Energy Savings Technology
The CGS Heater Skid uses significantly less energy than a standard heater skid. A traditional pressure Zadra circuit maintinans a temperature of 65 C in the barren tank, 148.9 C in the elution vessel and 88 C in Electrowining. Lower temperatures in the elution vessels will result in longer elution cycle times. Higher temperatures in the barren tank result in increased cyanide destruction. Lower temperatures in Electrowinning result in lower current efficiencies and therefore lower recoveries while higher temperatures in Electrowinning can result in E cell vaporization.
The CGS heater skid utilizes a third heat exchanger to recouperate energy from the Electrowinning cells. This allows the same temperature profile as the traditional Zadra process to be maintained across the barren tank, elution vessel and electrownning cells, while dramatically lowering the energy input of the immersion heater. The reduction in energy is primarily attritubed to a compete elimination of energy losses through cooling water.
Zinc Feeder
Elution Modeling and Cell Sizing
CGS begins a job by mathematically modeling the solution tenure entering the cell during every minute of the cell's simulated operation. The CGS elution and electrowinning tenure model is based on both first principles and years of staff experience. Our model accurately predicts the rate at which precious metals are desorbed from activated carbon and removed from pregnant solution.
Merrill Crowe Deaeration Tower
The CGS kiln is both efficient and reliable. It is designed to keep carbon attrition at a minimum by keeping the oxygen levels low.
The CGS proprietary seal uses a wear based system which gives the kiln the ability to maintain a proper seal over its lifetime of operation, rather than a standard seal that produces uneven wear and allows more oxygen ingress over its life. When the life of the CGS seal is complete, its simple removable design makes replacing the seal a job that takes a matter of minutes rather than a standard tail end rebuild.
The CGS kiln is also heavily insulated to reduce power and fuel consumption. In addition to reduced fuel consumption the CGS kiln offers the benefit of being "cool to the touch", completely eliminating one of the primary safety hazards in an ADR plant.
Electrowinning Cells
In a Merrill Crowe plant zinc powder is added to bind to the cyanide and drop the silver/gold out of solution. After proper clarification, to ensure suspended solids are kept to a minimum, and dearation, to minimize zinc consumption and optimize precipitation, the process solution is ready for zinc addition and precious metals precipitation. The CGS zinc addition system is an easy to install skid that includes an appropriately sized hopper, head tank, mix cone, turntable, motor, control panel and VFD controls.
Carbon Regeneration Kiln
Heater Skid
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Indirect Cooling
A traditional Zadra process is cooled through a combination of flashing and the introduction of cooling sprays inside the elution vessel. A process that takes
approximately 1-2 hours. Common problems include calcium precipitaton inside the elution vessel, which plugs the vessel screens and decreases carbon activity. The cooling of the vessel is often the most dangerous part of the elution cycle due to the rapid discharge of steam from the elution column.
The CGS skid eliminates this problem by employing an oversized trim heat exchanger and a primary heat exchanger bypass line. The cooling operation is simple. The operator opens the cooling water valve to the trim heat exchanger, which due to the high efficiency of the heater skid has been turned off the entire cycle. The solution exiting the elution vessel is cooled 100 degrees F in a single pass.
The primary heat exchanger is than bypassed, directing the 300 degree F solution exiting the elution column into the trim heat exchanger. The solution is cooled 140 degrees and returned safely into the barren tank. This process is takes 30 minutes, as the 300 degree F solution in the elution column is displaced by 150 degree solution from the barren tank.
Due to the indirect nature of the cooling precipitation inside the elution column
is completely eliminated. No steam is vented to atmosphere maintaining
operator safety.