Merrill-Crowe Zinc Precipitation Circuit

The Operation of a Merrill-Crowe Zinc Precipitation circuit requires for Preparation

for its Startup that the following items be checked before the equipment in
the Merrill-Crowe Zinc Precipitation Circuit is started.
1. Note the levels in the pregnant solution, clarified solution and barren
solution tanks. The pregnant and barren solution tanks should be
approximately half full. If the pregnant solution tank is full and the barren
solution tank close to empty, the Merrill-Crowe Circuit may have to be the
first area of the plant to be started.
2. Check that power is available to the equipment and that all equipment
that has been subjected to maintenance is unlocked.
3. Check that the zinc feeder is full and operational, and the lead nitrate tank
has adequate stock.
4. Check any major equipment to be used for readiness, particularly the
precipitate presses and clarifiers. Also, check that the proper valves are
adjusted for the operation of the desired clarifier and filter press.
5. Check vacuum pump and seal water status.
6. All valves should be closed before start up.
Merrill-Crowe Zinc Precipitation Circuit Start UP Sequence
Start up of the Merrill-Crowe Circuit should proceed when thickener overflow or
filtrate flows to the pregnant solution tank.

1. Start the clarifier feed pump.

2. Adjust the appropriate valves in the clarifier inlet manifold to allow
pregnant solution to enter the clarifier and to take the clarifier discharge
pump off recirculation.
3. Open the butterfly valve on the vacuum line to the deaerator.
4. Start the deaerator feed pump.
5. Start the precipitate filter feed pump and ensure that the pump gland seal
tank is full of barren solution.
6. If it is not already running, start the barren solution pump.
7. Start the zinc feeder and lead nitrate metering pump and ensure that
barren solution is flowing to the zinc mix tank.
8. Turn on the timer on the pregnant solution sampler and the barren
solution sampler.

Normal Circuit Operation

After the Merrill-Crowe Zinc Precipitation Circuit has been brought up to normal
operating conditions, the operator must monitor the various process variables and
alarms. The operator is also required to sample and analyse process streams and
read local indicators.
The major difficulty in operating the Merrill Crowe zinc precipitation circuit is
keeping the flow through the various parts of the circuit equal. This is complicated
by the non-continuous nature of some of the processes (clarification and
precipitate filtration) and by the tendency of the various process unit steps to have
a significant variation in capacity over the operating cycle. This requires the
operator to continually monitor equipment operation and anticipate process
requirements.

Clarification
Depending on the solids content of the pregnant solution, the clarifiers will have a
long or short operating cycle. If the pregnant solution is exceptionally dirty (i.e. high
solids content), the operating cycle of the clarifier will become quite short. The
thickener operator and the filter operator must be made aware of the problem as
early as possible to prevent clarifier operation from limiting production.

The normal maximum operating vacuum on the clarifier is 18″ Hg. As the unit
approaches this vacuum it is an indication that the unit will soon require cleaning.
Monitor the vacuum pressure gauge to determine loading on the clarifier leaves.
When the 18″ Hg vacuum is achieved, the pressure switch will alarm and. shut
down the respective clarifier discharge pump. At this point the standby clarifier
must be put into operation.
Another reason for changing clarifiers is when the clarified solution indicates solids
breakthrough even before the 18″ Hg vacuum limit is reached. This condition may
be caused by a poorly or unevenly precoated clarifier leaves.

On the other hand, if the clarifier leaves are for some reason blinded and the unit is
unable to pass sufficient solution to keep the system in balance (i.e. a vacuum of
less than 18″ Hg is sufficient to diminish the pumping rate of the clarifier feed pump
to a level where trouble is anticipated). The clarifier must be taken out of service
and the cleaning cycle initiated.

The full clarifier must now be cleaned.

The sluice launder valve must now be opened and the contents (mainly solution)
drained to the filter feed pump box.

The clarifier spray bar motor is started as is the backwash sprays. The spray bar
motor is interlocked with the solenoid valve in the wash water (barren solution) line.
The solids are washed off of the filter leaves and sluiced into the thickener. When
all of the solids (dirty precoat) on the clarifier leaves have been washed off, the
spray bar motor is stopped and the spray water solenoid valve is automatically
closed. The clarifier tank is drained and the sluice valve is closed. The clarifier is
then ready to be precoated.

Deaeration Crowe Tower

The deaeration tower is run under high vacuum. The deaerator feed pump should
be running to give a slight excess of feed to the deaeration tower so that the tower
operates with a solution level part way up the level sight gauge glass.

The addition of zinc dust to the deaerated solution is the most important factor for
gold and silver recovery. Without the zinc dust, the gold and silver will remain in
solution and will not be recovered in the precipitate filter press. Therefore, the
operator must ensure that there is an adequate and continuous supply of zinc dust
being added to the deaerated solution. The optimum amount of zinc to be added
will be determined with operating experience, however, a slight excess of zinc dust
should always be added.

Once the clarified solution is deaerated and the zinc dust added, it is imperative that no air
be drawn into this part of the system. This explains the design of the zinc mix tank and the
flooded pump gland tank on the precipitate filter feed pumps. The operator must ensure
that the liquid level in both tanks is maintained at all times to prevent air entering the
system.

Zinc Precipitation
Normally only one precipitate filter press is in use while the other is on standby.
However, provision is made to operate both presses in series at one time. The
precipitate feed pressure should be monitored as an indication of the loading
condition within the press. The main items for the operator to ensure are:

• The barren solution from the press is clear. This can be checked regularly
by taking a small sample from the barren solution line.
• There is no dissolved gold or silver in the barren solution. If there is gold
or silver in the barren solution, indicated by the routine
analysis, the first step is to increase the zinc dosage rate. Check the zinc
feeder hopper to make sure it has not run out of zinc or is not plugged.
Also check that lead nitrate is still flowing.
• That the press is not leaking. A leaking press will result in losses of gold
and silver. The operator must ensure that the press is closed and sealed
properly. The filter press is closed with the hydraulic cylinder. When the
hydraulic pressure gauge reads 4800 psi (34,500 kPa), adjust the locking
nut on the cylinder to lock the press closed. Once the cylinder is locked,
release the hydraulic pressure. If the press begins to leak after it has
been operating for some time, the press must be immediately taken out of
service and replaced with the standby press.
The cycling, cleaning and precoating of the precipitate filter presses was previously
discussed in detail.
The barren solution is continuously and automatically sampled with the solenoid
valve timer, however, the operator should routinely check these samples to ensure
that barren solution clarity is maintained.

Merrill-Crowe Normal Shutdown Sequence & Procedure

It is preferred on shutdown, that as much solution as possible be in the barren
solution tank and as little as possible in the pregnant solution tanks.
On an orderly and routine shutdown of the plant, this circuit should be left running
as long as possible to maximize the amount of barren solution in the barren tank.
1. Stop the clarifier feed pump and, if flocculant is being added to the
clarifier feed line, shut off the flocculant metering pump.
2. Turn off the appropriate clarifier body feeder and close the shut off valve
in the barren line to the body feeder eductor.
3. If the plant is to be shut down for a short period of time, adjust the
appropriate valves in the clarifier inlet manifold to put the clarifier
discharge pump on recirculation. However, if the plant is to be shut down
for an extended period of time, close the shut off valves in the clarifier
feed lines and shut off the clarifier discharge pump. The clarifier must
then be drained and cleaned prior to restarting the plant.
4. Turn off the zinc feeder and the lead nitrate metering pump and close the
shut off valve in the barren solution line to the zinc mix tank.
5. Stop the deaerator feed pump.
6. Stop the precipitate filter feed pump.
7. Stop the barren solution pump.
8. Shut of the timers on the pregnant solution sampler and the barren
solution sampler.
In the Merrill-Crowe Zinc Precipitation, the pregnant solution tank collects the gold and
silver bearing solution recovered from other circuits of the plant: thickener overflow;
primary and secondary filtration? and the Argentite circuits. Normally these solutions
contain very little solids content (15-100 ppm), however, even this small amount of solids
is sufficient to inhibit efficient gold and silver recovery.

In the Merrill-Crowe Zinc Precipitation, the pregnant solution tank collects the gold and
silver bearing solution recovered from other circuits of the plant: thickener overflow;
primary and secondary filtration? and the Argentite circuits. Normally these solutions
contain very little solids content (15-100 ppm), however, even this small amount of solids
is sufficient to inhibit efficient gold and silver recovery.
The solution with the gold and silver precipitate is pumped through a filter press
where the gold and silver solids are removed. The barren solution is discharged to
the barren solution tank. The barren solution is recycled as process solution
throughout the rest of the plant where any remaining free cyanide can be
utilized. This section is intended to be read in conjunction with Flowsheet and
Piping and Instrument Diagram.

The Merrill-Crowe Circuit is designed to operate to the following criteria:

Degassing Pressure ——————–20″ Hg vacuum
Zinc Dust/Gold Ratio ——————1.5 gm zn/gm Au
Zinc Dust/Silver Ratio —————- 2.5 gm Zn/gm Ag
Lead Nitrate —————————- 10% of Zn b.w.
Detailed Merrill-Crowe Zinc Precipitation Process Description and Control

Thickener overflow and filtrate from all drum filters flow into the 6 meter diam. x 4
meter pregnant solution tanks. The two tanks are connected with a 10″ diameter
pipe, with no isolation valve, hence these two tanks are considered as one tank.
The thickener overflow flows into the first tank at a normal rate of 36.9 cubic meters
per hour, and the combined filtrate from the vacuum receivers flows into the
second tank at a rate of 68.4 cubic meters per hour. A multi point level switch,
mounted through the top of the first tank, has four solution level switch points set
for high high (LSH) , high (LSH), low (LSL) and low low (LSL). All points alarm at
the mill control panel annunciator. The high and low alarms should be interpreted
as an impending problem; either the clarifier or the filtrate feed pumps are not
functioning, or the throttling valve on the outlet line requires adjustment to balance
the system. Under normal flow rates the high-high alarm will sound ten minutes
after the high alarm if the problem is not alleviated, indicating a tank overflow
condition. If a low-low alarm occurs, the tank will run dry in approximately 20
minutes. A local level indicator (LIX) has been provided in the form of a pressure
gauge mounted at the bottom of the tank. All of these instruments are located on
the first tank, but measure the level in both tanks as the tanks are piped together.
Pregnant solution is pumped by the 7.5 HP 6″x4″ clarifier feed pump at a rate of
105.3 cubic meters per hour to one of two vacuum precoat clarifiers. The two
clarifiers are cycled; while one is operating, the other is being cleaned and
prepared for operation.

The pregnant solution enters the clarifier and is drawn through the 19-30 square
foot leaves of the clarifier by a 5 HP 5″x5″ clarifier discharge pump. Flocculant can
be added to the pregnant solution, just prior to the clarifier, to aid clarification if
desired. A filtering mat of diatomaceous earth, referred to as precoat, is
continuously added to the clarifiers to keep the coat porous and permit longer filter
cycles. This continuous feed of precoat is known as body feed and is educted, with
barren solution, into the inlet manifold of the clarifier. As solution flows through the
clarifier leaves it encounters resistance in passing through the many small
openings between the precoat particles. As the suspended solids in the pregnant
solution are trapped in the pre-coat, the leaves begin to blind and resistance to flow
through the leaves increases. This increase in resistance is measured as a
pressure drop across the clarifier with a pressure gauge at the clarifier outlet. A
level control valve at the clarifier inlet is throttled by a float mechanism in the filter.
As the leaves begin to blind, the level will rise and the control valve will gradually
close, slowly decreasing flow into the clarifier. At this time the blinded clarifier
should be taken out or service and the other clarifier put into service. If these
warnings are ignored, a low pressure (vacuum) switch at the clarifier outlet will stop
the associated clarifier discharge pump on a high vacuum. The blinded clarifier
taken out of service should be cleaned and precoated for the next cycle.

After the blinded clarifier has been taken out of service, the contents of the filter
must be drained to the filter feed pump box by opening the lower drain plug valve.
Turn on barren solution to the clarifier spray bar and rinse the plates. The spray bar
is equipped with a small motor which turns the spray bar, turn this on also. After
the plates are rinsed, drain the filter boot again. The clarifier is now ready for
precoating. The procedure for precoating follows in the penultimate paragraph of
this section.

The operating clarifier discharge pump delivers the clarified pregnant solution to a
5 meter diam. x 6 meter clarifier solution tank. This tank is equipped with a
multipoint admittance level switch, which has a high point and a high high. Both will
alarm at the mill control panel annunciator. The high alarm should be reacted to
immediately, as it has been calibrated, at normal flow rates, to give a 7 minute
warning before the tank overflows. The high high switch will alarm on an overflow
condition and is interlocked to stop the operating clarifier discharge pump.

Clarified solution is pumped out the clarified solution tank to the 5′ diameter x 10′
high deaerator by the 15 HP 6″x4″ deaerator feed pump. The flowrate into the
deaerator is controlled by the level in the vessel through the controller. Level is
measured by a differential pressure transmitter, with diaphragm seals, which
measures the pressure difference between the upper and lower deaerator outlets,
and sends a 4-20 mA signal to a level controller. The controller sends its output
signal to an electrically operated butterfly valve to maintain the setpoint level. Two
level gauge glasses installed in the deaerator will give a local indication of level.

As the pregnant solution in the deaerator flows down over the horizontal baffles it is
subjected to a high vacuum which removes the oxygen from the solution. The
vacuum applied to the deaerator is supplied by the filtration circuit vacuum pumps.
The vacuum in the deaerator is measured with a pressure gauge and can be
adjusted with a manually operated butterfly valve.

Deaerated pregnant solution is pumped out of the bottom of the deaerator with a
40 HP 4″x3″ in-line precipitate filter feed pump. Zinc dust and lead nitrate, mixed
with 3.5 cubic meters per hour of barren solution in the zinc mix tank, are
introduced into the suction line of the precipitate filter feed pump. Gold and silver
precipitation occurs as soon as the zinc and lead nitrate are added to the pregnant
solution. To prevent oxygen from entering the deaerated solution, the precipitate
filter feed pump is submersed in barren solution in a pump gland seal tank. A
pressure gauge is located at the inlet to the filter feed pump, and at the zinc slurry
line entering the pump suction.

The precipitate filter feed pump delivers the gold and silver precipitate at a rate of
108.5 cubic meters per hour to two 36″ x 36″, 25 plate precipitate filter presses. An
orifice plate and flow transmitter monitor slurry flow, and a flow totalizer in the mill
control panel totalizes the amount of precipitate being fed to the presses. A panel
mounted counter displays the totalized amount. A high pressure switch will alarm
at the mill control panel at a pressure of 50 psig.

The filter presses serve to filter the zinc/gold/silver precipitate from the slurry. The
plates are precoated with the same precoat system used by the clarifiers. The two
presses can be operated in parallel or series; however, under normal operating
conditions they will operate in parallel, with one being in service while the other is
being cleaned and prepared. The pressure filter cycle time is approximately every
two days.

The slurry line from the precipitate filter feed pump divides into two separate filter
press feed lines. Manually adjusted butterfly valves can be operated to direct flow
to either or both filter presses. A pressure gauge in the slurry line prior to the line
dividing to the two filters, can be monitored by personnel, as it will give an
indication of when the operating press(es) is becoming loaded. As the slurry enters
a press, the solids are trapped in the precoat, and the now barren solution flows
out of the press to the barren solution tank. During the filtering process, the plates
will load, much as in the clarifiers, as the precipitate is trapped in the precoat the
resistance to flow through the plates increases creating an increase in pressure
drop across the press. A pressure gauge at the inlet to each filter will give local
indication of the increasing pressure. The pressure at the inlet of a newly cleaned
filter will be approximately 10 psig and will rise to approximately 50 psig when the
press is full. At this time the loaded press must be taken out of service and the
other cleaned nd precoated press put into service, by adjusting the appropriate
butterfly hand valves.

Once feed to the loaded press has been discontinued, the plant air inlet ball valve
is opened to blow air through the press to remove any excess liquid or barren
solution entrained in the filter cake and to separate the cake from the plates. The
filter cake from the press will have a final moisture content of approximately 50%
solids. The press is then opened and the cake is manually scraped off the plates
into a collection chute below the press. The chute delivers the cake to a screw
feeder which feeds the rotary dryer described in the following section.
Both clarifiers and precipitate filter presses must be precoated after cleaning. Only
one clarifier or filter can be precoated at one time. The precoat must be batch
mixed, prior to its use, in the precoat tank. Barren solution and dry diatomaceous
earth (precoat) are added to the tank, and thoroughly mixed with the 3 HP precoat
agitator. When mixed, the 7.5 HP 6″ x 4″ precoat pump is started, ensuring that all
valves feeding precoat to the filters and clarifiers are closed. The precoat will
recirculate back to the precoat tank. It is important that this pump not be dead-
ended. The precoating procedure for the clarifiers is slightly different from that of
the filter presses.

For the clarifiers, open the appropriate valves to allow the precoat batch to fill the
clarifier tank. The precoat pump can now be stopped. Adjust the valves at the
clarifier to allow flow to recirculate through the clarifier and its discharge pump.
Turn on the clarifier discharge pump and allow
recirculation until the recirculating precoat solution is clear, indicating that the
leaves are now coated. The clear solution must be left in the clarifier and the pump
left running on recirculation, until the unit is returned to service, to prevent the
precoat from falling off the leaves.
For the precipitate filter presses, the precoat pump becomes the recirculating
pump. Mix up a batch of precoat as described above, and start the precoat pump
on recirculate back to the pre-coat mix tank. Ensure that the precipitate filter press
is closed after discharging the cake. Adjust the
appropriate valves to allow precoat mixture to circulate through the press and back
to the precoat mix tank. Allow circulation to continue until the precoat solution is
clear, indicating that the plates are now coated. Turn off the precoat pump, and
allow the clear solution in the lines to drain back to the pre-coat mix tank.
tails of good silver sulphide leaching and filtration circuit operation and instructions
for sequencing and preparing for startup.

The following items must be checked before the equipment in this EXAMPLE
Argentite Leaching Circuit is started.

1. The leach tank agitators should be running.

2. Check that the Argentite filter feed pump, drum filter, repulper and tailings
sampling pump are available to start up.
3. Ensure that shut-off valve in the air line to each leach tank is open.
4. Ensure that the timer for the lime addition has power and that the shut-off
valves in the appropriate lime lines are open.
5. Check the level of cyanide solution in the cyanide day tank to ensure
there is an adequate amount to start the Argentite Leach Circuit.
6. Ensure there is an adequate supply of flocculant available and that the
flocculant metering pump is available to operate.

Start UP Sequence and Procedure of this EXAMPLE Silver Leaching &

Filtration Circuit
1. Start the Argentite drum filter, filter boot agitator and the filter repupler.
Ensure that gland seal water is flowing to the repulper and adjust the flow
rate with flowmeter.
2. Start the tailings sampler pump and turn on the reclaim repulp water to
0.2 cubic meters per hour.
3. Start the Argentite filter feed pump.
4. Turn on the filter wash water to 0.1 cubic meters per hour and if closed,
open the vacuum valves at the drum filter.
5. When feed from the Flotation Circuit begins to enter the Argentite Leach
Circuit, adjust the air rate to each leach tank with flowmeters to 5.4 cfm.
6. Start lime addition timer at the first leach tank, making sure that the lime
lines are not plugged.
7. Start cyanide addition to the first leach tank.
8. When leached slurry begins to enter the filter boot, turn on the
appropriate flocculant metering pump and adjust the flow rate to the filter
to 500 litres per hour.

Procedure of Silver Leaching & Filtration Circuit Normal Operation

After the Argentite Leaching and Filtration Circuit has been brought up to normal
operating conditions, the operator must monitor the various process variables and
alarms. The operator is also required to sample and analyse process streams and
read local indicators.
The operator must routinely monitor the air flow rate into each leach tank and
adjust the appropriate air flowmeter if the air rate deviates from the normal design
rate of 5.4 cfm.

Like the primary leaching circuit, the protective alkalinity and free cyanide levels
should be determined in the , first leach tank every 2 hours and the appropriate
adjustments made to the cyanide metering pump and lime timer. Occasional
checks (2 per shift) should be made on the remaining Argentite leach tanks for lime
and cyanide and any adjustments made.
The operation of the small Argentite drum filter is identical to that of the larger
primary and secondary drum filters. Refer to Section 6.3.3 for details.

1. Ensure that the Flotation Circuit and cleaner concentrate pump has shut
down before shutting down the Argentite Leach Circuit.
2. Once slurry has stopped flowing from tank to tank, the air to each tank
can be shut-off.
3. Discontinue cyanide addition to the first leach tank.
4. Shut-off the lime timer and close appropriate lime shut-off valves.
5. Shut down the Argentite filter feed pump.
6. Leave Argentite leach tank agitators running.
7. Allow the filter boot to empty as much as possible with the filter operating.
Once the filter is no longer picking up solids, allow the filter cloth to be
cleaned with wash water.
8. Shut off the flocculant metering pump and close the shut-off valves in the
wash and repulp water lines.
9. If the filter is to be down for an extended period of time, the filter boot
should be drained. However, if the filter is down for a short time, the boot
does not have to be drained, but the boot agitator must be left running.
10. Close the shut-off valve in the air line to sampler and shut off the tailings
sampling pump.
11. In the event of an emergency, the leach tank agitators, the Argentite filter
feed pump and the Argentite drum filter can be shut down from locally
mounted STOP switches or from the MCC located in the mill control room.

12. After the equipment is shut down, the cyanide metering pump, the flocculant
metering pump and the lime timer must be shut down. Also close all shut off
valves in the air lines to the leach tanks and drum filter and in the reclaim
water line to the drum filter.