Overview
The Essakane Gold Mine in Burkina Faso operates a sophisticated carbon-in-leach (CIL) processing plant with two parallel production lines (Line A and Line B). The facility has undergone several expansions since its initial 9.0 Mt/a design capacity, now capable of processing over 11.7 Mt/a of blended ore (saprolite, transition, and fresh rock). The plant features a SABC grinding circuit, gravity concentration, and intensive cyanidation for optimal gold recovery.
Key Process Stages
- Crushing Circuit: Primary gyratory crusher + secondary cone crusher (MP1250) at 1,912 t/h capacity with double-deck vibrating screen
- Grinding Circuit (SABC): Two 9.1m×4.3m SAG mills (7 MW each) + two 6.1m×10.2m ball mills (7 MW each) with pebble crushers, achieving P80 of 125μm
- Gravity Concentration: Four centrifugal concentrators recovering ~45% of gold, with intensive cyanidation reactors
- CIL Circuit: Two parallel trains (Line A: 10 tanks, Line B: 8 tanks) of 16.56m×19.56m leach/CIL tanks with oxygen injection
- Gold Recovery: Carbon adsorption, acid wash, elution, electrowinning, and smelting to doré bars
- Tailings Management: Thickening and water recycling system with dedicated storage ponds
Critical Data
| Parameter | Value |
|---|---|
| Design Throughput | 11.7 Mt/a (blended ore) |
| Fresh Rock Capacity | 10.8 Mt/a |
| Grinding Energy | 6.0 kWh/t (saprolite) to 17.5 kWh/t (hard rock) |
| Plant Power Consumption | 35 MW (average) |
| Oxygen Plant Capacity | 15 t/day |
| Pre-leach Thickener | 50m diameter @ 50% solids |
Recent Upgrades
- Secondary crusher upgrade from MP1000 to MP1250
- New high-capacity primary screen installation
- Gravity circuit improvements with double-deck scalping screens (5mm/2mm)
- Pebble crusher modifications for bypass operation
- Cyclone underflow distribution system optimization
Reagent System
The plant utilizes sodium cyanide, lime, activated carbon, and various process chemicals including flocculants, anti-scalants, and smelting fluxes. Water management combines river water, pit dewatering, and extensive recycling from the tailings storage facility.
Technical report and processing history
The following archived source profiles have been consolidated here to preserve the project’s processing history and study context.
Essakane Gold Mine — 2023 Technical Report
Essakane Gold Mine — 2023 Technical Report
| Company | IAMGOLD |
| Date | 2023 |
| Region | Burkina Faso |
| Commodities | Gold |
| Throughput | 11.7 Mt/a |
Executive Summary
This section of the NI 43-101 Technical Report details the recovery methods and metallurgical flowsheet for the Essakane Gold Mine. The plant currently processes ore using a combination of crushing, semi-autogenous grinding (SAG), ball mill grinding, pebble crushing, gravity concentration, and a Carbon-in-Leach (CIL) gold plant. The facility has undergone significant expansions, with Line A originally designed for 9.0 Mt/a and Line B added in 2014 to double fresh rock processing capacity to 10.8 Mt/a.
By 2019, the targeted plant capacity was revised to over 11.7 Mt/a of total ore, accommodating blends of saprolite, transition, and fresh rock. Modifications included upgrading the secondary crusher, installing new primary screens, and modifying pebble crushing and cyclone underflow distribution systems to improve efficiency. The process plant design includes a gyratory primary crusher, cone secondary crusher, SAG and ball mills, and a CIL circuit with pre-leach thickening and gravity concentration for gold recovery.
The report outlines the specific equipment specifications, such as 7,000 kW motors for the SAG and ball mills, and details the reagents and consumables required for operations. Energy consumption varies by ore type, ranging from 6.0 kWh/t for saprolite to 17.5 kWh/t for hard rock. Water management relies on the Gourouol River and storage ponds, while power is sourced from generators and a solar plant.
Processing Details
Reports
Website: https://www.iamgold.com/English/operations/essakane-gold-mine-burkina-faso/default.aspx
Report Date: 2023
Region: Burkina Faso
Project Status:
Commodity: Gold
Throughput: 11.7 Mt/a
Mine Life:
Mine Type:
Ore type:
Essakane Gold Mine — 2020 Technical Report
Essakane Gold Mine — 2020 Technical Report
| Company | IAMGOLD Corporation |
| Date | 2020-01-31 |
| Region | Burkina Faso |
| Commodities | Gold |
Executive Summary
This NI 43-101 Technical Report details the recovery methods and operational performance of the Essakane Gold Mine operated by IAMGOLD Corporation. The existing Carbon-in-Leach (CIL) plant has been in commercial production since July 2010. Following a 2014 expansion, the fresh rock processing capacity was doubled to 10.8 Mtpa. Operational improvements have allowed the plant to exceed its original nameplate capacity of 9.0 Mtpa, with 2018 throughput reaching 13.0 Mtpa. The ore processed includes saprolite, transition, and fresh rock types, with a head grade averaging around 1.18 g/t Au in 2018.
Production performance in 2018 saw the mine produce 450,000 oz of gold with a recovery rate of 90.9%. The report outlines the current processing circuit, which includes primary and secondary crushing, SAG and ball mill grinding, gravity concentration, and CIL leaching. The plant has demonstrated robust performance, though recovery rates fluctuate slightly based on ore blend and head grade. The report also highlights ongoing investigations to upgrade the concentrator to handle higher tonnages, targeting 11.7 Mtpa of fresh rock equivalent.
Additionally, the report introduces a proposed Heap Leach operation designed to process 8.5 Mtpa of re-handled ore from a stockpile over an estimated 5-year life of mine. This circuit utilizes a three-stage crushing plant with HPGR, agglomeration, and heap leaching followed by Carbon-in-Column (CIC) recovery. The project aims to extend the mine’s life and increase overall gold recovery by processing lower-grade ore that is not suitable for the CIL plant. The report provides detailed design criteria, equipment lists, and process descriptions for both the existing CIL plant and the proposed Heap Leach expansion.
Reports
Entities
Concepts
Website: https://www.iamgold.com/English/operations/essakane-gold-mine-burkina-faso/default.aspx
Report Date: 2020-01-31
Region: Burkina Faso
Project Status:
Commodity: Gold
Throughput:
Mine Life:
Mine Type:
Ore type:
Essakane Gold Mine — 2018 Technical Report
Essakane Gold Mine — 2018 Technical Report
| Company | IAMGOLD Corporation |
| Date | 2018 |
| Region | Sahel Region, Burkina Faso |
| Commodities | Gold, Silver |
Executive Summary
This section of the NI 43-101 Technical Report details the recovery methods employed at the Essakane Gold Mine, operated by IAMGOLD Corporation. The existing processing plant utilizes a SABC (Semi-Autogenous Grinding, Ball Mill, Pebble Crusher) circuit coupled with gravity concentration and a Carbon-in-Leach (CIL) gold plant. The plant was commissioned in July 2010 and has undergone expansions to increase hard rock processing capacity, reaching a revised nameplate capacity of 9.0 Mtpa. In 2017, the mine achieved a throughput of approximately 13.9 million tonnes with a gold production of 432,000 ounces.
The report also outlines a proposed Heap Leach (HL) expansion designed to extend the mine life by processing low-grade material that would otherwise be waste. This HL circuit involves a three-stage crushing system utilizing High Pressure Grinding Rolls (HPGR), followed by cyanide heap leaching and carbon adsorption. The HL project is designed for a 10 Mtpa processing rate with an estimated mine life of 6.2 years. Modifications to the existing concentrator are planned to process gold-loaded carbon from the HL circuit, including upgrades to the desorption, electrowinning, and carbon handling systems.
Operational data indicates the mine treats a mix of saprolite, transition, and hard rock ores. The CIL plant maintains high recovery rates, averaging around 90% in recent years, while the HL circuit targets 55% gold recovery and 21% silver recovery. The facility is designed as a zero-discharge system for water management, utilizing lined ponds and recycling solutions to minimize environmental impact. Reagent consumption includes sodium cyanide, quicklime, and anti-scalant agents, with power requirements carefully managed to support the expanded operations.
Website: https://www.iamgold.com/English/operations/essakane-gold-mine-burkina-faso/default.aspx
Report Date: 2018
Region: Sahel Region, Burkina Faso
Project Status:
Commodity: Gold, Silver
Throughput:
Mine Life:
Mine Type:
Ore type:
Mineral Processing Circuit of Essakane Mine
The Essakane Gold Mine employs a comprehensive gold recovery process combining crushing, grinding, gravity concentration, and carbon-in-leach (CIL) cyanidation. The processing circuit has undergone expansions and optimizations since its initial 2008 feasibility study, increasing throughput capacity from 7.5 Mt/a to >11.7 Mt/a.
Processing and Recovery Methods
1. Crushing Circuit:
– Primary Crushing: Gyratory crusher processes ore at 1,912 t/h.
– Secondary Crushing: Upgraded from MP1000 to MP1250 cone crusher (750 kW) to enhance capacity.
– Screening: Double-deck vibrating screen separates oversize for secondary crushing.
2. Grinding Circuit (SABC Configuration):
– SAG Mills: Two lines (A & B), each with a 9.1 m diameter × 4.3 m EGL mill (7 MW motor).
– Ball Mills: One 6.1 m diameter × 10.2 m EGL ball mill per line (7 MW motor).
– Pebble Crushers: One per line, operating in closed circuit with SAG mills.
– Cyclones: Classify ground slurry to a target P80 of 125 µm.
3. Gravity Concentration:
– Centrifugal Concentrators: Two per line recover coarse gold, achieving ~45% recovery (theoretical potential: 75%).
– Intensive Cyanidation: Gravity concentrate undergoes inline leaching, with gold recovered via electrowinning and smelting.
4. Leach-CIL Circuit:
– Pre-Leach Thickening: Cyclone overflow thickened to 50% solids in a 50 m diameter thickener.
– CIL Trains:
– Line A: Ten tanks (16.56 m diameter × 19.56 m tall), first tank for pre-aeration.
– Line B: Eight tanks (same dimensions).
– Cyanidation: Oxygen (15 t/day plant) and cyanide are added; activated carbon adsorbs gold.
– Elution & Electrowinning: Loaded carbon is acid-washed, eluted, and regenerated in a kiln. Gold sludge is smelted into doré.
5. Tailings Management:
– Thickened tailings are stored in a pond, with water reclaimed for reuse.
Technical Specifications & Operational Parameters
– Throughput: 11.7 Mt/a (blended ore) or 10.8 Mt/a (100% fresh rock).
– Power Consumption:
– Grinding: 6.0 kWh/t (saprolite), 10.0 kWh/t (transition), 17.5 kWh/t (hard rock).
– Total plant demand: ~35 MW (out of 40 MW total site usage).
– Reagents: Sodium cyanide, lime, activated carbon, flocculants, and grinding media (50–120 mm balls).
Innovations & Challenges
– Expansions:
– Line B (2014): Doubled fresh rock capacity via secondary crusher, additional SAG/ball mills, and CIL tanks.
– 2019 Upgrades: MP1250 crusher, high-capacity screens, and pebble crusher bypass mode improved efficiency.
– Energy Optimization: Solar plant (14.92 MWp DC) reduces CO2 emissions by 18,000 t/year.
Recovery Efficiencies
– Gravity circuit recovers ~45% of gold; overall recovery via CIL is not explicitly stated but optimized for ore blends.
Key Challenges
– Ore Variability: Hard rock increases energy demands (17.5 kWh/t vs. 6.0 kWh/t for saprolite).
– Water Management: Reliance on seasonal Gourouol River, mitigated by recycling from tailings.
The Essakane circuit exemplifies a robust, scalable design with continuous debottlenecking to adapt to ore hardness and throughput demands.
