Knelson O&M Rev 1

CONSEP ACACIA
Pilot Acacia
Model CS50
Operation &
Maintenance
Manual
ConSep Pty. Limited
PO Box 6625
8-10 Hallstrom Place
Wetherill Park NSW 2164
AUSTRALIA
Phone: 61 2 9756 5299
Fax: 61 2 9756 5102
[email protected]
ACN 053 177 898
Prepared for
Knelson Concentrators
ConSep Job: C4582
Pilot Acacia Serial No.
CS50-4582-03-007
ConSep Acacia CS50: Knelson Concentrators

Operation & Maintenance Manual
TABLE OF CONTENTS
SECTION 1. INTRODUCTION ............................................................................................3
1.1.
WHAT IS THE C ONSEP ACACIA DISSOLUTION
MODULE? ......................................3
SECTION 2. INSTALLATION ..............................................................................................4

2.1.
2.2.
2.3.
MECHANICAL ASSEMBLY ............................................................................................4

ELECTRICAL................................................................................................................5
REQUIRED SERVICES ....................................................................................................5
SECTION 3. SAFETY.............................................................................................................6
3.1. GENERAL SAFETY .......................................................................................................6
3.1.1. Electrical Safety .................................................................................................7
3.1.2. Ten Commandments of Safety ...........................................................................7
3.2. CONS EP ACACIA S PECIFIC SAFETY .............................................................................8
SECTION 4. OPERATION ..................................................................................................10
4.1. REMINDERS & C AUTIONS ..........................................................................................10
4.1.1. Reagents...........................................................................................................10
4.1.2. Wiring...............................................................................................................10
4.1.3. Water supply .....................................................................................................11
4.1.4. Storage .............................................................................................................11
4.2. PROCESS S TAGES ......................................................................................................11
4.2.1. Transfer of concentrate to the reactor .............................................................11
4.2.2. Pre-washing of the gold concentrate to remove slimes ...................................12
4.2.3. Mixing of leach reagents..................................................................................12
4.2.4. Leaching...........................................................................................................13
4.2.5. Recovery of pregnant solution and washing of residue....................................14
4.2.6. Discharging of the leach residue......................................................................14
4.2.7. Analysis.............................................................................................................14
SECTION 5. MAINTENANCE ...........................................................................................15
5.1. ROUTINE MAINTENANCE...........................................................................................15
5.1.1. Daily .................................................................................................................15
5.1.2. Weekly ..............................................................................................................15
5.1.3. 3 Monthly ..........................................................................................................15
5.1.4. 12 Monthly........................................................................................................15
5.1.5. 3 years ..............................................................................................................15
SECTION 6. G.A. DRAWINGS ..........................................................................................16
Page 2
Knelson O&M Rev 1.doc

SECTION 1. INTRODUCTION
1.1. WHAT IS THE CONSEP ACACIA DISSOLUTION
M ODULE?
The ConSep Acacia Dissolution Module is a process in which the leaching of
high gold grade gravity concentrates, primarily Knelson Concentrator
concentrates. The Module allows this to be accomplished with very high
efficiency with very low operations and maintenance requirements.
The process is a batch system based around the main leach Tank, a
fluidised bed that enables the very efficient dissolution of the gold.
Page 3

SECTION 2. INSTALLATION
2.1. M ECHANICAL ASSEMBLY
Please ensure all items are present please refer to GA Drawing included in this manual
for details. For shipping, the reactor is partially disassembled, with final assembly to be
carried out at the location where the testing is to be conducted.
The assembly steps are as follows:
1. Remove main Reaction Cone (Item 1) from the plastic drum, invert and place on
the floor.
2. The top sections of the support legs (Item 5) should be still attached to the
Reactor Cone.
3. Remove the three (3) bottom support leg sections (Item 6) from the crate and
slide them into their housing. Tighten the grub screws (Item 27) holding the
bottom leg section firmly do not over tighten.
4. Remove the three (3) tie rods (Item 7) from the crate and connect to the mating
lugs on the support legs. Insert the supplied bolts and attach nuts.
5. Turn the Reaction Cone upright, then level and then tighten bolts.
6. Place the rotameter (Item 16) and mounting bracket (Item 8) onto the Reaction
Cone (Item 1) near the launder discharge and rest the lower section of the
bracket on the leg.
7. Insert the Filtration Bed (Item 4) into the Distribution Cone (Item 3) ensuring it is
seated correctly. If seated correctly, the top surface of the metal ring should be
approximately flush with the inner lip of the Distribution Cone. If the metal ring is
raised, the 8 filter tie bolts are most likely resting on the locating tabs. Turn the
Filtration Bed slightly such that the bolts clear the locating tabs and are seated
in the correct position.
8. Place the rubber seal on top of the Filtration Bed ensuring that the seal is
correctly located around the outer edge.
View of seal from top of Reactor Cone
Page 4

9. With the Filtration Bed (Item 4) and seal in place, Position the Distribution Cone
(Item 3) under the Reaction Cone (Item 1) to align the 4 catches with the
latches.
10. Carefully raise opposite latches and lock into place. Only firm tightening
pressure is required to create a seal. If excessive force is required, ensure that
seal is correctly seated, and if so loosen off the latch eye. Then raise the
remaining 2 opposite latches and lock firmly in place.
11. Connect the hose (Item 22) from the submersible pump (Item 24) to the bottom
connection point on the rotameter (Item 16).
12. Connect the hose (Arrangement including ball valve) from the top connection
point on the rotameter (Item 16) to the inlet of the distribution cone (Item 3), with
the ball valve connected at bottom of the distribution cone.
13. Connect the diaphragm valve (Item 15) to the solids discharge outlet.
View of assembled CS50 ConSep Acacia
2.2. ELECTRICAL
The submersible pump is to be plugged into a GPO.
2.3. REQUIRED SERVICES

The Acacia reactor requires the following services:
Page 5
Potable water:
For leach reagent make up &
Raw (or potable) Water:
For solids desliming


Electricity:
Operation of Submersible pump
Sodium Cyanide solution (>4%):
Reagent Make up
Sodium Hydroxide solution:
Reagent Make up
SECTION 3. SAFETY
3.1. GENERAL SAFETY
Page 6
Read and understand each of the warning, cautions and instructions

in the operator's manual and on signs fixed to the equipment.
Report all accidents, immediately to your supervisor. Consult a doctor

or medical facility as soon as possible if personal injury is involved.
Keep a list of emergency telephone numbers close to the telephone

and instruct all work area personnel as to the location of the list,
Do not operate or work around equipment whilst under the influence

of alcohol, medicines, tranquillisers or other drugs that can make you
less alert or affect your judgement.
Wear safety glasses, whenever there is any danger of flying debris,

chips, objects or dust. Be extra safe - always wear eye protection,
Keep the general work area clean and free of debris
Keep safety equipment in a designated place and ensure that all

personnel know the location and the proper use of the safety
equipment.
Do not allow unskilled persons to start or operate any equipment

without the proper Supervision of a skilled operator.
Do not work on equipment while it is in operation, Perform all required

inspection, maintenance, lubrication or adjustments before starting or
operating the equipment, or after the equipment is shut down. Use
extreme caution during inspection, maintenance, lubrication or
adjustment procedures.
Perform all inspection, maintenance, lubrication and adjustments with

caution in accordance with manufacturers recommended
procedures.

3.1.1.
3.1.2.
Page 7
Electrical Safety
o
Permit only licensed electricians to work on electrically live parts or

any plant or equipment
Always assume that an electrical circuit is live until it is proven dead

by proper testing procedures
Lockout and tag electrical / mechanical controls before performing

any inspection, maintenance, lubrication or adjustment procedures.
Repair or replace electrical wires, cables and connectors that are

frayed, cut, broken or damaged in any way.
Check that electrical ground wires, motor plugs and power cable
connections are properly and securely connected before starting any
equipment.
Never work on electrical equipment while it is running or while

standing in water or on wet surfaces unless you know that the power
is disconnected.
Be alert when working around or with electricity. Report any electrical

hazard immediately to your supervisor.
Ten Commandments of Safety

o
Support efforts to make your workplace safe and healthy. Do your

part; observe safety regulations and established work practices.
Act responsible and with concern for the safety of others, as well as
your own.
Check all tools and protective equipment frequently, to make sure

they are in safe working order.
Educate yourself and others in the hazards associated with your job
and the safe ways to perform familiar tasks.
Ask others how to perform tasks with which you are unfamiliar.
Playing it "by ear" can lead to costly accidents.
Think over any potential accident and injury possibilities before

starting on any project. Take appropriate precautions to protect
yourself and others .
Warn others of the possibility of accidents and injuries if you see

them working unsafely or creating potential hazards.
Stay alert for changes in work conditions made in the work process.
Report unsafe acts and conditions immediately to your supervisor.

Don't assume that someone else will do it.

Keep your work area clear. Keep tools and materials picked up and
properly stored,
3.2. CONSEP ACACIA SPECIFIC SAFETY

Only personnel trained in the safety procedures of the
Consep Acacia Module, including cyanide handling,
emergency procedures and cyanide exposure symptoms
should be allowed to work on or around the Module. Limit
access to authorised personnel.
The operation of the Consep Acacia Module involves the use

of concentrated sodium cyanide (NaCN) and caustic soda
(NaOH) solutions, and as such extreme care is required with
operation of the system.
It is ABSOLUTELY ESSENTIAL that when creating the leach

solution batch that the sodium cyanide (NaCN, in
concentrated liquid or solid form) is added to the required
volume of potable water which has been raised in pH to
above 10.5 by the addition of caustic soda (Sodium
Hydroxide). Addition of NaCN directly to water without prior
increasing of pH to a level above 10.5 addition may result in
the hydrolysing of CN- and the formation of high levels of
HCN gas and an extremely dangerous situation possibly
resulting in death.
Adequate ventilation of the ConSep Acacia Module area is

required, as at the concentrations of NaCN & NaOH used,
there will be an equilibrium concentration of HCN form if no
ventilation present.
Vessels covered and fitted with an extraction system or

open vessels with forced fume hood type extraction systems
are recommended. Alarms MUST be interlocked to operation
of extraction system, warning of extraction system failure.
Page 8

It is recommended that a fixed HCN vapour monitor is

installed at a location at the nearest operator exposed
access point, with relays to an audible alarm for HCN levels
above 5 ppm. At an absolute minimum, operators must wear
personal HCN monitors.
Report any leaking valves or other fittings as soon as

noticed, all leaks should be fixed as soon as practical.
Leaking leach solution is a significant hazard.
Safety glasses must be worn at all times in vicinity of the

Acacia Reactor
Page 9

SECTION 4. OPERATION
Operation of the Consep Acacia Pilot plant is relatively simple, however
awareness of some fundamental concepts will ensure safe, efficient
operation of the Module.
4.1. REMINDERS & CAUTIONS

4.1.1.
Reagents
The operation of the Consep Acacia Dissolution Module
involves the use of concentrated sodium cyanide (NaCN) and
caustic soda (NaOH) solutions, and extreme care is required
with operation of the system.
Correct batching of reagents is essential, For details of the

procedure to be followed please refer to Section Error!
Reference source not found. & Error! Reference
source not found.
4.1.2.
Wiring
To prevent personal injury or damage to the equipment:
Page 10
All wiring connections must be properly isolated
Be sure that voltage and wiring are correct and match

the nameplates on pump motors
All drives are to be isolated and locked out before

working on the components
Failure to comply with these warnings could void the

warranty.

4.1.3.
Water supply
There are two water requirements for the Consep Acacia Dissolution Module:
4.1.4.
Potable grade water is necessary for reagent solution make up, and
barren solids washing. This stage requires good quality water due to
interferences in leaching and subsequent electrowinning from ions in
solution with low quality water.
Normal plant process water is used for the stratification, desliming

and barren solids return stages. It is not necessary for water used for
this stage to be clear, drinking quality, however it is not
recommended that water with significant solids loadings be used as
plugging & channelling of the diffusion bed may result.
Storage
When the Consep Acacia Dissolution Module is shut down and/or stored for
extended periods of time, the Solution tank and Consep Acacia should be
completely drained of liquid, and any residual solids flushed from the tanks.
Pumps should also be flushed & drained. Before re-starting, the diffusion
Cartridge should be inspected for any blockages or other possible causes of
channelling.
4.2. PROCESS STAGES

The pilot model CS50 ConSep Acacia is designed to be a direct scaled down version of
a full scale Acacia Reactor, therefore the exact operating stages of a full scale reactor are
carried out. In summary these stages are:
1. Transfer of concentrate to the reactor
2. Pre-washing of the gold concentrate to remove fines
3. Mixing of leach reagents
4. Leaching
5. Recovery of pregnant solution and washing of residue
6. Discharging of the leach residue.
4.2.1.
Transfer of concentrate to the reactor
The capacity of the pilot Acacia is nominally 50 kg, However lower amounts can be
accepted with no problem. Larger masses may be accepted providing that the distance
from the top lip of the reactor to the solids level is at least 200 mm. This amount is
nominally 2 flushes from a 30 or 1 flush from a 48 Knelson Concentrator.
Page 11

Ensure that the solids deflector is located at the solids discharge point, stopping solids
entering the discharge line.
It is recommended that solids are added to the reactor in a dewatered form by hand. Drying
is not necessary, as dry weights of residue are obtained at end of test.
4.2.2.
Pre-washing of the gold concentrate to
remove slimes
1. Ensure the diaphragm valve is fully closed.
2. Disconnect the Submersible pump at the Kamlock coupling at the base of the
Rotameter and attach the Flushing hose that is supplied loose to this point so that
water flow will be through the Rotameter and into the Side of the Distribution
cone.
3. Connect Raw Water to the Minsup hose connection.
4. Regulate flow in until a nominal flow of 40 l/min as measure by the rotameter is
achieved.
5. Collect overflow in the reagent drum or other vessels. If slimes are not required to
be retained, then overflow can be discarded. However it is recommended that
slimes are retained for accurate mass balancing.
6. Keep the water flow at a constant for a minimum period of 10 minutes, typically 15
minutes.
7. At the completion of the de-sliming time the stop the raw water.
8. Place a 20 litre bucket underneath the reactor and open the drain valve to drain all
the water contained in the reactor into the bucket. There should be virtually no
solids in the drained water due to the filtering effect of the solids.
9. Decant off the supernatant in the collected overflow and trans fer solids to buckets.
4.2.3.
Mixing of leach reagents
The reagent dosages are based upon the following factors:

?
?
?
?
?
Final gold concentration aim

Cyanide addition rate
Caustic Addition rate
Maximum Leachaid addition rate
Typical Leachaid Addition rate
5 g/l Au
5 kg / kg Au
0.5 kg / kg Au
1.5 kg / kg Au
0.5 kg/kg Au
CAUTION
A personal cyanide monitor should be worn at all times from this point.
Extreme care to be exercised mixing and handling reagents
1. Place the pump inside the empty (& clean) reagent drum.
Page 12

2. Connect a tie rope to the camlock fitting to allow the retrieval of the hose when
full. Coil the discharge hose inside the drum.
3. Add a measured volume of potable water into the drum. Below is a table with
recommended volumes of water, the minimum volume is approximately 100 litres
(to ensure sufficient volume to pump).
4. Start the pump, the flow will stir the drum contents.
5. Add the recommended mass of Sodium Hydroxide (caustic) to the drum and
allow to mix.
6. Add the recommended mass of solid Sodium Cyanide to th e drum and allow to
mix until Cyanide is dissolved completely.
7. Add the required mass of solid Leachaid to the drum and allow to mix until
Cyanide is dissolved completely (add slowly to avoid clumping of the powder).
8. Retrieve hose from drum and wash thoroughly to enable handling.
The table below indicates the typical masses of reagents required per 10 kg of solids
Solids grade(g/t Au)
1,000
2,000
5,000
10,000
20,000
50,000
10
20
40
100
50
100
250
500
1000
2500
Caustic - g (0.5 g / g Au)
10
25
50
100
250
Leachaid - g (0.5 g/ g Au
10
25
50
100
250
Reagent make up volume (litres)

Sodium Cyanide - g (5g /g au)
4.2.4.
Leaching
1. Disconnect the Flushing Hose from the base of the Rotameter.

2. Connect the pump disharge to the bottom connection of the rotameter such that
water flow is from the pump through the rotameter.
3. Close 40NB manual ball valve
4. Start the Submersible pump.
5. Slowly open the ball valve until a nominal flow of 30 l/min as measured by the
rotameter is achieved.
6. The overflow is collected in the reagent drum, and the pump recycles it to the
Acacia.
7. Take samples at regular intervals from the overflow for analysis. Typical intervals
for the sampling are: 0 min, 10 min, 30 min, 45 min, 60 min, 90 min, 2 hr, 3 hr, 4
hr, 6 hr, 10 hr, 24 hr. The total length of the leach time is at the discretion of the
operator. Typically with sufficient Leachaid, maximum leach recovery is usually
achieved within 16 hrs, however a leach time of 20 - 22 hours would be
recommended to allow a leach test to be fully completed within 24 hours.
8. At the completion of the leaching time close the valves and the stop the pump.
Page 13

4.2.5.
Recovery of pregnant solution and washing
of residue
1. Place a 20 litre bucket underneath the reactor and open the drain valve to drain all
the solution contained in the reactor into the bucket. There should be virtually no
solids in the drained water due to the filtering effect of the solids. Transfer this
solution transferred into the main reagent drum.
2. Disconnect the hoses and collect and transfer all residual solution in lines to
drum.
3. Carefully pour a measured volume of potable water, 10 litres typically, onto the
dewatered solids, and collect at the drain underneath. This is to wash the solids of
pregnant solution. Transfer this washed volume into the reagent drum.
4. Take a sample of the solution in the drum, and determine the volume of solution,
thus allowing determination of mass of gold leached.
4.2.6.
Discharging of the leach residue
1. Remove the solids deflector from the reactor.

2. Ensure the 40NB manual ball valve is fully closed.
3. Connect Raw water to the bottom connection of the rotameter using the Flushing
hose that was supplied loose so that water flow is through the rotameter.
4. Open the solids discharge diaphragm valve and collect solids in 20 litre buckets.
5. As required, open the 40NB manual ball valve to fluidise the solids to aid the
discharge of solids.
6. Not all solids are required to be removed, the remaining solids can be collected
by removing the distribution cone and rinsing the solids remaining on the filter
bed into a bucket.
7. If required the Filter Bed can be removed from the Distribution Cone by removing
the seal and lifting out. The Filter Bed and Distribution Cone are then rinsed of
solids.
4.2.7.
Analysis
1. Deslimed material is to be filtered, dried, weighed and assayed for gold.

2. Each solution sample collected during leach to be assayed for gold, and if
deemed necessary, cyanide titration and dissolved oxygen concentration.
3. The final solution to be assayed for gold, and residual cyanide concentration
titration.
4. The residual solids collected to be washed, with the solution volume to be
measured and gold assay. The solids dried, weighed and fire assayed for gold.
A complete mass & gold balance determined.
Page 14

SECTION 5. MAINTENANCE
The Consep Acacia Dissolution Module is designed such that there is
minimal maintenance requirement, achieved through the limiting of moving
parts.
5.1. ROUTINE MAINTENANCE

Please refer to Error! Reference source not found.: Error! Reference
source not found. for further information on sub-vendor equipment.
5.1.1.
5.1.2.
Daily
o
Inspect the system for any leaks, including around valves, pumps, etc
Upon completion of the cycle, Look inside the Acacia and check the
fluid bed for any damage wear or plugging. Also check for excessive
build up of material on the Screen.
Weekly
o
5.1.3.
5.1.4.
5.1.5.
3 Monthly
o
The Diffusion cartridge is to be removed and the apertures in the

wedge wire are to be cleared of any blockages. If excessive localised
wearing is occurring then the Diffusion cartridge is to be rotated.
If excessive wear of the entire screen is evident then the top screen
and the bottom screen are to be swapped around (See section 5.2.2)
12 Monthly
o
Inspec t solution pump impeller & seals
Inspect submersible pump oil level
3 years
o
Page 15
Check for any accumulation of solids inside the Solution tank and
hose out if necessary.
Remove Consep Acacia Diffusion Cartridge and replace media

SECTION 6. G.A. DRAWINGS
Page 16

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CONSEP ACACIA

ConSep Acacia CS50: Knelson Concentrators

WHAT IS THE C ONSEP ACACIA DISSOLUTION

SECTION 2. INSTALLATION ..............................................................................................4

MECHANICAL ASSEMBLY ............................................................................................4

Knelson O&M Rev 1.doc

ConSep Acacia CS50: Knelson Concentrators

Knelson O&M Rev 1.doc

ConSep Acacia CS50: Knelson Concentrators

View of seal from top of Reactor Cone

Knelson O&M Rev 1.doc

ConSep Acacia CS50: Knelson Concentrators

2.3. REQUIRED SERVICES

For leach reagent make up &

Raw (or potable) Water:

For solids desliming

ConSep Acacia CS50: Knelson Concentrators

Operation of Submersible pump

Sodium Cyanide solution (>4%):

Sodium Hydroxide solution:

Read and understand each of the warning, cautions and instructions

Report all accidents, immediately to your supervisor. Consult a doctor

Keep a list of emergency telephone numbers close to the telephone

Do not operate or work around equipment whilst under the influence

Wear safety glasses, whenever there is any danger of flying debris,

Keep the general work area clean and free of debris

Keep safety equipment in a designated place and ensure that all

Do not allow unskilled persons to start or operate any equipment

Do not work on equipment while it is in operation, Perform all required

Perform all inspection, maintenance, lubrication and adjustments with

Knelson O&M Rev 1.doc

ConSep Acacia CS50: Knelson Concentrators

Permit only licensed electricians to work on electrically live parts or

Always assume that an electrical circuit is live until it is proven dead

Lockout and tag electrical / mechanical controls before performing

Repair or replace electrical wires, cables and connectors that are

Never work on electrical equipment while it is running or while

Be alert when working around or with electricity. Report any electrical

Ten Commandments of Safety

Support efforts to make your workplace safe and healthy. Do your

Check all tools and protective equipment frequently, to make sure

Think over any potential accident and injury possibilities before

Warn others of the possibility of accidents and injuries if you see

Report unsafe acts and conditions immediately to your supervisor.

ConSep Acacia CS50: Knelson Concentrators

3.2. CONSEP ACACIA SPECIFIC SAFETY

The operation of the Consep Acacia Module involves the use

It is ABSOLUTELY ESSENTIAL that when creating the leach

Adequate ventilation of the ConSep Acacia Module area is

Vessels covered and fitted with an extraction system or

Knelson O&M Rev 1.doc

ConSep Acacia CS50: Knelson Concentrators

It is recommended that a fixed HCN vapour monitor is

Report any leaking valves or other fittings as soon as

Safety glasses must be worn at all times in vicinity of the

Knelson O&M Rev 1.doc

ConSep Acacia CS50: Knelson Concentrators

4.1. REMINDERS & CAUTIONS

Correct batching of reagents is essential, For details of the