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One free scan finds every outdated or missing driver and matches the right update for your exact hardware.Free scan · exact hardware matchGold ore is turned into a doré bar through a sequence of engineered steps: mining and haulage, crushing, grinding, optional gravity or flotation concentration, cyanide leaching, activated-carbon recovery, electrowinning, and finally filtering, drying and smelting. The doré bar is an intermediate gold-silver product that still goes to a refinery; it is not normally 99.99% pure bullion.
There is no single universal flowsheet. Hardness, gold grain size, sulphide content, liberation, deleterious elements, water balance, tailings conditions and regulatory requirements determine which unit operations a mine installs and how long each stage runs.
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1. Mining produces the plant feed
Drilling, blasting and underground stoping
At a hard-rock operation, ore is produced either by drilling and blasting in an open pit or by underground stoping and development. The mining method, blasting pattern and grade-control system are specific to the deposit. Broken rock is loaded and hauled to a crusher, an ore stockpile or a designated low-grade area.
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Technical reports describe the material entering the plant as run-of-mine, or ROM, ore. ROM contains a mixture of valuable minerals, barren rock and material with different hardnesses and gold associations. Blending from the mine and stockpile helps the mill receive a manageable feed rather than abrupt changes in hardness or sulphide content. Mine haulage and the distance to the crusher are project-specific, so they cannot be inferred from another mine’s design.
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2. Crushing and grinding liberate the gold
Primary crushing
A jaw or gyratory crusher reduces large ROM rocks to a size that conveyors can carry and the grinding circuit can accept. A coarse-ore stockpile commonly sits after primary crushing. Reclaim feeders draw material from the stockpile at a controlled rate, allowing the mill to operate while truck deliveries fluctuate.
SAG mills, ball mills and classification
Grinding reduces crushed ore until gold-bearing particles are exposed, or liberated, from the surrounding minerals. A plant may use a semi-autogenous (SAG) mill, a ball mill or a combination. Hydrocyclones classify the ground slurry: coarse particles return to the mill, while the fine fraction moves to concentration or leaching.
Particle size is a design decision, not a universal target. The Tocantinzinho project design specifies a final grinding P80 of 125 micrometres. P80 means 80% of the classified product is finer than that size. A harder ore or a more tightly locked gold grain may require more grinding energy, while excessive grinding can consume power and create slimes that complicate downstream recovery.
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Gravity concentration for coarse free gold
When a meaningful share of the gold is coarse and liberated, centrifugal or other gravity equipment can be placed on the grinding circuit. Gravity separates high-density gold particles from lighter gangue. The resulting concentrate is usually treated by intensive cyanidation, with a dedicated electrowinning step possible for the dissolved gold.
Gravity is not automatically installed at every mine. It is justified by mineralogical and metallurgical test work showing that coarse free gold can be recovered economically before the main leach circuit.
Flotation for sulphide-associated gold
If gold is hosted by sulphide minerals, flotation may produce a sulphide concentrate rather than sending all of the material directly to whole-ore leaching. Air and reagents create bubbles that carry selected sulphide particles to a froth product. That concentrate can be reground and cyanide-leached under conditions chosen for its mineralogy.
The Tocantinzinho design includes a two-stage sulphide flotation circuit. A flotation route can reduce the mass that requires intensive treatment, but it adds cells, reagents, concentrate handling and another control loop. Whether it improves recovery depends on how gold is locked in the ore.
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4. Pre-aeration and cyanide leaching dissolve exposed gold
Conditioning the slurry
Before cyanidation, a plant may use pre-aeration or air conditioning. The purpose is to establish the oxygen and chemical conditions needed for the selected ore. Residence time, oxygen supply and reagent additions come from metallurgical testing and operating experience with that deposit; they are not fixed globally.
How cyanide creates a recoverable solution
Sodium cyanide reacts with exposed gold in the presence of oxygen, forming a soluble gold-cyanide complex. The gold moves from the solid particles into the water phase, which operators call the pregnant solution. Unliberated gold remains in the solids, so crushing and grinding quality directly affects the amount available to leach.
Cyanide leaching is an industrial process requiring enclosed equipment, monitored reagent systems, trained personnel and engineered containment. It is not suitable for household, small-shop or improvised use.
Whole-ore and concentrate leaching
A whole-ore circuit leaches the main ground stream. A concentrate circuit leaches a smaller, higher-grade product after gravity or flotation. Some mines use both: gravity removes coarse gold early, flotation treats sulphide-associated gold, and the remaining material enters a conventional leach train.
5. Carbon adsorption: CIP versus CIL
What both circuits do
Activated carbon adsorbs dissolved gold complexes from the slurry or clarified solution. Carbon is screened between tanks so it moves counter-currently to the slurry, building a high gold loading before it is removed for stripping.
| Feature | Carbon-in-pulp (CIP) | Carbon-in-leach (CIL) |
|---|---|---|
| Where adsorption occurs | In dedicated adsorption tanks after a separate leach stage | In tanks that perform leaching and adsorption in the same train |
| Process arrangement | Leach first, then contact the leached slurry with carbon | Add carbon while cyanide leaching is still taking place |
| Why a plant may choose it | Provides a distinct leach and adsorption section that can suit the tested ore and existing plant layout | Can capture dissolved gold as it is generated and may reduce the need for a separate adsorption section |
| What controls the design | Gold dissolution kinetics, slurry characteristics, carbon loading and tested residence time | The same metallurgical factors, plus the interaction between leaching and adsorption in each tank |
CIP and CIL are arrangements, not quality grades. The labels do not establish recovery, reagent consumption or a standard number of tanks. A 2022 Tocantinzinho feasibility study uses 36 hours of CIL residence time as a project design parameter; that figure should not be treated as a requirement for every orebody.
6. Loaded carbon is washed, eluted and regenerated
Screening and acid washing
When carbon reaches its target loading, screens separate it from the slurry. An acid wash removes carbonate scale and other foulants that block adsorption sites. The wash chemistry and handling system are designed to protect carbon and prevent contaminants from entering the strip circuit.
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Elution produces a gold-rich strip solution
Elution removes the adsorbed gold from the washed carbon and transfers it into a concentrated solution known as pregnant eluate. The exact elution conditions depend on the plant’s selected process, water quality and carbon characteristics.
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Thermal regeneration restores adsorption capacity
After elution, carbon is thermally regenerated to burn off organic foulants and restore capacity. It is screened for size and returned to the adsorption circuit. Carbon losses are managed through make-up carbon and mass-balance controls.
7. Electrowinning turns eluate into cathode sludge
Pregnant eluate flows through electrowinning cells. An electrical current plates metal onto cathodes, producing a wet sludge rather than a finished bar. The sludge contains gold and commonly silver, along with other metals carried through the solution.
Electrowinning is separate from refining. Its job is to recover metal from the solution in a form that can be filtered, dried and smelted. The final separation of gold from silver and impurities occurs later at a refinery.
8. Filtering, drying and smelting make doré
Preparing the cathode sludge
The cathode product is filtered to remove process water and then dried. Moisture control matters because water trapped in a furnace feed can create violent boiling and handling hazards. Operators also sample and record the material before smelting.
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Fluxes and furnace smelting
Dried sludge is blended with smelting fluxes selected for the contained metals and expected impurities. In the furnace, the charge melts; gangue and selected impurities report to slag while the dense metal phase collects as a bar. The official description in Aura Minerals’ 2025 Era Dorada Gold Project technical report summarizes this stage as: Gold refining – Gold electrowinning (sludge production), filtration, drying and smelting to produce gold doré.
What a doré bar is—and is not
Doré is an intermediate gold-silver alloy. Its exact gold, silver and impurity content must be established by assay for that batch. It is sent to an off-site refinery for further separation and purification, so a mine doré bar is not normally 99.99% pure bullion. No single doré fineness or recovery percentage applies to all mines.
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9. Cyanide destruction and tailings management
Detoxifying residual cyanide
After gold recovery, the remaining slurry can contain residual cyanide and metal-cyanide compounds. A destruction or detoxification circuit treats the residue before discharge to the tailings system. The selected chemistry, control limits and monitoring program are set by the ore, permit and site risk assessment.
Thickened, filtered or conventional tailings
Tailings are the finely ground solids left after valuable minerals are recovered. A plant may thicken them, filter them to make a stackable product or pump them to a storage facility. Water recovered from thickening or filtration is often returned to the process circuit, reducing fresh-water demand and helping maintain the water balance.
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Tailings storage is an engineered facility, not an incidental waste pile. Its design must account for solids density, seepage control, embankment stability, stormwater, reclaim-water ponds and closure requirements.
Independent reader supportYour contribution helps us test, update, and keep practical guides available for everyone.10. Why mines use different flowsheets
Engineers select a flowsheet from test work and ore characterization rather than copying another mine. The key decision axes are:
- Mineralogy and liberation: whether gold is free, locked in quartz, associated with sulphides or affected by preg-robbing and other behaviors.
- Particle size and hardness: the grind size needed for liberation and the energy required to reach it.
- Concentration opportunity: whether coarse gold supports gravity recovery and whether sulphide flotation can produce a treatable concentrate.
- Leach strategy: whole-ore leaching versus concentrate leaching, with pre-aeration or other conditioning where testing supports it.
- Adsorption arrangement: CIP or CIL, tank volume, carbon movement, loading targets and residence time.
- Water and residue controls: cyanide destruction, water recovery, tailings density and storage requirements.
- Capital, operating complexity and regulation: extra circuits can improve recovery but add equipment, maintenance, reagents, controls and permitting obligations.
Metallurgical variability matters. A circuit that works on oxide-rich feed may perform poorly when sulphide ore arrives, and a design sized for one hardness distribution may lose throughput when the mine plan changes.
11. Published design examples and what they mean
| Published figure | Project and date | How to interpret it |
|---|---|---|
| 4.3 million tonnes per year nominal mill capacity | Tocantinzinho Project technical report, 2019 | A stated plant design capacity for that project, not an industry-wide standard |
| 174,000 ounces of planned annual gold production | Tocantinzinho Project technical report, 2019 | A project production plan tied to its resource, recovery assumptions and operating schedule |
| 125 micrometres final grinding P80 | Tocantinzinho design documentation | The specified product-size target for that grinding circuit |
| 36 hours of CIL residence time | Tocantinzinho feasibility study, 2022 | A tested project design parameter, not a universal cyanide-leach requirement |
These figures illustrate why mine-to-doré descriptions need context. Capacity, annual ounces, grind size and residence time belong to a particular orebody, plant design and mine plan.
12. Common operating problems and the correct response
Gold recovery falls after a harder ore zone arrives
Check crusher product size, mill power draw, cyclone classification and the measured liberation size. If coarse gold is no longer liberated, adding cyanide without correcting grinding will not solve the underlying problem.
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Carbon loading declines
Review carbon activity, acid-wash performance, thermal regeneration, screen integrity and the presence of organic or mineral foulants. Confirm that dissolved gold is actually being generated in the leach stage before changing adsorption conditions.
Flotation concentrate becomes unstable
Compare feed mineralogy, grind size, reagent additions and froth characteristics with the test-work basis. A change in sulphide mineralogy can alter both concentrate grade and the cyanide demand of the regrind-and-leach circuit.
Cyanide remains above the permitted discharge target
Keep the affected stream contained, verify the analyzer and sampling result, and investigate the detoxification circuit’s reagent feed, mixing, residence time and solids density. Tailings should not be released outside the approved management system while the cause is unresolved.
13. Safety and environmental boundaries
Cyanide, caustic and acidic reagents, hot carbon-regeneration equipment, electrowinning cells and smelting furnaces each require specialized procedures. Acid washing and cyanide systems must be segregated to prevent the formation of toxic hydrogen cyanide gas. Plants use interlocks, ventilation, gas monitoring, emergency response plans, secondary containment and trained operators.
The environmental footprint is managed through several linked controls: closed-loop process water where practical, cyanide destruction, seepage collection, tailings dam or filtered-stack monitoring, reclaim-water management and progressive closure planning. The right control package depends on local geology, climate, regulations and facility design.
14. What happens after the mine ships doré
The doré bar is weighed, sampled and assayed so the refinery and mine can settle the payable gold and silver content. The refinery then separates precious metals from one another and from base-metal impurities, producing marketable bullion and other refined products. The mine’s revenue therefore depends on assay, payable terms, treatment and refining charges, metal prices and penalties for deleterious elements—not simply the gross weight of the doré bar.
For that reason, a statement such as “one tonne of ore makes a certain amount of gold” is incomplete without grade, recovery, moisture, production schedule and assay data. The process creates a saleable intermediate, but its economic value is established only after measurement and refining.
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