PART F: Operational details - Iluka Resourcesops)_part-f_operational-details.pdf · PART F: Operational details . Jacinth-Ambrosia Mineral Sands Mining Project — Mining and Rehabilitation

PART F: Operational details

Jacinth-Ambrosia Mineral Sands Mining Project — Mining and Rehabilitation Program (Operations) Page 59

6. Operational infrastructure and details

The Jacinth-Ambrosia Project is an open-pit mineral sand mining operation. Operations will be undertaken over of two ore bodies (Jacinth and Ambrosia) over a project mine life of 10-15 years.

6.1 Mine Infrastructure

A summary of the operational mine infrastructure on site is detailed in Table 6.1 with the location of infrastructure detailed on Figures 6.1, 6.2 and 6.33. Further discussion of the infrastructure is provided in Sections 6.3 – 6.21.

Table 6.1 Operational Mining Infrastructure

Mining Infrastructure and areas

Jacinth mine pit Mining Unit Plant (MUP)

Ambrosia mine pit Topsoil and overburden stockpile areas.

Tailings Storage Facility (TSF)

Processing Area

Wet Concentrator Plant (WCP) – including thickener and flocculent plant.

Heavy Mineral Concentrate (HMC) stockpile area

Process water storage dams. Ore and tailings pumping units and pipelines.

Process plant buildings

Ancillary Infrastructure

Communications and Information Technology infrastructure

On-site waste storage and management facilities

Power generation and reticulation system Operational fuel storage areas

Water supply bore field Water supply and treatment facilities

Vehicle and equipment wash down facilities Office accommodation and amenities

Warehousing Workshop and vehicle maintenance facilities

Site access roads Accommodation Village

Airfield

6.2 Jacinth deposit

6.2.1 Test pit/opening void details

A test pit/opening void has been established in order to test the deposit and establish the MUP near the final design pit floor.

3 Figures included in Section 6 of the MARP(Ops) should be considered as indicative. There is a chance that during

operations infrastructure location and/or details may be modified to improve operational efficiency. Amended infrastructure locations or details will be discussed with relevant authorities and additional information provided in annual compliance reports (Refer Section 9.3.1) in accordance with lease and licence conditions

Page 60 Jacinth-Ambrosia Mineral Sands Mining Project — Mining and Rehabilitation Program (Operations)

The test pit/opening void is approximately 103 m wide and 364 m long and had a maximum depth of approximately 24 m. The pit has been used to:

access a representative volume of the free flowing Ooldea sands that are located in the lowest 15 m of the orebody

access an example of a harder band within the ore zone; and A summary of the test pit/opening void details is provided in Table 6.2 below. The location of the area is provided in Figure 6.4.

Table 6.2 Test pit/opening void design constraints and criteria

Constraint Value Justification

Ramp Width 25 m Minimum width requirement for transport of dozer mining unit into the void. The dozer mining unit is 20 m wide by 47 m and requires an additional 5 m width for manoeuvring

Entry Ramp Angle

1:3 As steep as practically possible to reduce footprint and cost

Exit Ramp Angle

1:10 Poor footing expected in the loose sands of the ore horizon, exit ramp angle therefore designed to compensate.

Wall Angles Overall slope 38 to 42o.

Loose sands in the bottom 7 m of the pit require slopes of 31o up to an elevation of 134 mRL.

Following a 3 m safety berm at that height, the slope is projected up to the surface at 50o.

As detailed in Table 6.2 the pit wall angles within the Ooldea sands section of the ore body have been designed at 31o while in the upper red and brown loams the pit angles have been designed at 50o. The red and brown loams vary in thickness from 7 to 16 m and 8m of the Ooldea sands are exposed by the pit. At the interface of the two material types a 3 m berm has been established to aid the overall wall stability.

Safety bunds around the perimeter of the pit are 1 m high and 4 m wide at the base. These have been constructed at least 10 m from the edge of the pit so that any localised easing of the pit walls will not affect the bunds.

6.2.2 Final pit design

The final pit design incorporates the area established for the test pit.

The Jacinth mining operation will extract ore from an area of up to 900 m wide, approximately 3.2 km long and up to 47 m deep. The average ore thickness is 20 m. and the overburden thickness varies from 0 to 37 m averaging 7 m. Pit slopes have been designed in accordance with recommendations from specialist geotechnical investigations undertaken by AMC Consultants in 2008.

After an initial development phase of approximately 18 months, the mine will be progressively backfilled and rehabilitated as the mine face advances.

Figure 6.4 shows the location of the opening void in relation to the project site with Figure 6.5 providing more specific details of the void. Indicative cross sections for the mine are provided in Appendix J.

Lake Ifould

Yellabinna Regional Reserve

225000

225000

230000

230000

235000

235000

240000

240000

245000

245000

6575

000

6575

000

6580

000

6580

000

6585

000

6585

000

Drawn By:

Date:

Client Ref:

2100540_GIS_F108Drawing No.:

C2

JACINTH-AMBROSIA PROJECT

0 1,000 2,000

metres

Checked by:

31/03/09

1:60,000 at A3

Jacinth-Ambrosia Mineral Sands ProjectMining Lease Infrastructure

Figure 6.1

Revision:

JGDF/RPData Source: Geoscience Australia, DEH, PIRSA

SITE LOCATION

CEDUNA

ADELAIDE0 125 250

kilometres

Coord. Sys.: GDA94 MGA Z53

NOT REQUIRED

APPROVED FOR AND ON BEHALF OF Parsons Brinkerhoff Australia Pty limited

____________________DATE

____________________SIGNED

© Parsons Brinkerhoff Australia Pty Ltd ("PB") Copyright in the drawings, information and data recorded in this document ("the information") is the property of PB. This document and the information are solely for the use of the authorised recipient and this document may not be used, copied or reproduced in whole or part for any purpose other than that which it was supplied by PB. PB makes no representation, undertakes no duty and accepts no responsibility to any third party who may use or rely upon this document or the information. NCSI Certified Quality System to ISO 9001

GIS File: J:\A302-ENG\PROJ\2100540_CADD_GIS\10_GIS\Projects\Drawings_Figures_Sketches\2100540_GIS_F108_C2.mxd

Mine Outline

Miscellaneous Purpose License (MPL111)


Mineral Lease (ML6315)

Watercourse

Mine Layout

Waterbody

Nullarbor Regional Reserve


Jacinth Mine Pitand Stockpile Areas

Tailings Storage Facility

Process Plant

Ambrosia Mine Depositand Associated Stockpiles

Jacinth Mine Deposit

Satellite Deposit

DDDD

DD

DD

DDDD

DD

DDDD

DD

DD

DDDD

DDDDDD

DD

DD

DD

DD

DD

DDDD

DDDD

DDDDDDDDDDDDDDDDDDDDDDDDDDDD

DD

DD

DDDD

DD

DDDD

DD

DD

DD

DDDD

DDDD

DDDD

DDDD DD

DD

DD

DDDDDD

Lake IfouldNullarbor Regional Reserve


200000

200000

210000

210000

220000

220000

230000

230000

6570

000

6570

000

6580

000

6580

000

Drawn By:

Date:

Client Ref:


A


Z0 2,000 4,000

metres

Checked by:

16/02/09

1:100,000 at A3

Jacinth-Ambrosia Mineral Sands ProjectMPL (111) Infrastructure

Figure 6.2

Revision:

JGHD/DFData Source: Geoscience Australia, DEH, PIRSA, Iluka, SKM

!

!

!

CEDUNA

ADELAIDE

COOBER PEDY

JACINTH-AMBROSIA

0 150 300

kilometres Z


NOT REQUIRED


____________________DATE

____________________SIGNED

' Parsons Brinkerhoff Australia Pty Ltd ("PB") Copyright in the drawings, information and data recorded in this document ("the information") is the property of PB. This document and the information are solely for the use of the authorised recipient and this document may not be used, copied or reproduced in whole or part for any purpose other than that which it was supplied by PB. PB makes no representation, undertakes no duty and accepts no responsibility to any third party who may use or rely upon this document or the information. NCSI Certified Quality System to ISO 9001

GIS File: J:\A302-ENG\PROJ\2100540_CADD_GIS\10_GIS\Projects\Drawings_Figures_Sketches\2100540_GIS_F111_A.mxd

DD DD 33kv Distribution Line




Watercourse

Waterbody



Pumping Station

230000

230000

Drawn By:

Date:

Client Ref:


A


Z0 250 500

metres

Checked by:

16/02/09

1:12,000 at A3

Jacinth-Ambrosia Mineral Sands ProjectMPL (110) Infrastructure

Figure 6.3

Revision:

JGHD/DFData Source: Geoscience Australia, DEH, PIRSA, Iluka, SKM

!

!

!

CEDUNA

ADELAIDE

COOBER PEDY

JACINTH-AMBROSIA

0 100 200

kilometres Z


NOT REQUIRED


____________________DATE

____________________SIGNED

' Parsons Brinkerhoff Australia Pty Ltd ("PB") Copyright in the drawings, information and data recorded in this document ("the information") is the property of PB. This document and the information are solely for the use of the authorised recipient and this document may not be used, copied or reproduced in whole or part for any purpose other than that which it was supplied by PB. PB makes no representation, undertakes no duty and accepts no responsibility to any third party who may use or rely upon this document or the information. NCSI Certified Quality System to ISO 9001

GIS File: J:\A302-ENG\PROJ\2100540_CADD_GIS\10_GIS\Projects\Drawings_Figures_Sketches\2100540_GIS_F146_A.mxd

Village Layout

Airfield Layout

Watercourse




Waterbody



Village Infrastructure


The final phase of the Mining of the opening void will commence from mid to late 2009.

6.3 Ambrosia deposit

The Ambrosia deposit consists of a larger central zone up to 700 m wide, approximately 2.2 km long and up to 35 m deep as well as two smaller satellite pits to the east and north. The average ore thickness is 12 m. and the overburden thickness varies averages 8 m.

Ore mining is currently scheduled to commence in Ambrosia in late 2017 and be completed in late 2020. The location of the Ambrosia deposit is shown on Figure 6.1. Given that mining of the Ambrosia deposit is not scheduled to commence until 2017, specific information regarding the design of the Ambrosia deposit will be provided in subsequent MARP(Ops) documents. Further details of the review and update requirements for the MARP(Ops) is detailed in Section 9.3.3.

6.4 Deposit cutoff grades

The decision as to whether a mineral deposit is considered ore or waste involves the consideration of a number of inputs. The decision is made on the basis of calculating the block’s value separately as ore and as waste and choosing the option that provides the highest value, which may even be negative.

The cost and revenue estimation process involves the following inputs from the geological model:

heavy mineral grade grades of component minerals in the heavy mineral fines (-54micron) percentage of the total ground coarse (+2mm) percentage of the total ground hardness index of the ground location relative to known areas of poor quality mineral.

A cutoff grade can be estimated at nominated values of the above inputs. Assuming the average above inputs for the deposit, the current cutover grade for the project would be approximately 1.5%HM. That is, at 1.5%HM, the value of the average block as ore is exactly the same as the value as waste.

6.5 Mining unit plant

The MUP consists of four main components;

dozer trap with apron feeder Wet Rotating Grizzly (WRG) ore slurry pumping and secondary screening.

Three of the components are located in the pit as one item of equipment, with the secondary screen located at the WCP.


The single unit MUP will be mounted on hydraulically driven dozer tracks to facilitate movement of the unit every 4–6 weeks during operations.

During operations the MUP will be located at the base of the working pit (i.e. Jacinth initially and then relocated to Ambrosia). The MUP will be relocated around the respective pit base as may be required for operational purposes.

The MUP feed rate will vary between dominantly 1,050 to 1,250 t/h. After screening out of coarse oversize the output will 1,000 to 1,200 tph for a majority of the minelife.

6.5.1 Dozer trap

The dozer trap unit is mounted on the front of the single chassis MUP.

A separate Motor Control Centre (MCC) operates within the unit to provide power to the apron feeder which transports Run Of Mine (ROM) to the WRG feed chute and cleanup conveyor drives.

The cleanup (dribble) conveyors are located under the apron feeder to catch any ROM ore that may slip between the joints of the feeder.

6.5.2 Wet rotating grizzly (WRG)

The WRG is the component of the MUP that slurries, scrubs, scalps and screens the ore received from the dozer trap. ROM ore is fed via the dozer trap feed chute to the WRG where process water is added to create an ore slurry. A scalping screen is located between the apron feeder and WRG to eliminate material >300 mm in size from entering the WRG. Oversize material will be directed to a stockpile adjacent to the MUP.

The slurried ROM ore will spill into the scalping/screening section of the WRG where product >10 mm in size is deposited to an oversize material stockpile. A spray bar delivers high pressure water along the length of the screen section to wash ore off the oversize material. The <10 mm product is transported to a slurry sump and associated slurry pipeline and then to the secondary screen located at the WCP and discussed in Section 6.6.

Both the WRG unit and slurry pump sump module will be mounted on hydraulically driven tracks, due its total mass and mobility requirements (i.e. it will be required to be moved within the pit during operations). An MCC will provide power to the MUP.

6.5.3 Ore slurry pumping

Ore slurry pumping is facilitated via pumps and pipelines which deliver slurry from the in pit MUP to the wet concentrator (details of the wet concentrator are contained in Section 6.6).

Two pumps are located on the MUP. The pumps are mounted in series and allow the ore to first be pumped to the top of the pit (from the WRG) and then to the secondary screen located at the WCP and discussed in Section 6.6.

100500 300200

Full Size 1:5000 ; Half Reduction 1:10000SCALE (m)

100500 300200



As the MUP relocates within the pit during operations, the location of the pumps and ore slurry pipelines will also alter however they will predominantly be located within the services corridors as adjacent to the pit.

Further details on ore slurry pipelines etc are provided in Section 6.12.1.2.

6.5.4 Secondary screen

The secondary screen consists of two twin deck vibrating banana screens and is located at the WCP.

The <10 mm ore is pumped from the WRG and screened at 2.5 mm through the deck screen. Oversize (>2.5 mm) material is stockpiled via a stacking conveyor (this may be used for road maintenance activities during operations). Pumping of the oversize material as slurry to the TSF may also be undertaken as required during operations.

The <2.5 mm product will be contained within a slurry and pumped to the WCP.

Figure 6.6 shows a typical operating Mining Unit Plant.

FIGURE 6.6 Typical mining unit plant


6.6 Wet concentrator plant

The WCP at the Jacinth-Ambrosia operations has been re-located from Lulaton, Georgia (United States).

The plant has been refurbished (with replaced electrics, increased re-cleaner spirals capacity, new pumps, hoppers and upgraded corrosive protection to cater for saline water) and preassembled at Whyalla before transportation to and final assembly at the Jacinth Ambrosia mine site. A new Constant Density (CD) tank, process water tank and HMC stacking system has also been installed.

Figure 6.7 shows the location and general arrangement of the WCP (within the site processing area).

6.7 HMC stockpile area

The HMC stockpile area consists of a base geo-fabric membrane that is overlain with a coarse free draining product. Spoon drains and silt traps have been established to provide for a collection and screening capacity for water from the stockpile area during operations. During operations, water collected from the HMC stockpile area will be collected, screened and gravity fed to the process water dams. A drive in solids trap structure is located at the western end of the stockpile area to capture and recycle solids from surface runoff back to the WCP.

The HMC stockpile area is approximately 200 m long and 55 m wide and provides for the storage of three material stockpiles which will have an estimated total capacity of 45 kt. The layout allows time for the HMC to dry by gravity and drainage to 4–5% moisture. Three individual cyclone stackers will have also been established in the stockpile area.

Figure 6.7 shows the general layout of the HMC stockpile area.

6.8 Tailings storage facility

During the first 18 months of operations, a Tailings Storage Facility (TSF) will be required for the deposition of mining by products (MBP). MBP will be placed in the mine following the creation of an appropriate void.

6.8.1 Design

The TSF has been established to the south west of the test pit as outlined on Figure 6.5. The TSF has been constructed using compacted soil and overburden and includes:

2m perimeter walls with the exception of the decant area where the walls are 7 m high; and

a central discharge spine (5m in height and higher (as required) in the north).

As tailing operations continue, the TSF central discharge spine will continue to be built up in advance of the rising tailings levels.

WORK IN PROGRESS

20100 40 60



The design of the TSF meets the requirements of Iluka Major Risk Procedure Tailings (PRC3077), and those of the EPA and PIRSA (Regulatory Guideline No. 5 Tailings and Tailings Storage Facilities).

These requirements include:

geotechnical input for design, including provision for extreme weather events

the TSF design shall specify the tailings parameters and range that the design is based on (e.g. density, % solids, % slimes, utilisation)

TSF design shall incorporate a provision for dewatering, for example through a decant system or by pumping

where ‘uphill’ tailing is required a specific procedure must be developed for levee/wall construction on the downhill side (that includes a geotechnical design)

periodic audits by geotechnical specialists to confirm structural integrity and to ensure design is relevant for current use (more frequent audits may be required subject to the outcome of risk assessment and type or utilisation of TSF)

tailings pipeline route that considers pumping efficiency, containment of spills and risk to environmentally sensitive areas and proximity to lease boundaries

erosion control of tailings discharge points

levee wall vehicular access and erosion control

a system of bunds and drains to collect any unplanned discharge/spillage and divert this to a holding area within the operational limits; and

metallurgical test work to understand the properties of material being processed and how it will behave as tailings material (i.e. beaching angle, porosity/permeability, water retention, rheology, acid sulphate soils).

6.8.2 Operation

The Modified Co-disposal (ModCoD) MBP will be deposited from an elevated position, via a maximum 20 m long discharge pipe. The ModCoD system has two discharge mixers and the tails discharge will be capable of being changed over on the run from one mixer to the other. The ModCoD mixer and discharge pipe arrangement are portable to enable movement as may be required during operations.

Water released from the stacked ModCoD mix is collected at the toe of the TSF embankments. This water is collected at the in-pit sump and pumped to the Reclaim Water Bin to be used for the MUP. Groundwater monitoring will be undertaken during operations to assist in the management of dewatering and reclaiming activities.

The storage rate of MBP within the TSF will be determined by the mining schedule.


6.9 Mine operations

An estimated 150 Mt of ore with an average grade of approximately 5% and comprising approximately of 48% zircon, 4% rutile and 28% ilmenite will be mined during the operations.

Ore will be mined and processed at a rate of approximately 10 Mt per annum (depending on oversize and clay percentage) using dry-mining techniques. A process flow chart of the mining and processing operations is provided in Figure 6.8.

6.10 Airfield

The airfield will be located on MPL111 as outlined on Figure 6.3.

The airstrip is 2.5 km in length with a 30 m wide runway and 30 m flanks (i.e. 90 m wide in total). The airstrip has been designed and constructed in accordance with Civil Aviation Safety Authority (CASA) requirements.

In addition to the compacted earthworks (i.e. the runway) the airfield also includes provision of a terminal hardstand area, open unlined drainage channels for stormwater diversion and collection as well as security fencing and navigational aids

6.11 Accommodation village

The mine worker accommodation village will be located on MPL111 as outlined on Figure 6.3.

The accommodation village includes the following facilities:

Ensuite accommodation for up to 150 operations staff.

Ancillary buildings (all pre fabricated) that include:

Administration building: incorporating a small store (for the sale of everyday items) and a IT server room

Training and conference facility Recreation room and air conditioned gymnasium Wet and dry mess Kitchen (including refrigerated containers) Ablution and laundry blocks Car parks: unsealed for up to 160 cars total Swimming pool: inground pool plus adjacent in ground swimming pool with associated fencing, paving, plant room and shade structures

6.12 Water supply and treatment system

Water supply for the mine will be sourced from the borefield located on MPL110. Details of the operational water treatment system are provided below. The location of the plant is provided on Figure 6.7.

Exploration Topsoil Removal Rehabilitation Overburden Removal

Recontouring Sand/clay Backfill Overburden Replacement

Ore Mining

Mining Unit Plant (MUP)

To feed preparation

Oversize to mining void

Fines separation

Spiral Separation

Thickener

Sand Tails

Mine Pit Dewatering

Thickened Clay Fines

Overflow

Flocculant

Process Water Dams

HMC

Truck to Port Thevenard

Magnetic Separation

Magnetic

Non-Magnetic

Secondary Mineral

Separation

ILMENITE

LEUCOXENE RUTILE ZIRCON MSP

SAND TAILS

ILMENITE

To Mine Void or Disposal at Facilities

at MSP Location

Recycle Water

MINERAL SEPARATION PLANT (MSP)

WET CONCENTRATOR PLANT (WCP)

To Mine Void or Tailings Storage

Facility

Water

Decant Water

Secondary concentration

ILUKA RESOURCES TYPICAL MINERAL SANDS PROCESS FLOW DIAGRAM

FIGURE 6.8

Ship to Existing Mineral

Separation Plan (MSP)


6.12.1 Water supply

Water supply for the project will be sourced from the borefield located on MPL110 approximately 32 km from the mine site (as outlined on Figure 6.1). Based on an extraction rate of 300 L/s, the annual extraction volume is estimated to be 9.5 GL/yr. The volume of water extracted from the borefield will decrease as efficiency in water recovery activities increase during operations (e.g. from the TSF and as outlined in Section 6.8.2).

A transfer pumping station has been established within the bore field which receives water from the borefield and pumps it via the water transfer pipeline to the process water dam and water treatment facilities on the mine site. The location of the station is outlined on Figure 6.2. The pumping station consists of:

two balancing tanks three transfer pumps and associated pipe work, valving and structure supports electrical MCC room, and surge mitigation equipment (pressure vessel or pump motor flywheels).

6.12.2 Water treatment

Details of the water treatment system components for the operations are provided below. The location of the plant is provided on Figure 6.7.

6.12.2.1 Reverse osmosis plant

Process water

Treatment of water on site will be undertaken via Reverse Osmosis (RO).

The RO treatment plant facilities include tanks (for raw water storage, and potable water) and a series of pumps and pipes. Tank configuration and storage capacity provides for approximately five days raw water storage.

The facilities also include a pre treatment plant as well as a pre dosing and pre filtration system a chemical pre treatment system, flow meters, treatment membrane systems membrane systems (including a chemical Clean In Place (CIP) treatment unit), pressure gauges, conductivity meters low/no/and overflow protection (including alarms), water sampling ports and instrumentation to allow automatic operation (with manual operations were appropriate). The plant production capacity of permeate is approximately 2L/s with approximately 8L/s wastewater (brine) discharge. The brine will be discharged to the 97ML process water dam (refer Section 6.12.3.1 below).

Wastewater (brine) from the plants will be recycled through the process water dam.

Potable water

A Potable Water RO WTP has also been installed. Once operational, wastewater (brine) from this plant will be used as feed water for the process water RO plant (detailed above).

During operations this plant will produce potable water to a quality that meets the disinfection and water quality requirements of the National Health and Medical Research Council’s “Australian Drinking Water Guidelines”.


Storage for approximately 400,000 L will be provided on site.

The location of the water treatment infrastructure is provided on Figure 6.7.

6.12.2.2 Demineralised water plant

A Demineralised Water Plant may be constructed as part of the water supply operations. Following treatment within the RO plant, water required for flocculent generation within the processing operations will be treated in the demineralisation plant. A storage capacity of 6ML will initially be established on site for demineralised water.

6.12.2.3 Neutralisation plant

Variation in the pH of water has the ability to affect flocculent behaviour; as a result a neutralisation plant may be established as part of the operational water treatment system.

A neutralisation plant may be located to the north of the waste transfer station and site of the temporary concrete batch plant as outlined on Figure 6.7.

6.12.3 Water storage

6.12.3.1 Process water storage

The process water storage facilities will consist of a return sedimentation pond and 97 ML main process water pond as outlined on Figure 6.7. Both ponds are lined.

The ponds are constructed from locally sourced soils, approximately 2–3 m deep with 1 in 3 slopes on walls and lined with a HDPE liner.

The process water pond is located at the head of an existing drainage line. During operations, runoff and process return water will be directed to the first sediment pond, with overflow into the main dam for reuse during operations.

6.12.3.2 Water supply tanks, pumps and pipes

The process water supply for the MUP is provided from a semi mobile tank. Water is supplied to this tank from the process water dam and from reclaimed tails water (via the process water dam). Having the mobile tank in the field decreases the pumping distance of the reclaimed water.

6.13 Waste storage and transfer station

A waste storage and transfer station is located within the main processing area on site. The location of the waste transfer station is outlined on Figure 6.7.

The area consists of a separate storage areas for waste streams that includes:

scrap metal empty containers putrescibles waste waste grease and oil


oily rags machinery filters tyres batteries electrical cable medical waste (first aid facilities) plastics – poly pipe etc. paper and cardboard office toners and printer cartridges chemicals used chemicals.

The final layout of the area will be determined following input from a waste services contractor and will consider compatibility of wastes, access requirements (including loading requirements) areas required for sorting, compaction and or bailing etc.

The storage site is securely fenced with storage areas for waste oils, chemicals, batteries etc to be bunded in accordance with EPA design guidelines. Surface water runoff will be diverted around the area and captured within the larger drainage system for the site processing area. Signs and labels will be provided within the area as appropriate.

6.14 Power generation and reticulation

6.14.1 Generation

A power plant is being established on site to provide operational power requirements of the mine. The power plant consists of ten (10) 950KW diesel generators (eight (8) running and two (2) standby) to meet an initial 7 MW Diversified Maximum Demand (years 1-8), stepping up to 9 MW for the last three years.

Details of the diesel generators are summarised in Table 6.3.

Table 6.3 Summary of diesel generator specifications

Parameter Details

Capacity per generator 950KW

Number of stacks per generator 2

Stack height 9-10 metres

Stack diameter 0.42 metres

Exit velocity 55.7 m/s

Temperature 420°C

A small sub station that supplies power to the various pumps associated with the mining operations also is being established on site. Discussion of the pumps required for operations are discussed in Section 6.15.

Figure 6.7 shows the location the power station within the plant processing area.

A power station provider will build own and operate the power station at the mine site.


6.14.2 Reticulation

The site power station will provide power at 11 kV. This shall be stepped up to 33 kV, for overhead reticulation to the remote borefield and village as outlined on Figure 6.2 with the mine being supplied by an 11 kV overhead reticulation system. Power to the process plant area will also be supplied at 11 kV however this will be underground reticulation.

Power reticulation infrastructure on site includes the following:

Connection between Generator Power Station and 11 kV Main Switchroom 11 kV Main Switchroom 11/33 kV Substation 33 kV Overhead Powerline to Borefield and Village 11 kV Overhead Powerline to Mine completed in three stages (Jacinth South, Jacinth

North, Ambrosia) 11 kV Underground services to RO Plant, Process Plant and Support Buildings Site Earthing System.

6.15 Supporting mine infrastructure

6.15.1 Ore and tailings pumping units and pipelines

6.15.1.1 Pumping units

Field pumping units are mounted on skids to facilitate relocation (as may be required) during operations.

The pumping units consist of:

ore slurry pumps tailings disposal pumps; and in pit pumps.

Overhead reticulated power lines will supply power to the ore slurry and tailings and disposal pumps with power to the in pit pumps to be fed via trailing cable.

6.15.1.2 Pipelines

All pipelines are HDPE. Mining hose will be used to provide flexible connection to the pump suction and discharge.

Pipelines on site consist of:

a single ore pipeline

three tailings pipelines – one pipe for the slurry mix of barren sand tails and thickened clay fines, one that will contain flocculent dilution water and one that will contain flocculent solution that is used to stabilise the tails mix within the mine void

a water recovery pipeline.


Booster pumps along pipelines are spaced accordingly to suit the ground conditions, pipe length and the characteristics of the slurry/solution that is being pumped.

Pipelines will be located in services corridors around the site as outlined on Figures 6.4 and 6. 5.

6.15.2 Operational fuel storage area

A fuel storage depot and self bunded fuel storage tank (or tanks) and pumping facilities will be established in the processing area and adjacent to the power station. The storage area within the processing area is located adjacent to the contractor workshop as outlined on Figure 6.7.

The design provides for a capacity of up to 450,000 L (equivalent to eight days standby requirement) to supply diesel for the power station and vehicle refuelling facilities. Fuel will be stored in appropriately designed and constructed tanks with the area being bunded in accordance with EPA Guidelines. Petrol storage areas will be locked and an inventory of fuel use maintained.

6.15.3 Process plant buildings

A contractors workshop shed approximately 36 x 25 m incorporating services, storage, office and a gantry crane is located adjacent the processing area. The area includes a gravelled parking lot for earthmoving equipment.

Transportable buildings will predominantly be used for mine site buildings with workshops being steel framed and steel clad. Size and layout of these buildings has been based on similar facilities at other Iluka mine sites, including Eneabba, Gingin and Murray Basin Stage 2.

Facilities include:

first aid building - fully operational first aid building with ablution, 18 m² ablutions – fully operational ablution laboratory – fully operational laboratory office building – this transportable building will be used for detailed design at Kent

Town in Adelaide and later transported to site crib room – fully functional crib room contractors workshop – 36 m x 25 m including facilities for maintenance of mining

equipment; and small equipment workshop using proprietary industrial shed and warehouse/store using

proprietary industrial shed.

Figure 6.7 shows the general layout of the process plant buildings.

6.15.4 Vehicle and equipment washdown facilities

A vehicle and equipment washdown facility will be established adjacent the contractors workshop and processing area.


The area is approximately 200 m2 in size and will includes an oil water separation unit.

Figure 6.7 shows the location of the wash down bay within the plant processing area.

6.15.5 Communications and information technology infrastructure

Information technology infrastructure consists of 16 x 2 Mbs PDH digital radio system (microwave), using two hops (source, repeater, destination).

As part of the works a 40 m communications tower has been established at the site of the main processing area.

The communications tower within the processing area is located adjacent (to the north) to the general office area as outlined on Figure 6.7.

6.15.6 Site access roads

Where possible, existing tracks have been used to access the site and associated infrastructure areas. Where required during operations, additional site access roads will also be established.

The location and layout of site access roads has attempted to separate heavy and light vehicles within a minimal footprint.

The access road to the HMC stockpile is via a way loop on sealed access road, all other site roads will be unsealed. Site access roads have been established as outlined in the MARP(Construction) using material from within the ML area and additional Extractive Mineral Licence (EML) areas approved as part of the project4. Use of material from these sites will continue during operations as part of road maintenance activities.

6.15.7 Site wastewater treatment facilities

Disposal of effluent from all on site wastewater treatment facilities (accommodation village and ablutions from processing area/worker facilities around the site) may include use of a lined and fenced evaporation pond, and re-use of the treated effluent (Class B wastewater) on the roads as a dust suppressant. Site wastewater treatment facilities will be established at the accommodation village (as detailed on Figure 6.3) and the processing plant.

The site treatment plants, disposal facilities and re-use options will be approved by the South Australian Department of Health.

4 Iluka has obtained the following EMLs as part of the project: EML6325, EML6326, EML6331, EML6331, EML6333

and EML6334. The ongoing use and management of these areas is subject to an approved Mining and Rehabilitation Plan in accordance with respective licence conditions.


6.16 Drainage design

The drainage system in and around the mine and associated process area will transfer stormwater shed from the roads and other areas either into the process water dam. The process water dam has been designed to meet the requirements of a 1 in 100 year event.

In areas where water from undisturbed areas may approach the mine workings, drainage systems have been established to divert or contain the water. The drainage systems predominantly involve the diversion of water around the workings into natural creek lines using bunds, channels and culverts as is applicable.

6.17 Drilling and blasting activities

6.17.1 Resource and geotechnical drilling

During operations there will be a requirement to undertake drilling within the mining lease to further define the characteristics of both ore bodies (Jacinth and Ambrosia). This drilling will be conducted for purposes such as grade control, resource definition, sterilisation and pit delineation. Figure 6.9 shows the identified heavy mineral reserve and the identified heavy mineral resource.

Drilling will be undertaken by contractors or in-house drill rigs. Each drill team will generally comprise three vehicles. The rigs will vary from track and truck mounted to Toyota mounted 4 or 6 wheel drive aircore rig drilling BQ or NQ sized (60 mm to 75 mm hole diameter) drill holes. The drill rig will be supported by a rod truck (which is generally a Mitsubishi Canter 4WD light truck) which will also carry approximately 1,200 litres of water and a fire fighting pump. A light vehicle will be used as a logging vehicle for the geologist.

Figure 6.10 below shows typical exploration drill equipment to be used.

In areas to be mined (i.e. within the Jacinth and Ambrosia pits), drill cuttings will be put back down the hole on a last out first in basis. In the case where all sample cannot be put back in the hole, excess material will be buried in a small pit greater than 30 cm in depth. Holes will be back filled to the surface with a plastic plug placed at approximately 1 m depth.

In areas located on the lease, but not directly within the planned mine pits, drilling on the lease will be undertaken in accordance with PIRSA Information Sheet M21.

Disturbance at any exploration site will be limited to the hole, the sample pit, access track and a vehicle turnaround point.


FIGURE 6.10 Typical exploration drill equipment

6.17.2 Water bore drilling

In addition to resource definition drilling, drilling for the installation of additional water supply bores (within the borefield) and ground water monitoring bores (within and around both the borefield and mine area) will also be conducted during operations.

Water bore drilling will be undertaken in a similar fashion to that described in Section 6.17.1 with drill holes cased and well screens installed to facilitate groundwater sampling.

Figure 6.11 details the indicative locations at which water monitoring bores (piezometers) will be located around the mine deposits.

6.17.3 Blasting

Based on the nature of the operations (mineral sand mining) it is not anticipated that blasting activities will be undertaken during operations. In the event that blasting is required (i.e. to remove calcrete from within the deposit area), blasting activities will be undertaken in accordance with relevant standards and statutory requirements (including gaining necessary approvals). Explosives will temporarily be stored on site prior to blasting activities. No long-term storage of explosives will occur on site.

6.18 Operations equipment

6.18.1 Equipment

During operations, a variety of equipment will be used.

FIGURE:(A4)ORIG: DRAWN: SCALE: DATE: DWG No:

235000

235000

6580000 6580000

6585000 6585000

6.9G.Jones DRB 24/02/09 170433v081:50,000

JACINTH & AMBROSIA RESOURCE OVERVIEW

PLAN A

N

CEDUNA

MAP AREA

TARCOOLA

LOCATION DIAGRAM

LegendHM ReserveIluka Tenements

HM ResourceYellabinna Regional Reserve

YELLABINNA REGIONAL RESERVE

0 1 20.5

Kilometers

0 200

Kilometers

MGA Coordinates, GDA 94

EL 3742

ML 6315

AMBROSIA

JACINTH

!A

!A

!A

!A

!A

!A !A

!A

!A

!A !A

!A

Lake Ifould

MB8

MB7

MB4

MB3

MB1

MB12

MB11MB10

MB9 S&D

MB6 S&D

MB5 S&D

MB2 S&D

230000

230000

240000

240000

6580

000

6580

000

Drawn By:

Date:

Client Ref:


A1


Z0 1,000 2,000

metres

Checked by:

15/09/08

1:55,000 at A3Jacinth-Ambrosia Mineral Sands Project

Groundwater Monitoring Bore LocationsMineral Lease

Figure 6.11

Revision:

-HDData Source: Geoscience Australia, DEH,PIRSA, Iluka

!

!

!

CEDUNA

ADELAIDE

COOBER PEDY

JACINTH-AMBROSIA

0 150 300

kilometres Z


NOT REQUIRED

APPROVED FOR AND ON BEHALF OFParsons Brinkerhoff Australia Pty limited

____________________DATE

____________________SIGNED

© Parsons Brinkerhoff Australia Pty Ltd ("PB") Copyright in thedrawings, information and data recorded in this document ("theinformation") is the property of PB. This document and theinformation are solely for the use of the authorised recipient andthis document may not be used, copied or reproduced in whole orpart for any purpose other than that which it was supplied by PB.PB makes no representation, undertakes no duty and accepts noresponsibility to any third party who may use or rely upon thisdocument or the information.NCSI Certified Quality System to ISO 9001

GIS File: J:\A302-ENG\PROJ\2100540_CADD_GIS\10_GIS\Projects\Drawings_Figures_Sketches\2100540_GIS_F110_A1.mxd

!A Monitoring Bore Locations

Plant Site Layout




Watercourse

Mine Layout

Waterbody



The final equipment and associated numbers will be determined as operations progress however it is anticipated that the following equipment will be used on site:

excavators front end loaders graders grid Rollers/vibrating rollers dozers scrapers/tractor scoops water trucks drill rigs crushers haulage vehicles (including dump trucks) delivery vehicles site caravans and accommodation units 2 and 4WD vehicles service vehicles fuel trucks/tankers; and delivery trucks.

6.19 Operations workforce and responsibilities

6.19.1 Workforce details

The operations workforce will be approximately 110 – 120 (excluding the mining and camp contractors).

The workforce will be made up of contractors and permanent Iluka staff and will be a combination of local, South Australian and interstate resources.

6.19.2 Operational responsibilities

The organisation structure (excluding the mining and camp contractor) during operations is detailed in Figure 6.12.


FIGURE 6.12 Operations organisation chart


6.20 Site preparation

6.20.1 Vegetation, soil and overburden removal

The vegetation on site is largely composed of a light covering of the Western Myall trees to a height of approximately 7 m plus areas of Mallee on sand dune and chenopods in low near flat areas.

Clearing on site will be undertaken progressively by a dozer and pushed to marginal stockpiles or transported for use in rehabilitation activities (where possible).

All topsoil will be stripped prior to high impact ground disturbance works and stockpiled for rehabilitation. Topsoil from different vegetation communities will be maintained in two separate stockpiles, one for the very distinct mallee woodland and the other for the chenopod shrubland and myall woodland with chenopod understorey.

All vegetation, soil and overburden removal will be carried out in accordance with the Rehabilitation Management Plan and Mine Closure Plan.

Topsoil may be cleared by tractor scoops (or grader scraper for areas such as the process area), commonly utilised in existing Iluka operations. Tractor scoops are ideal for the clearing of topsoil because of their high accuracy and low foot pressure. Accuracy is provided by laser control and low cut depth and the foot pressure results from low vehicle weight across the dual tyre configuration.

Overburden (generated throughout the mine operations during pit development) will be mined by a twin drive scraper fleet. Due to the soft nature of the upper levels of overburden it is expected that in-pit haul roads will require sheeting with screened oversize. A support fleet of ripping dozer, water cart, and grader will be used for the overburden operations and, in part, for the topsoil operations.

6.20.2 Overburden use

Approximately 370,000 bcm of ‘brown loam’ overburden removed from the test pit has been used for the construction of the central discharge spine of the TSF.

Overburden not required for construction of the TSF spine has been located in a stockpile area to the north west of the process water ponds as outlined on Figure 6.4.

6.20.3 Stockpiling

Subject to operational constraints, stockpiling of soils will be kept to minimum, with soils being directly returned to rehabilitation areas where possible.

Topsoil from different vegetation communities will be maintained in two separate stockpiles (as outlined above).

To optimise the balance between the clearing footprint required for stockpiling, versus maintenance of soil quality, the following thresholds for stockpile height will apply:


Topsoil (0–50 mm): maximum of 2 m high. Stockpiles will be separated by vegetation association. No traffic will be permitted on topsoil stockpiles once complete.

Subsoil (50–200 mm): maximum of 4 m high. Stockpiles will be separated by vegetation association.

Overburden: maximum of 10 m high. Yellow sand, brown sandy loam and red loam will be stockpiled to facilitate rehabilitation and are likely to be stockpiled separately.

Stockpile locations have been designed to facilitate the shortest practicable haul distance when removal is taking place and minimise vegetation clearance.

6.21 Closure and rehabilitation

6.21.1 Closure

Closure and decommissioning activities will be undertaken following the completion of operations. Decommissioning activities will involve the removal of:

above ground water supply infrastructure (subject to negotiations with the landowner and regulatory agencies)

worker camp and ancillary buildings power supply and distribution hydrocarbon and chemical storage areas communications infrastructure solid waste management.

Closure activities will also include the reshaping and contouring of the site (including the TSF and mine pits). Further details of the activities associated with mine closure are detailed in the Mine Closure Plan outlined in Part I of this MARP(Ops).

6.21.2 Rehabilitation

In addition to removing infrastructure, the areas disturbed during operations will be rehabilitated to recreate a safe, stable, vegetated landform that is consistent with surrounding conditions and allows the re-establishment of biodiversity conservation, passive tourism and traditional Aboriginal land uses.

Further details regarding the approach rehabilitation are contained in the Rehabilitation Management Plan contained in Part I of this MARP(Ops).

Documents

PART F: Operational details - Iluka Resourcesops)_part-f_operational-details.pdf · PART F: Operational details . Jacinth-Ambrosia Mineral Sands Mining Project — Mining and Rehabilitation