Silver and gold bearing ore from the Palmarejo mine, located within the Mexican state of Chihuahua, contains a complex mix of electrum, native silver, silver sulfides and silver chlorides. This paper presents a case study that describes the selection, development and engineering of a tailored process plant for the recovery of silver and gold from this ore._x000D_
Process circuit feasibility study modelling, metallurgical test work and engineering studies are outlined. Options considered to optimise the recovery of the contained silver and gold are compared, based upon cost, operability, recovery and engineering aspects._x000D_
Concentration by flotation was found to be the preferred primary recovery route. Intensive leaching of the flotation concentrate resulted in solution grades sufficient to allow direct electrowinning to be evaluated against the more traditional Merrill Crowe process. The flotation tailings stream is processed through a separate leaching stage as there is sufficient economic metal extractable from this stream._x000D_
The processing flow sheet, which is designed to maximise the recovery from both the flotation concentrate and tailings, and to utilise a common metal production facility, is presented.