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LeachStar

Mintek’s LeachStar, distributed by Molycop, is a smart process control suite designed specifically for gold circuits. It incorporates leading technology to optimise the performance of various process units found on gold circuits, including thickeners, leaching circuits and carbon circuits.

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Features

Smart control algorithms and real-time data analysis
Optimises key parameters such as leach time, pH levels, temperature and reagent dosage
A flexible and scalable solution
Customisable to meet the unique requirements of different leaching processes

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Overview

Mintek’s LeachStar Smart Process Control suite, distributed by Molycop, is a cutting-edge solution designed to optimise performance and increase recovery rates in gold leaching circuits.

By integrating real-time process data and advanced control algorithms, LeachStar ensures precise control of key parameters including leach tank conditions, cyanide levels and oxygen concentration. This smart control system optimises gold recovery while minimising reagent consumption, boosting operational stability and enhancing the overall efficiency of the leaching process. The LeachStar suite of controllers increases plant performance and improves safety by deploying:

advanced signal fault detection
safety checks, ensuring safe control of cyanide in particular
advanced control techniques, especially designed for each process unit.

The LeachStar Smart Process Control works in conjunction with Cynoprobe to help reduce cyanide consumption by as much as 20%.

Thickener Control

When thickeners are positioned between unit operations, such as milling and leaching, they offer a valuable opportunity for integration into a comprehensive control strategy. Implementing an effective thickener control and optimisation solution can significantly stabilise both individual thickeners and the downstream circuit operation.

The LeachStar Thickener Controller provides these benefits:

Reduces flocculent consumption.
Improves clarity of thickener overflow water.
Ensures stable thickener operation by minimising bed slides of high-rake torque scenarios.
Stabilises the flow rate and density of the underflow, improving the performance of downstream processes.

Cyanide Control

Cyanide is a major operating cost, and its effective use depends on accurately adjusting the dosage rate based on plant conditions while maintaining the solution’s pH within the optimal range. Additionally, cyanide poses one of the most significant health and safety risks in gold circuits, making safe and precise control of its dosage crucial.

The LeachStar modules on StarCS include cyanidation-related control and estimation modules:

Cyanide Concentration Signal Fault Detector.
Cyanide Concentration Soft Sensor.
Cyanide Controller.

Adsorption Control

Carbon-in-pulp plants can achieve excellent gold recovery, but optimal operating conditions are essential. Early detection of performance anomalies is critical to ensure timely corrective action.

In addition to cyanide and pH controllers for adsorption control, the LeachStar control suite features a carbon management strategy that optimises carbon flow upstream, enhancing overall process efficiency.

Typical Uses

The LeachStar Smart Process Control suite is used by metallurgists and plant operators in gold mining operations to optimise leaching processes. LeachStar is used to control critical variables such as cyanide addition, oxygen levels and slurry conditions, ensuring higher gold recovery rates by maintaining optimal conditions throughout the leach cycle.

Benefits

Maximises efficiency and recovery in leaching operations.
Increases plant performance.
Reduces cyanide consumption.
Reduces carbon losses.
Increases recovery.

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Innovation

At Molycop, we see innovation as a way to find solutions to some of the mining industry’s greatest challenges. We aim to improve on today so we can deliver better for tomorrow.