Hey Captain Kirt:
After reading your posts a couple of times, I'm guessing your "ore" is from a dredging operation, and I want to congratulate you on 4 oz. gold recovery for every 5 gallon bucket of cons. If all things are relevant, that sounds like a good number. The question I'm not sure of is, exactly what are you trying to leach, the head material going into the dredge, the tails coming out of the dredge, the 5 gallon bucket of cons or the recovered gold?
A chlorine leach is an effective and powerful method to convert several elements to a higher valance, but it can sometimes be a bit confusing to the neophyte chemist. The ideal chlorine leach converts molecular chlorine to nascent (new born) chlorine, then back to molecular chlorine for continuous reuse. This is normally done in a nanosecond using a secondary acid/oxidizer, like nitric acid.
It's during the nascent phase that the chlorine attacks (puts into solution) the metal. Unfortunately, the nascent phase is not gold specific. On the EM Series there are several metal that will go into solution before gold and can/will use up your leach potential. Keep in mind that a lot of good info on this forum relates to some form of already refined gold and may not work as well on your material. But, the basic info that Harold, GSP, Steve, 4Metals and all the others, keep trying to pound into everyone's head is to get rid of, or control the base metal contaminates, still applies to ores.
My expertise is in the mining and metals extraction from placer/hard-rock ores on a large scale (XXX TPH), so I don't normally refine the metals beyond the first pyrometallurgy pour. Maybe I can help get your ore to a better leach stage, and then some of the other forum members can take over for the refining. You mentioned using a roasting procedure. Does your material contain any sulfides or tellurides that need roasting? And, what exactly is being assayed, heads, tails, cons or the gold, and what type of assay are being done?
I always do a lot of homework on my mining projects to try eliminating as many of the problems before they happen, so I may ask a lot of question before I can pass along any helpful info. In regards to a safety issue, I will say stay away from the muriatic (HCl) acid and mercury combination, as they can produce some nasty chemical mixtures that will stunt your longevity. Maybe you could post a start-to-finish flow chart of your operations, up to the "it-ain't-working" point. There might be some earlier steps in your process that can be changed to improve the gold recovery ratio.
And, don't get discouraged. From the numbers, it sounds like you might be on a good enough mining project to make a living.
Good luck,
John