa ltd uses the Zadra process. The eluant is continuously circulated through the
column and an electrowinning cell in series. A caustic cyanide solution, normally 0.2 to 0.5 %
NaCN and 2% NaOH, is pumped to the elution column and is pre-heated by the solution leaving
the column. The temperature is further raised by a steam heat exchanger. After stripping the gold
from the carbon, the solution is partially cooled in the incoming heat exchanger and further
cooled to below its ambient boiling point in a cooler heat exchanger. The gold is then stripped
from the solution by electrowinning and the solution is returned to the elution column.
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2.3. Elution stages at Jema Africa
The process of gold elution has three stages which are acid washing, cyanide pre-treatment and
elution.
1: Acid washing
Starting with acid washing which involve the use of acids. Acid washing has three stages which
are acid wash circle, acid soak circle and acid rinse circle.
Acid wash cycle; A dilute hydrochloric acid solution [3%] is circulated into the elution
magnesium, sodium salts, fine ore minerals such as silica and fine iron particles. The acid
Acids soak circle; The acids soak circle is simply a situation where the acids solution
sits in the column, allowing time to dissolves the inorganic foulants. The acid soak circle
take about 40 minutes to dissolve inorganic foulant present in the loaded carbon. The
Acid rinse circle; The acids rinse circle stage involve flushing four bed volume of water
through the column. The water flushes away the minerals impurities that have been freed
by the acids wash. The wash also rinse the carbon of acid and raise [ neutralize] the pH in
the column. If this were not done, the remaining acid would react with the elute, releasing
B: Cyanide pre-treatment
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The next stage involves treating the carbon with a caustic-cyanide solution at high temperature
[ 110-115-120] and pressure of [230kPa]. Sodium cyanide is requred for solubilizing the
adsorbed the adsorbed gold cyanide complex and caustic [sodium hydroxide] is added to
maintain a high pH to minimize the evolution of HCN gas. No gold is removed into solution
during this stage but the attraction between the compex and carbon is weakened allowing it to be
easily desorbed in the following elution stage. High temperature are used and hence high
pressure is maintained to prevent the solution from boiling. [Water boil at 100 °c at atmospheric
C: Elution process
This is actual gold removal stage. Potable water [ water with low ionic strength] is pumped
through the column at high temperature [ 110-{115°c}-120 ] and pressure [230kPa]. High
temperature are used as the gold loading capacity of carbon is reduced with increasing
temperature.
The process of elution has two stages which are recycle elution stage and water elution stage
1. A: Recycle elution stage; During the recycle stage, batch of solution [called the recycled
elute] containing small a small amount of gold from previous elution cycle is flushed
through the carbon bed. This solution has a relative low ionic strength, however does not
have low gold concentration as it contain gold from previous strip in the form of gold
cyanide complex ions. The solution in this stage also report to the electrolyte tank
2. Water elution column; The water elution stage is essentially a repeat of the recycle stage
except that fresh potable water is used, and solution leaving the column reports to the
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recycle elute tank, becoming the “recycle elute” for the next strip. With potable water is
able to extract most of remaining gold, bringing the total gold recover up to 97%. A split
system is used to achieve the highest possible gold grade in the final solution and also to
minimise both electro winning solution volume and potable water consumption.
Activated carbon is used to adsorb gold that is leached by cyanide solution. The gold is then
stripped from this loaded carbon by means of elution to form a concentrated eluate which is then
processed for gold recovery by electrowinning. Essentially elution is the reverse of the
adsorption process. Some of the base metals that are contained in the ores are also leached with
Some of the factors that influence the elution are: temperature, flow rate, gold in the eluant, free
NaOH. The washing of loaded carbon with a diluted acid prior to the elution and the
decomposition of cyanide during elution are known to affect the rate of elution under certain
condition. The elution is a slow process that requires from 8 to 96 hours for completion at
elevated temperature. This is primarily due to slow down diffusion of aurocyanide ion within the
micropores of the relatively large particles of activated carbon. The degree of gold adsorption on
carbon is strongly dependant on the nature and concentration of the alkaline metal cation present
Adsorption is strongly dependant on the pH value of the adsorption medium, the amount of gold
adsorbed in the pH range 4 to 7 being almost twice the amount that is adsorbed in the pH range 8
to 12. It should be noted that carbon’s selectivity for gold appears to increases with increase in
pH and free cyanide concentration. This is probably because at high pH (>10) most other metal
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2.5. Elution Circuit
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The elution column operates with a 2-2.5% NaOH solution with a temperature range of 120 C-
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135 C. The gold is stripped from the carbon into the solution. An elution will start when there is
The caustic solution that returns from the electrowinning circuit is pumped into the eluant tanks.
This solution is sent through a primary heat exchanger where the heat from the exiting solution
of the column is used to preheat the entering solution. It is then sent through a steam heater
The caustic solution is circulated through the elution column. Eluant enters at the bottom and
eluate leaves at the top through the outlet. This pregnant solution goes to the electrowinning
where it passes through the cells. The eluant is pumped to the eluant tanks and from there it is
circulated back to the elution columns. The process is slow with a residence time of 17-24 hours
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Figure 3: Elution flowsheet
The pregnant solution flows from the flash tank to the electrowinning cells. A current is passed
through the cells from a set of rectifiers. The gold is attracted to the cathodes and electroplates
onto it. The cathodes are called baskets and consist of stainless steel mesh to increase the surface
area exposed to the plating process. These baskets are removed once the plating is done and
washed with water under high pressure. The particulate concentrate is passed to a filter press
where it is collected and weighed. Final product is the concentrate which is stored in bins, which
are sealed and dispatched, to the central smelt-house. The gold barren solution is pumped to the
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Figure 4: Cross section ofelectrowinning circuit
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CHAPTER THREE
Acid wash is the process of washing steel wool at cathode plate after electro winning using two
types of acids are sulphiric acids [H2SO4] and nitric acids [HNO3] with water dilution, for
determination of elements in solids subsequent. At Jema Africa this process was done in large
dishes in which sulphiric acid and nitric acid are added respectively then put into special room
Acid wash is done to reduce the amount of impurities associated with gold in order to rise
percentage purity of gold. Also acid wash aim to dissolve the steel wool into solution form which
is easy for continue processes. Acid wash also play a vital role in removing of associated metals
such as silver.
3.2. Flocculation
Flocculation is the process by which colloidal particle come out of suspension to sediment under
the form of floc or flakes. Flocculent or flocculating agent are chemical that promote flocculation
by causing colloids and other suspended particles in liquid to aggregate forming a floc.
Flocculent are used in gold concentration when present in suspension of solution. At jemaafrica
Ltd they use gold mine water treatment flocculent non-ionic polyacrylamide high molecular
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Figure 5: Flocculation process
3.3. Decantation
This process involve separation of mixture, by removing the layer of liquid, generally one from
which a precipitate has settled. Due to high specific gravity of gold the gold concentration settle
to the bottom while the solution stay up. The decantation process may take up to 15min for
efficiently settling of the concentrate. The decantation process takes place in large drum where
3.4. Filtration
Is the physical operation which is used for the separation of solids from fluids by interposing a
medium through which only the fluid can pass. The fluid passes through is called the filtrate.
Over sized solids in the fluids are retained but for increasing purity the filtration process a gold
sample obtained poured into a dishand put into charcoal burner until dried, pouring of nitric acid
to a gold samlpe until white soot is seen. At jema elution the gold concentrate from decantation
is filtered using cotton cloths embeded into steel filte. After this process the cotton cloth is
removed from steel filter then folded until all water drained off. After this stage the gold
concentrate folded into cotton cloth is sent to smelting room.
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Filtration process
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CHAPTER FOUR
4.1. Smelting
The purpose of smelting is to remove the metallic and other impurities into slag phase and
produce the gold silver bullion containing typically ≥ 95 % of precious metal. The smelt
temperatute is maintained for a period of time to ensure complete separation of the impurities
into slags. The molten silver gold form an alloy that is heavier than the slags and hence sink to
the bottom of the melting crucible. Smelting is achieved using borax flux that act to reduce
melting point and viscocity of slag which may get entrained in the presence of silica. The
Gold smelting
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4.2. Gold smelting
Smelting is the process by which a metal [Gold] is obtained by heating beyond the melting point
by using gas in which the source is a gas tank. The purpose of smelting is to remove the mettalic
and other impurities into slag phase, and produce gold with some impurities such as silver. 3.5.
Smelting process.
Prepare a crucible – a crucible is the container usually made of clay that capable
Mix the flux with the gold pieces inside the crucible – A flux is the mixture of
sodium carbonate and borax. This substance remove impurities into slag phase,
Melt a gold by using a torch – There are different type of torch you can use. At
jemaafrica propane torch was used. Use the torch directly into the crucible until it
melt.
Pour melted gold into an ingot – An ingot is a mould made from heavy metal.
This is where you will pour melted gold to achieve a certain shape, cool down
and harden. Use the pair of tongs made from heat resistant materials to hold and
move the crucible while while pouring the gold into ingot.
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III. Open a flame pump and scratching a match box to obtain a flame, open a pressure pump
IV. Heat the mixture in the crucible until all other impurities will be removed and the mixture
is totally melted in the form of liquid then pour into the mould and then pourinto the
nitric acid for for more purification and remove remaining impurities. Then remove the
gold which is associated with borax and remain with gold only.
Machine part such as eletro winning box, wire, heater, transformer and pump are being
chekedregulary so that desorption of gold from loaded carbon could take place efficiently. The
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temperature of the system also is checked regulary not to exceed 120 °c and not to fall below
115 °c. Alsoeletric current is measured regularly so that not to corrupt production process. The
eletric current both A/C and D/C current are measured by device called current clamp meter.
Caustic soda is added to solubilize the adsorbed gold cyanide complex and to maintain
pH.
pump and heater are switched on, as temperature reach 90 °c the rectifier is switched on
to start eletrolysis
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CHAPTER FIVE
5.1 CONCLUSION
This report focused on the elution and electrowinning sections as the base metals contained in
the reefs were leached, loaded and eluted during the leach, the CIP and elution stages. The same
base metals end up in the final gold during the electrowinning process.
Prior to starting the experimental phase, the main focus was to understand the kinetics of the
Four parameters were critically evaluated in the elution process namely, the flow rate, the
temperature and the pH (or free caustic soda concentration) and the cyanide concentration. Three
of the four parameters had an impact on the elution process but the most significant ones were
It was found that running the elution at a temperature of 135 º C did not improve the elution as
the best average temperature range was found to 120 ºC - 125 ºC. Any increase of temperature
favors the formation of AuCN, which is known to slow down the elution efficiency.
The reduction of free caustic from the range of 2-2.5% to 1.5-1.9% also assisted in the
improvement of the fineness as the low caustic strength had an effect of keeping the base metal
Therefore two parameters were reduced in a range that would favor the elution of gold only and
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3
The increase of flow rate (35 m /h) resulted in the deterioration of elution efficiency of gold and
3
other base metals compared to when flow rate is 30 m /h. This is due to the shortage of
3
The reduction of flow rate to 25 m /h did improve the stripping efficiency but this has resulted in
the deterioration of the fineness as more gold and base metals were stripped. The flow rate of
3
30m /h appears to be the best flow rate for the elution as the elution efficiency and the fineness
However, some authors like Kar (1995) claims the increase in cyanide concentration improve the
elution efficiencies, but this was found not to be the case in this study.
From these parameters, a new elution operating strategy was implemented. This resulted in the
oftemperature range and free caustic concentration are the predominant factors that maintain
base metals on the carbon and assist in the improvement of the fineness.
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5.2. Recommendation
I recommend that at JEMA AFRICA LTD the personal protective [ppe] should be considered to
the working area especially in the elution plant because there is a lot of fumes especially during
fume release, acid digestion and smelting process. I recommend that personal protective
equipment [PPE] should be used efficiently to avoid healthy destruction and penalty from
OSHA. Also I recommend that machine should be regularly checked so that to ensure the
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REFERENCES
Adams, M.D and Nicol, M.J. (1986) The kinetic of the elution of gold from activated carbon.
C.E. Fivaz and R.P. King (Editors), Gold 100, Proceeding, SAIMM, Johannesburg, pp111-121
Adams, M. (1989) Chemistry of the CIP process, PhD Thesis, Wits University, Johannesburg.
Adams, M.D (1990) Kinetics of elution of gold from activated carbons by Zadra methods, Trans
Banini, G.A., (1993) Modeling of the elution process, Msc thesis, Wits University,
Johannesburg.
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Barbosa, LAD, Sobral, LGS, Dutra, AJB (2001) Gold electrowinning from diluted cyanide
liquors: Performance evaluation of different reaction systems, Centre for mineral technology-Rio
Fisher MJ and Labrooy SR (1997) The effect of nickel on gold recovery during adsorption and
Kar, Jugal (1995) Effect of caustic and cyanide level on nickel reduction in stripping circuit,
Paul, R.L, Filmer, A.O, Nicol, M.J (1983) The recovery of gold from concentrated aurocyanide
Stanley, G. The extractive metallurgy of gold in South Africa, Volume 2, SAIMM monograph
series M7.
Van Deventer, JSJ and Van der Merwe, P.F. (1993) Factors influencing the elution of gold from
Africa Van der Merwe, P.F. (1991), Fundamentals of the elution of gold cyanide from activated
carbon, PhD, University of Stellenbosh 38Vegter, N.M, Van Vuuren C.P.J and Botha A.J (1993)
The kinetics of elution of gold cyanide from activated carbon. Hydrometallurgy: Fundamental,
Technology and innovation, TMS, Society for mining, metallurgy and exploration, Inc, Colorado
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