We did our first test with the steel plate. It turned out that the titanium plate Allen's boss had was too thick and not flexible, so he had to go with two, 4" x 5" flexible steel plates. He didn't have caustic (you said 'hot caustic'....did you mean caustic soda heated up, or something else?) to wash it with, so he hit both sides of both plates with a grinder then a sander to take the surface off.
We mixed 4 gal of thiosulfate leach & 5 lbs of finely ground ore (as we did before), but this time added just over 1/16 of a teaspoon of copper sulfate. You mentioned 1 tsp per 50 gal, so this would be close for 4 gal.
We were able to recover a little over 3 gal of leach from the ore, ran it through a 1 micron filter and got it very clean. The ph was 8.4.
Allen connect a wire to each plate using a DC power supply with knobs to control volts and amps. It puts out 7 amps at its highest, and we had it set at 5 volts.
He suspended the plates with fishing wire from a board across the top of a plastic 12 gal tote and put them into the leach, approx 5" apart. The ph jumped to 8.7 (we checked it about 10 min in) and within about a minute of starting the leach was bubbling and swirling along the edge of the negatively charged plate and the swirls were turning dark. I'll post pictures in order of what happened. First the positive plate started turning totally black from water level down, and the leach got a tinge of green/black, then slowly turned totally green/black. After the positive side of the plate turned black, the top edge just under the fluid started turning orange, like rust. Nothing seemed to be adhering to the negative plate at that time. It ended up having a very thin black film on it that wiped completely off.
We didn't know if we should move the leach around (stir it lightly) to get all of it in contact with the plates, so he did a couple of times. But we noticed the orange line started breaking apart and orange/gold flakes were falling into the leach and floating on top. By the time we finished and removed the plates, there were some very large patches of orange floating on top.
We left the plates in for about an hr then lifted them out. At first it looked like we'd lost all of the strip of orange, but, as you can see from the picture of the plate, after it dried it turned from black to orange on the top 1" or so, and still black below, but with an orange tinge when hit with a flashlight.
As it was drying, little flakes of black were falling off. We caught them on a filter and I also took pics thru the microscope of what those look like close up.
Here are our concerns & questions.
Was the distance apart of the two plates correct? We weren't sure of your instructions on the decimeter distance. Did you mean that it's one decimeter of distance per inch of plate? If that's the case, then with a 4" wide plate, would we be multiplying that by 1 decimeter? If so, we were way off on our distance.
Do the pictures I posted look anything like what it should or did we do it all wrong?
When we pulled the plates out it was still bubbling & swirling around the negative plate. We pulled them due to our concern over so much residue falling off the positive plate into the leach.