Ore is processed at Gedabek to produce either gold doré (an alloy of gold and silver with small amounts of impurities, mainly copper) or a copper and precious metal concentrate.
Gold doré is produced by cyanide leaching. Initial processing is to leach (i.e. dissolve) the precious metal (and some copper) in a cyanide solution. This is done by various methods:
- Heap leaching of crushed ore:
Crushed ore is heaped into permeable “pads” onto which is sprayed a solution of cyanide. The solution dissolves the metals as it percolates through the ore by gravity and it is then collected by the impervious base under the pad.
- Heap leaching of run of mine (“ROM”) ore:
The process is similar to heap leaching for crushed ore, except the ore is not crushed, instead it is heaped into pads as received from the mine (ROM) without further treatment or crushing. This process is used for very low-grade ores.
- Agitation leaching:
Ore is crushed and then milled in a grinding circuit. The finely ground ore is placed in stirred (agitation) tanks containing cyanide solution and the contained metal is dissolved in the solution. Any coarse, free gold is separated using a centrifugal-type Knelson concentrator.
Slurries produced by the above processes with dissolved metal in solution are then transferred to a resin-in-pulp (“RIP”) plant. This plant selectively absorbs then de-absorbs the gold and silver. The gold and silver dissolved in the solution which is produced are then recovered by electrolysis and are then smelted to produce the doré metal, comprising an alloy of gold and silver.
Copper and precious metal concentrates are produced by two processes, SART processing and flotation.
- Sulphidisation, Acidification, Recycling and Thickening (“SART”):
The cyanide solution after gold absorption by resin-in-pulp processing is transferred to the SART plant. The pH of the solution is then changed by the addition of reagents which precipitates the copper and any remaining silver from the solution. The process also recovers cyanide from the solution, which is recycled back to leaching.
- Flotation:
Flotation is carried out in a separate flotation plant. Feedstock is mixed with water to produce a slurry called “pulp” and other reagents are then added. This pulp is processed in flotation cells (tanks), where the pulp is stirred and air introduced as small bubbles. The sulphide mineral particles attach to the air bubbles and float to the surface where they form a froth which is collected. This froth is dewatered to form a mineral concentrate containing copper, gold and silver.
During 2023, the capacity of the flotation plant was increased from approximately 80 to 160 tonnes per hour. This was achieved by installing new pumps and other equipment and “debottlenecking” the plant. An additional seven cells for the flotation plant have also been acquired together with a new thickener and filter press at a total cost of approximately $3 million. The seven new cells use “Imhoflot” pneumatic flotation technology, which require less energy and offers better recoveries than traditional stirred tank cells and flotation columns. These new flotation cells and ancillary equipment will increase the versatility of the flotation plant and enable the production of a zinc concentrate. The installation of the new flotation cells has been postponed until 2024.
Table 2 summarises the ore processed by leaching at Gedabek for the year ended 31 December 2023.
Table 2 – Ore processed by leaching at Gedabek for the year ended 31 December 2023
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Quarter ended | Ore processed (tonnes) | | | Gold grade of ore processed (g/t) | | |
| Heap leach pad (Crushed ore) | Heap leach pad (ROM ore) | Agitation leaching plant | Heap leach pad (Crushed ore) | Heap leach pad (ROM ore) | Agitation leaching plant |
31 March 2023 | 94,518 | 196,595 | 62,006 | 0.74 | 0.49 | 1.30 |
30 June 2023 | 56,522 | 202,788 | 105,213 | 0.75 | 0.46 | 1.40 |
30 September 2023 | 25,690 | 34,621 | - | 0.83 | 0.45 | - |
31 December 2023 | - | - | - | - | - | - |
Total for the year | 176,730 | 434,004 | 167,219 | 0.76 | 0.48 | 1.40 |
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Table 3 summarises the ore processed by flotation for at Gedabek for the year ended 31 December 2023.
Table 3 – Ore processed by flotation at Gedabek for the year ended 31 December 2023
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Quarter ended | Ore processed (tonnes) | Gold content (ounces) | Silver content (ounces) | Copper content (tonnes) |
31 March 2023 | 192,516 | 1,487 | 19,787 | 1,133 |
30 June 2023 | 190,593 | 1,033 | 10,380 | 1,191 |
30 September 2023 | 62,369 | 478 | 4,358 | 363 |
31 December 2023 | - | - | - | - |
Total for the year | 445,478 | 2,998 | 34,525 | 2,687 |
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Previously heaped leached ore
Gold production at Gedabek from 2009 to 2013 was by heap leaching crushed ore until the start-up of the agitation leaching plant in 2013. The heaps remain in-situ and given the high grade of ore processed prior to the commencement of agitation leaching, and the lower recovery rates, much of the previously heap leached ore contains significant amounts of gold. This is now being processed by agitation leaching. Table 4 sets out the amount of previously heap leached ore processed for the year ended 31 December 2023.
Table 4 – Amount of previously heap leached ore processed for the year ended 31 December 2023
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| In-situ material (tonnes) | Average gold grade (g/t) |
1 January 2023 | 1,390,624 | 1.39 |
Processed in the year | (262,825) | 0.72 |
31 December 2023 | 1,127,799 | 1.55 |
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