PROCESS CHARACTERESTICS OF KARNATAKA Au ORES B.P.Ravi, V.A.J.

Aruna and Indira Ravindran,

RODL,Indian Bureau of Mines, Bangalore56022 rodlbng@vsnl.com

ABSTRACT
Gold ores from Hutti, Ajjanahalli and G.R.Halli mines of M/s Hutti Gold Mines Co. Ltd. [HGML], Karnataka, India were subjected to diagnostic characterization and evolution of flow sheet for maximum Au recovery. The order of refractoriness of the ores were Hutti < Ajjanahalli < G.R.Halli. About 90% of gold could be extracted; by pre-aerated split CIP in case of Hutti ore, flotation of sulphides- sulphatizing roast CIP of concentrate in case of Ajjanahalli ore and flotation of sulphides - dead roast acid leach and alkali treatment CIL of concentrate for G.R.Halli ore. The evolved processes appear viable for all the three ores in present market prices. [NOTE: CIP Carbon in pulp. CIL - Carbon in leach, DLT - diagnoistic leach test, .> = greater than, < = less than]. Keywords: Characterization, flotation, gold ores, leaching, roasting.

INTRODUCTION
M/s Hutti Gold Mines Co. Ltd. [HGML] is Indias leading primary gold producer. HGML is operating a plant at Hutti comprising of Crushing, SAG milling, ball milling, gravity concentration and cyanidation-CIP and mostly treats free milling ore from Hutti with over 90% Au recovery. Three sulphidic gold ores which posed recovery problems at Hutti mill were from Hutti, Ajjanahalli and G.R. Halli mines. These ores were subjected to diagnostic characterization and evolution of flow sheet. The review of literature on treatment of refractory gold ores centers on diagnostic characterization, preconcentration, CIL, conventional roast leach CIP / CIL, oxidative leaching CIP / CIL, bio-oxidative pretreatment, CIP / CIL of concentrate ( Anon (1993) , Lorenzen (1993 & 1995), Nataraja et al. ( 2003) and Ravi et al. ( 2004))

MATERIAL AND METHODS

The chemical analysis, grindability studies, mineralogical studies, diagnostic amenability and leach tests data are given in Table 1 and shown in Fig.1and 2. Characterisation and diagnostic tests indicate that the order of preconcentration of gold bearing heavy minerals, refractoriness, granulometry, C, As and S content is G.R.Halli > Ajjanahalli > Hutti and may be due to varying content of sulphides, carbon, iron oxides, carbonates, granulometry and mineral interlocking.

Table 1: Chemical Analysis, Mineralogical analysis, liberation size and Ore type
Data Chemical assay Quartz Mica and sericite Chlorite and amphibole Carbonates Iron oxides Pyrite Pyrrhotite Arsenopyrite Other base metal sulphides Graphite Liberation size Ore Type Hutti 4.5ppm Au, 18.64 ppm Ag, 0.81% As, 1.21% S, 6.44% Fe, 56.19% SiO2 35 40% fine medium grained granular aggregate matrix 5 7% biotite medium sized associated with silicates 20 25% chlorite and 15 20% amphibole, subhedral medium sized grains mutually associated with each other 2 3% fine grains intermixed with quartz Traces as coating over silicates 1% fine medium subhedral to euhedral grains in silicate matrix 1% fine medium grains anhedral aggregates and disseminations in silicate 2% Medium coarse subhedral grains and fine grains in silicate matrix, as fine inclusions of other sulphides Traces of fine grained sphalerite and chalcopyrite in silicates --Fairly liberated at 74 m Grayish Black, Medium hard hard, Fine grained, sulphidic, free milling ore Particulars Ajjanahalli 1.83 ppm Au, 28 ppm Ag, 0.89% As, 3.32% S, 17.03% Fe, 50.77% SiO2 & Traces FC 40 45% fine medium granular aggregate matrix 3% fine medium grains intermixed with quartz 3% fine medium grains intermixed with quartz 25 30% fine medium grains intermixed with quartz ~10% as coatings and fine inclusions of magnetite in pyrite 5 7% fine to coarse grained as vein and finely intermixed with silicates and has fine inclusions of other minerals. 1% fine to medium grain anhedral aggregates and disseminations in silicates 1-2% fine medium grains disseminated with silicates Traces of fine inclusions of chalcopyrite in pyrite and silicates Traces, fine grains intermixed with quartz Fairly liberated at 74 m Black, medium soft medium, Fine grained, labile sulphidic semi refractory ore G.R.Halli 4.73 ppm Au, 229 ppm Ag, 1.05% Pb, 1.74% As, 7.27% S, 12.25% Fe, 56.81% SiO2, 0.4% FC 50 60% medium coarse granular aggregate matrix 5 7% fine medium grains intermixed with quartz ----2 3% of siderite and 10 15% of ankerite as fine medium grains intermixed with quartz ----8 10% medium coarse subhedral grains intermixed with granular sulphides and silicates and also with fine inclusions of other minerals ----3 4% subhedral grains with pyrite and has fine inclusions of other minerals Galena 1% fine medium subhedral grained network in pyrite 1% fine medium grains intermixed with quartz. Fairly liberated at 212 m Dark grey, Medium medium hard, Coarse granular sulphidic carbonaceous, refractory Au, Ag bearing Pb ore.

Fig. 1. Diagnostic Leach test 105 95 85 75 65 55 45 35 25 15 Huttti Free milling Labile Sulphides Carbonaceous Ajjanahalli CO3-IO-Pyh Sulphides,Arsenides Encapsulated G R Halli

Fig 2: Diagonastic Sink and Float Test 100 90 80 70 60 50 40 30 20 10 0 Hutti Ajjanahalli Slimes Float GR Halli Sink

Percent Au Recovery

RESULTS AND DISCUSSION

Lorenzen (1995) opined that the successive pretreatment stages of diagnostic leach test (DLT) varies according to the stability, granulometry, film formation, passivation, reactant consumption and preg-robbing properties of mineral / phase associates of the material. It is suggested to carry out DLT on amenability products to reduce interference effects. Flotation and cyanidation test results on ores and concentrates were conducted. Bulk flotation tests to concentrate gold and silver bearing sulphides indicate that ~90% of gold values can be concentrated for all the ores. However, the Au and Ag recovery is low for Ajjanahalli ore probably due to presence of significant amount of iron oxide coatings, fine labile sulphides and pyrrhotite. Diagnostic characterization test data for Ajjanahalli ore indicate that ~27% of gold is deported to iron oxides and pyrrhotite. In the case of Ajjanahalli and G R Halli 17% of sulphidic gold is due to labile sulphides. The cyanidation test data on ore and concentrate for Hutti, Ajjanahalli and GR Halli yielded results similar to DLT, indicating 92%, ~ 60% and ~50% Au respectively. The CIL test data on ore and concentrate for Hutti, Ajjanahalli and GR Halli extracted 92%, ~ 65% and ~60% Au respectively. However, the cyanidation of Ajjanahalli concentrate yielded the Au recovery of 83% probably due to elimination of iron oxides, and coated host minerals, labile sulphides from gold bearing sulphides. The cyanide consumption was very high in case of Ajjanahalli probably owing to reactant consuming iron oxides, pyrrhotite and labile sulpides as opined by Annon ( 1993). The pre-aerated H2O2 aided cyanidation test on Hutti, Ajjanahalli and G.R.Halli reduced the residue losses by ~30% in case of Hutti and Ajjanahalli ores and ~5% in case of G.R. Halli ore probably by tackling the problem of oxygen starvation during cyanidation mainly by pyrrhotite and labile sulphides (Anon ( 1993)) Sulphatizing roast water leach cyanidation/CIL and dead roast - cyanidation/CIL data of concentrates were conducted . Results of sulphatizing roast cyanidation test yielded 91%, 86% and 57% Au recovery for Hutti, Ajjanahalli and G.R.Halli ores, respectively, confirming the DLT data. Results of sulphatizing roast CIL test yielded 92%, 88% and 82% Au recovery for Hutti,

Percent Au Recovery

Ajjanahalli and G.R.Halli ores, respectively. The Au recovery for G.R.Halli is low due to the presence of preg-robbing carbon in the residue. The data is confirmed by increase in Au extraction from 57 to 82% Au extraction in case of G R Halli ore. Similar results were obtained for dead roast cyanidation test The Au recovery is 67% only for G.R. Halli ore despite destructing graphite. This was attributed to thick metal oxide coating on the grains probably causing encapsulations and cyanidation passivation. Lorenzen and Van Deventer (1993) indicated the selective destruction of passive film enhances the extraction. The use of gas suspension calciner (flash roaster) reduces the metal oxide encapsulation of gold due to short residence time(Anon (1993)). The test work in this regard with intermediate acid washes is warranted The condition, results and viability of final exploratory test recovering Au and Ag, values, by; pre-aeration, split CIP of concentrate and tails for Hutti ore; flotation, sulphatizing roast, leach, cyanidation / CIP for Ajjanahalli ore and flotation, dead roast acid leach, alkali treatment cyanidation/CIP for G.R.Halli ore are given in Table - 2. A final test comprising of H 2O2 aided pre-aeration, split CIP of concentrate and tails for free milling Hutti ore yielded ~94% gold recovery. The evolved process is similar to the current 2000TPD plant practice at Hutti. A final test comprising of: flotation of sulphides, sulphatizing roast - water leach- cyanidation/ CIP of concentrate for semi refractory Ajjanahalli Au, Ag ore yielded ~86% gold recovery. But flotation of sulphides, sulphatizing roast, water leach and CIL has extracted 88 and 82 % Au in case Ajjanahalli and GR Halli ores. A final test comprising of flotation of sulphides, dead roast- acid leach - alkali treatment cyanidation/ CIP of concentrate for refractory G.R.Halli, Au-Ag bearing Pb ore yielded ~95% Au and ~87% Ag recovery. The introduction of flash roasting (GSC) needs to be studied. The residue value for all the ores by diverse exploratory processes were 0.27 ppm Au, on par with plant residue values of HGML treating free milling ores (0.2 0.3 ppm Au) indicating maximum extraction. Natarajan et.al.(2003) extracted ~ 90% of Au by bacterial oxidation-CIL on sulphide concentrates from G.R.Halli and Ajjanahalli. The roast leach process may be replaced both by eco-friendly and cheap bio-oxidation method. The data of preliminary order of magnitude operating cost for G.R.Halli, (250 tpd), Ajjanahalli (250 tpd) and Hutti (2500 tpd) level keeping the reserve and present conditions in view indicated that all the three ores are viable under present precious metal prices. However, relatively the order of viability is Hutti > GR Halli>Ajjanahalli, mostly due high tenor of Au. The associated Ag values render GR Halli ore more viable though the ore is refractory. The implementation of concentration by flotation, eco-friendly relatively cheap bacterial oxidation-CIL process and attention to recover Ag and accessory base metal values from concentrate, may enhance the viability of refractory sulphidic ores of G.R.Halli and Ajjanahalli. Bacterial oxidation reduces about 30% capital and 20% operating costs7 vis--vis roast-leach CIL and pressure oxidative leach CIL process as indicated by works of Giber et al (1993) and Cole et al.(1993). Bhappu (1990) opined that the operating cost of biological treatment of refractory sulphidic gold ores increases by ~60% as compared to free milling ores.

Table 2 Conditions, results and tentative viability of final evolved process [open cycle] Hutti Grind :minus 150 mesh, gravity concentration Cyanidation of concentrate with 4 hrs pre-aeration with 0.125% NaCN for 36 hrs followed by 4 hrs CIP. Cyanidation of tails and conc. Residue after 4 hrs pre-aeration with 0.04% NaCN for 36 hrs followed by 4 hrs CIP. CaO 4 kg/t, H2O2 0.8 kg./t , activated carbon 20 kg/t, NaCN 1.12 kg/t, Pb acetate 0.4 kg./t. Ajjanahalli Grind: minus 150 mesh bulk flotation at 6.5 pH, 36% solids with CuSO4 KAX, MIBC. Roast at 550oC with Na2SO4 for 3 hrs, leach with water. Cyanidation/CIL : 0.1% NaCN, 11 pH, 24 hrs,[ 4 hours CIP in case of cyanidation] NaCN 0.72 kg/t, Na2SO4 5.8 kg/t , CaO 1 kg/t , MIBC 0.16 kg/t, KAX 0.18 kg/t, CuSO4 1.2 kg/t, H2SO4 1 kg/t, (carbon 20 kg/t.) Ajjanahalli Au Wt.% 200.0 100.0 100.0 --6.8 93.2 100.0 100.0 Assay (ppm) 2.27 0.25 2.93 --28.61 3.04 0.27 4.78 Dist. % 94.8 5.2 61.3 --40.7 59.3 5.7 100.0 Wt.% 12.0 12.0 12.0 Au Assay (ppm) 13.17 0.48 13.65 --11.22 0.24 0.27 1.84 Dist. % 85.8 3.1 88.9 --88.9 11.1 14.2 100.0 Wt.% 4.2 4.2 4.2 G.R.Halli Grind: minus 72 mesh bulk flotation at 6.5 pH, 36% solids withCuSO4 KAX, MIBC. Roast at 950oC , 3 hrs leached with H2SO4, NaCl / HCl, 95oC 50% solids 150 mesh for 3 hrs, treated with NaOH. CIL : 0.1% NaCN, 11 pH, 24 hrs, NaCN 0.6 kg/t , NaOH 6 Kg/t, NaCl / HCl 150 kg/t, H2SO4 350 kg/t, MIBC 0.16 kg/t, KAX 0.18 kg/t, CuSO4 1.2 kg/t, (carbon 20 kg/t). GR Halli Assay Dist. % (ppm) Au Ag Au Ag 97.86 1.04 98.90 --17.6 0.23 0.27 4.33 5328 10 5338 --950 43 41 257 94.9 1.0 95.9 --95.9 4.1 5.4 100.0 87.0 0.2 87.2 --87.2 12.8 13.0 100.0

Hutti Products CN Soln.[C&T] CN[T] Residue CN Feed {T} (Cal.) (Conc. Res+Tails) Loss on leaching and roasting Conc. Tails Residue [WL+CN{T}Res] Head (Calc.)

2.6 14.6 85.4 97.4 100.0

19.4 23.6 76.4 80.6 100.0

CONCLUSIONS
About 90% precious metal could be extracted with residue of 0.27 ppm Au; by pre-aerated split CIP in case of Hutti free milling ore; flotation of sulphides - sulphatizing roast - CIP of concentrate in case of Ajjanahalli semi refractory ore; flotation of sulphides dead roast - acid leach - alkali treatment-CIL of concentrate for G.R.Halli refractory ore. The exploratory process appears viable. Additional work is recommended for extracting Au and accessories by ecofriendly cheap biooxidation CIL method to enhance the viability.

ACKNOWLEDGEMENTS
The authors are thankful to M/s Hutti Gold Mines Company Ltd., for sponsoring and permitting to present the work. They are also thankful to, Controller General, IBM, Nagpur, and Head, O D Division, IBM, Nagpur for their keen interest in the study.

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