Gold smelting
Mercury removal
Mercury is a health hazard, especially when in gas form. To remove this hazard, before smelting, gold precipitates from electrowinning or Merrill-Crowe processes are usually heated in a retort to recover any mercury present, that would otherwise cause health and environmental problems due to its release (volatilization) during smelting. The mercury present is not usually from the mercury amalgamation process that is no longer used by formal gold mining companies, but from mercury in the ore that has followed gold through the leaching and precipitation processes.
In the event that there are high levels of copper or silver present, leaching of the precipitate using nitric or sulfuric acids may be required.
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Iron removal
Nitric acid or forced air oven oxidation can also be used to dissolve iron from the electrowinning cathodes before smelting. Gravity concentrates can often contain high grinding steel contents, and so their removal using shaking tables or magnets is used before smelting. During smelting iron can be oxidized using nitre. Excessive use of nitre will corrode the smelting pot, increasing both maintenance costs and the risk of catastrophic leaks (known as run-aways, or holes in the pot through which the molten charge is lost).
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