Chapter 3 Final
Chapter 3 Final
Page i
Table of Contents
3 Project Description .................................................................................................... 3.1
3.1 Site Location .................................................................................................................... 3.1 3.2 The Tailings Reserve ....................................................................................................... 3.2 3.3 Mining Process................................................................................................................. 3.4
3.3.1 3.3.2 Mining of Kingamyambo Tailings Deposit ........................................................................... 3.5 Mining of Musonoi Tailings deposit...................................................................................... 3.6
3.5 Sulfuric Acid Plant .......................................................................................................... 3.12 3.6 Infrastructure .................................................................................................................. 3.12 3.7 Waste Neutralisation ...................................................................................................... 3.15
3.7.1 3.7.2 3.7.3 3.7.4 3.7.5 Solid Tailings Disposal ....................................................................................................... 3.16 Aqueous Effluent................................................................................................................ 3.22 Treated sewage ................................................................................................................. 3.23 Solid waste management .................................................................................................. 3.23 Other waste management ................................................................................................. 3.24
ESIA Ch 3
April 2008
SRK Consulting
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3.10 Energy use ..................................................................................................................... 3.33 3.11 Security and communications ........................................................................................ 3.34 3.12 Employment ................................................................................................................... 3.39
3.12.1 Employment Policies.......................................................................................................... 3.41 3.12.2 Emergency medical evacuation ......................................................................................... 3.43 3.12.3 Occupational Illness/Disability ........................................................................................... 3.44 3.12.4 Employment during construction ....................................................................................... 3.44
ESIA Ch 3
April 2008
SRK Consulting
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List of Tables
Table 3.1 :Geographical co-ordinates of the Tailings Exploitation Area ........................................ 3.1 Table 3.2: Minerals observed in orebody (tailings) including formula and relative abundance .... 3.3 Table 3.3: Reserve details for the Kingamyambo and Musonoi Tailings ....................................... 3.4 Table 3.4: Annual consumption of chemical products ................................................................ 3.11 Table 3.5: Level of metal concentrations used to categorize mine tailings as low or high risk .... 3.16 Table 3.6: Results of Acid-Base Accounting test work on Tailings and Rock Dump samples..... 3.19 Table 3.7: Classification of rock type by acid generating potential .............................................. 3.19 Table 3.8: Expected flow in the Musonoi River as it enters the Kolwezi tailings as m3/month ... 3.26 Table 3.9: Discharge of water through the Nzilo spillway (from Kasobantu dam) as m3/month . 3.26 Table 3.10:Comparison of water drawdown at the Manga ore body under different transmissivity rates ............................................................................................................................ 3.28
ESIA Ch 3
April 2008
SRK Consulting
Page iv
List of Figures
Figure 3.1: Figure 3.2: Figure 3.3: Figure 3.4: Figure 3.5: Figure 3.6: Figure 3.7: Figure 3.9: Location of the Kingamyambo and Musonoi tailings deposits and proposed infrastructure ......................................................................................................... 3.51 Mining Schedule for Kolwezi Tailings Project indicating the source of tailings to be processed.............................................................................................................. 3.52 Schematic diagram of mining of the Kingamyambo Tailings Deposit ................... 3.53 Process Flow Diagram .......................................................................................... 3.54 Plant Layout .......................................................................................................... 3.55 The location of the alternative quarry sites investigated ....................................... 3.56 Location of potential limestone quarry .................................................................. 3.57 Discharge points from the tailings decant pond and stormwater control dam ....... 3.59
Figure 3.8: General arrangement of the tailings dam in the KMT Concession area ............... 3.58 Figure 3.10: Observed hourly discharges from Kasobantu Dam ................................................ 3.60 Figure 3.11: Spillages from return water dam ............................................................................. 3.61 Figure 3.12: Conceptual wet season water balance for Kolwezi ................................................. 3.62 Figure 3.13: Conceptual Dry Season Water Balance for Kolwezi ............................................. 3.63 Figure 3.14: Road and rail links, Lubumbashi to Kolwezi.......................................................... 3.64 Figure 3.15: Possible transport routes to and from Kolwezi ...................................................... 3.65 Figure 3.16: Fencing, location Construction Camp and Management Camp ............................ 3.66
ESIA Ch 3
April 2008
KMT plans to re-treat the tailings deposited on the Kingamyambo tailings dam and in the Musonoi River by previous mining operations. These tailings still contain copper and cobalt at an average grade of 1.49 % copper and 0.32 % cobalt. The original Definitive Feasibility Study (DFS) was undertaken for KMT by a joint venture between Murray and Roberts and GRD Minproc, under the management of Added Value Engineering Consultants (AVEC). Subsequently, First Quantum Minerals (FQM) has re-engineered some aspects of the project and these changes are reflected in the project description below. The engineering design for the project has been informed by the environmental and social baseline data collected by SRK. This information has provided input to the original siting and design of facilities, and mitigation measures have been developed in conjunction with the engineering ream. A number of alternatives have been investigated and those relevant to the current project are discussed in Chapter 4. The environmental design criteria (e.g. the limits for air, water and noise pollution) set out by the DRC government and the World Bank Group have also been provided to the engineering team so that these requirements have, as far as possible, been incorporated into the design of the project rather than being added on afterwards. Many of the measures designed to mitigate potential management of environmental and social impacts have been incorporated into operational controls to ensure that they become routine activities. Other measures have been developed into a series of Management Plans included as appendices to the Environmental and Social Management Plan (ESMP), found in Volume 3 of this report.
3.1
Site Location
The KMT concession area (Tailings Exploitation Area, TEP), where re-processing operations will be conducted, is located north of Kolwezi town and north-east of and adjacent to the existing mine workings. The TEP was awarded for an initial period until May 2022 and is automatically renewable. The licence area covers 6,100 hectares and extends 13.75 km from north to south and up to 9 km from east to west. The concession/development area occupies gently undulating ground that slopes gently to the Musonoi river course. A range of low hills borders the area to the north. The geographical co-ordinates of the area are included in Table 3.1 below. Table 3.1 : Geographical co-ordinates of the Tailings Exploitation Area
Points Degrees
A B C 25 25 25
Longitude Minutes
24 26 26
Latitude Seconds
30 30 30
Degrees
10 10 10
Minutes
35 35 36
Seconds
00 00 00
G H I J K L M N O P Q R S T
25 25 25 25 25 25 25 25 25 25 25 25 25 25
27 27 27 25 25 26 26 27 27 24 24 23 23 24
30 00 30 30 00 00 00 00 00 30 30 00 00 30
10 10 10 10 10 10 10 10 10 10 10 10 10 10
41 41 42 42 41 41 41 41 39 39 38 38 36 36
30 30 30 30 30 30 00 00 00 00 00 00 00 00
3.2
malachite), traces of Cu-Co-carbonate (probably Kolwezite, (Cu, Co) 2 (CO3) (OH) 2), Co-hydroxide (heterogenite), Cu-phosphate (probably pseudo malachite), and Mn-Ba-Co-Cu-hydroxide (probably romanechite (Ba, H2O) (Mn4+, Mn3+) 5O10. Heterogenite can contain Cu, Zn, Fe and Mn. The concentration of Cu-carbonate is higher than that of Cu-phosphate. The Cu- and Co- minerals occur either as coarse granular particles (up to 200 m) or as a network-like texture intergrown with quartz. In addition, Cu-sulfides (<30 m), predominantly covellite and chalcocite/digenite, occur either liberated or enclosed in Cu-carbonate. Fe-oxide/hydroxide is a minor mineral and can contain Cu and, to a lesser degree, Co. Sphalerite is the main sulfide and occurs liberated. It is believed to be a contamination phase, possibly originating from other mine dumps or treatment facilities (i.e. the now decommissioned UZK Zinc plant adjacent to the Musonoi River). Table 3.2: Minerals observed in orebody (tailings) including formula and relative abundance
Minerals Formula Residue Grain size (m)
<30 <20 Up to 100 <10 to 150 <100 Liberated or locked in quartz Liberated or associated with quartz With heterogenite Liberated or associated with quartz Liberated or locked in quartz or Cucarbonate Liberated or locked in quartz or Cucarbonate Liberated + integrown with quartz Contains Cu and lesser Co, Mg, Si, P +/- S Can contain: Cu, Zn, Al, Si, P, Mn, Fe
Mineral Association
With mica With quartz
Comments
Apatite Barite Chlorite Co-(Cu-Fe-) oxide/hydroxide (heterogenite) Cu-carbonate (malachite?) Cu-Co carbonate (kolwezite?) Cu-phosphate (pseudomalachite) Cu-sulfide (chalcocite/digenite)
CoOOH
Cu2CO3(OH)2
Trace
Trace Trace
<50 <100
Cu2S
Trace
<30
Cu-sulfide (covellite)
CuS
Trace
<30
Fe-oxide/hydroxide
Fe2O3/FeOOH
Minor
Feldspar Mica
(Na,K)AlSi3O8 K2Al4Si6Al2(OH)4O20
Trace Trace to
Trace
<80
Usually associated with quartz Predominantly liberated Liberated locked in quartz Liberated Liberated and locked in gangue
SiO2 TiO2
Major Trace
Sphalerite Zircon
ZnS ZrSiO4
Trace Trace
<80 <75
(FEED 1-7 2001). Major:>20wt-%, minor: 1 to 20 wt-%, trace:< 1 wt-% Source: AARL Applied Mineralogy Draft Report , 2001. The reserve details for the Kingamyambo and Musonoi Tailings are indicated below in Error! Reference source not found.. The volumes, tonnages and percentage copper and cobalt within the tailings are provided. Table 3.3: Reserve details for the Kingamyambo and Musonoi Tailings
Volume Resource
Kingamyambo Musonoi
Category
Measured Measured Indicated Total Totals
(m3)
31,516,909 50,681,440 2,333,871 53,015,311 84,532,220
Tonnes
42,316,297 67,424,650 3,061,698 70,486,348 112,802,64 5
Densit y
1.34 1.33 1.31 1.33 1.33
Tonnes Cu
563,094 1,070,337 42,968 1,113,305 1,676,399
% Cu
1.33 1.59 1.40 1.58 1.49
Tonne s Co
130,898 220,572 11,780 232,352 363,249
% Co
0.31 0.33 0.38 0.33 0.32
3.3
Mining Process
The Project will be implemented in a series of phases. These are: Operational Phase 1: Hydraulic mining of the Kingamyambo and dredge mining of the Musonoi. Operational Phase 2: draining and hydraulic mining of the Musonoi as indicated in the Mining Schedule on Figure 3.2.
The average production rates anticipated for the initial phase of the project are as follows: Plant throughput: Copper output: 2.4 million tpa 35,000 tpa
Cu Metal
Co Metal
Co Hydrox
Acid Plant
35ktpa
70ktpa 70ktpa 105ktpa
14ktpa 15ktpa
7ktpa
14ktpa 5ktpa
1 x 600tpd
unchanged unchanged additional 600tpd
Case 1
Dec 2011
Case 2
Mid 2012
Hydraulic mining of the tailings deposited on both the Kingamyambo tailings facility and in the Musonoi River will be carried out using high pressure water monitors (although in the first four years mining of the Musonoi will be by dredging). The amount of tailings from each source might vary between the wet and dry seasons, although it is intended to mine both deposits simultaneously to provide the correct grain size distribution for the process and minimise impurity excursions from, principally, Musonoi. Water from boreholes will pumped on the mining site, into a reservoir. Water is extracted from the reservoir by a series of pumps. These high pressure pumps deliver into a pipe that reticulates the water around and onto the tailings areas to be mined. This pipe feeds the monitors. Recovery of the tailings will take place 24 hours a day 365 days per year, utilising three 8 hour shifts and a relief shift. Four monitors will be operated simultaneously and will be manually controlled, although the production tonnage could be obtained from just one. However operating a single monitor would limit any blending potential. The tailings will be blended to achieve the desired grade and particle size distribution. .
Monitored tailings slurry will gravitate to a pump station for transfer to the treatment plant. The slurry, consisting of tailings and water, will flow over a finger screen to remove coarse debris and vegetation, and is then pumped over a vibrating screen to remove fine debris and any oversize material discharging into a surge tank. From the surge tank at the tailings dam the slurry is pumped approximately 8 km to the treatment plant. As mining operations will be continuous, the working areas will be floodlit at night using portable lighting equipment. Following the removal of the Kingamyambo tailings deposit, the potential for further open pit operations will be determined. An exploration programme will be initiated across the concession in 2008 and 2009.
Once the dredgeable portion has been exhausted after approximately 4 years, the reclamation method will be changed to hydraulic monitoring once the central part of the deposit has dried out following diversion of the Musonoi flow around the operating areas. This will require the utilization of two transfer stations along the west side of the dam, with monitored slurry gravitating from the dam to the station. To enable complete recovery of the tailings, the Kasobantu dam will be partially drained and run off waters running into the Musonoi from the Kakifuluwe, Kanamwamwa and other tributaries diverted around the operating areas. These tributaries, along with the main Musonoi river flow, will be diverted in a river diversion channel along the side of the Musonoi valley. No detailed design calculations have yet been made but the channel will have to be sufficiently large to accommodate the high flows experienced in the Musonoi River during the rainy season. Initial hydrological calculations suggest a channel of about 50m wide (at ground level) and 4 m deep and able to withstand the erosive forces of the high water flows. These studies have been deferred to take place during the Musonoi dredging operations. On completion of mining, the Kasobantu Dam will revert to a water reservoir. This will be larger than the current Kasobantu Dam as most of the tailings will have been removed from the valley.
3.4
Processing
The tailings are treated by a hydrometallurgical process. As they have already been treated (historically) in a conventional flotation plant to extract copper and cobalt, they are already milled to a variety of particle sizes, ranging from < 5m to 200 m. Extraction of the residual metals will therefore be by a leaching process followed by solvent extraction (SX) and electro-winning (EW) to produce cathode copper of 99.9%, and cobalt hydroxide. In time, cobalt metal of 99.8%, purity will be produced. The details of this process are outlined below. The overall process is illustrated in Figure 3.4.
Spillage from the CCD area is collected in a sump and returned to the copper leach thickener or closest CCD thickeners. The final CCD underflow is pumped to residue neutralisation where it is neutralised with lime to pH 8.5 and discharged to the tailings impoundment.
The electrolytic cells are equipped with Pb-Ca-Sn anodes and stainless steel cathodes. Copper is deposited onto the cathodes over a 6-7 day period. Copper is stripped from the stainless steel blanks and the copper sheets are bundled and stored for shipment. The spent electrolyte from the EW cells is returned to the main circulation tank. From here the bulk of the liquor is recirculated to the cells and a portion is forwarded to the primary copper SX as spent electrolyte for organic stripping.
Management System documentation produced for the site once Construction commences. Table 3.4: Annual consumption of chemical products 1
Quantity Tpa or m3/a
Flocculant Sulfur Burnt Lime Copper Extractant: Acorga Bentonite clay Guar Diluent: CuSX Limestone Zn/Co extractant: Cyanex 272 Diluent: Zn/Co SX Sodium Hydroxide Flake Butyl Hydroxytoluene Nitric acid Gelatine Anthracite Garnet Activated Carbon IX Resin Purolite S950 Diatomaceous earth Vehicle Fuel 37 105,000 litres/annum 10 10,000 litres 545 31,713 2,105 84 25 8 378 24,801 42 420 21,630 4.9 103 13 55 104 45 8,000 175 320 10 2 1,250 4,000 110 820 1,800 5 20 6 10 20
Source: D vd Westhuizen The storage of various substances will be in line with good international practice and in accordance with MSDS recommendations. Allowance will be made in each circumstance for the containment and management of spills, with bunded areas specific to each section of plant being designed to sound engineering principles to contain ad hoc inadvertent spills and catastrophic tank rupture of the largest tank in that given bunded area.
presented in Figure 3.5 shows designated areas for limestone, sulfur, reagents, organics and a main store, as well as copper and cobalt product storage areas. Liquids will be stored in areas with suitable bunds and drainage channels for capture of accidental spills. Detailed procedures will be developed according to the MSDS and Occupational Health and Safety criteria detailed in Annex B (Health and Safety Plan) This will also contain details of the emergency procedures for dealing with a variety of different types of incident.
3.5
3.6
Infrastructure
Figure 3.5 shows the proposed layout of the plant site. The following infrastructure will be developed as part of the proposed project: A new tailings dam for the tailings that have been retreated A process plant including: o o o o o o o o o o An electrode boiler, A sulfur burning acid plant, Copper extraction plant, Cobalt extraction plant, Limestone milling plant Offices and workshops, Finished product storage, Spares storage, Parking, Hardstanding, and
- Pipeline to take slurry from the Musonoi tailings site to the plant - Pipeline to take slurry from the Musonoi tailings site to the plant - Pipeline to take the neutralised retreated tailings to the new tailings dam; - Pipeline to take the neutralised aqueous effluent to the Luilu river; - Pipeline to take the tailings decant pond water to the plant; - Pipeline to take the tailings decant water via the tailings decant pond to the tailings reclamation area at Kingamyambo; - Pipeline from the well field to the tailings reclamation and plant sites; - Power line from the substation to the plant site; - Sealed gravel roads around the site; - Dirt track from the plant to the tailings dam; - 180 km access road from Zambia to Kolwezi, plus border post The following power lines have been identified: The main incomer from the Repeter Oest Substation to the main switchyard located at the plant site; And a feeder to the borehole well field from the transformer at Repeter Ouest.
Smaller transmission lines identified are: to the tailings dam from the plant site / switchyard at the plant; to the aggregate quarry to the plant site / switchyard at the plant ; to the tailings reclamation at Musonoi from the plant site / switchyard at the plant; To the tailings reclamation at Kingamyambo from the plant site / switchyard at the plant.
Other infrastructure associated with the project includes the following: A tie-in to the Kolwezi Repeter Ouest substation; Switchgear at the plant site and other electrical installations; Water supply boreholes; Sewage treatment system, of a masonry septic tank and filter field type; Mobile equipment; Fuel and reagent storage; Telecommunications masts etc;
The infrastructure will remain on site for approximately 23 years (subject to any plant expansion which would reduce this term), after which any necessary decommissioning will take place. The concession area is 6100 ha and stretches 13.75 km from north to south varying from a minimum of 0.5 km to 9 km wide from east to west. The servitude widths for access to the plant vary from 21.5m (pipeline, powerlines and main road) to 40 m (railway, road, pipelines and powerlines). The proposed facilities will have the following approximate footprint areas (given in hectares and kilometres): Tailings Dam: 420 ha (initially 50 ha) 2 x 2.5km Plant Site: 60 ha 800 x 1000m plus 300 x 600m for lime facilities Length of proposed gravel roads to and from site: 7 km Length of access road to site: 8.95 km Length of gravel roads around site: 4.36 km Length of gravel road to the existing quarry: 5.51 km
(The need for additional effluent related infrastructure once cobalt metal is produced needs to be clarified by FQM when it has resolved the metallurgical flowsheet for that operation, started to schedule in 2011.) During mining operations the tailings deposits at Kingamyambo and Musonoi will be removed, potentially leaving these areas available for other uses following reclamation. Pressures on land use in the Kolwezi area are acute and while a final land use has not been defined at this stage, this will be reviewed through the project life and discussed in conjunction with local communities and the municipal authorities. The Musonoi River will ultimately form an open water dam, the size of which will depend on the height of the final spillway. The new tailings dam (420 ha) will remain in perpetuity. It is planned to remove the plant; but if an alternative use can be made of the site, such as an industrial development, the road, rail, power and water links will remain in place for the benefit of future users. The areas to be developed will be cleared of the secondary scrub vegetation that predominates in the area, and where possible this will be composted for future use in reclamation. The sites selected for the plant site and tailings dam are relatively level, and little cut and fill is envisaged. Quarries
Quantum Minerals, and will be used exclusively during the construction phase to provide hard core for foundations, gravel for a number of applications and sand for acid-resistant concrete at the plant site. A temporary quarry licence has been applied for, this is for a period of one year and can be extended for one year. This will cover the requirements of the construction phase. Tests on the suitability of this material for construction purposes indicated that dust production during construction could be high. Borrow pits The precise requirement for borrow pits for the project has not yet been identified either in terms of location, size, type of material or duration of operation. The following are the potential project uses of borrow pit and/ or quarried material: Fill for the plant site; Aggregate for construction of the plant site and other permanent structures; Starter dam wall for the tailings dam; Dam wall for Storm Water Dam at the plant site.
Of these the largest requirement is for the starter wall for the tailings dam. This material will be taken from under the footprint of the tailings dam as far as possible, or from other locations close by. Test work is being carried out on laterite and waste rock in the area to determine their suitability for all or some of these uses. Limestone The SX EW process needs considerable amounts of lime and limestone. This will be bought commercially for the initial phase of operations. During this time the possibility of using the limestone deposit at Lusumbi, for which RPM owns an exploration licence for limestone, at some distance from Kolwezi, will be investigated, along with other supply sources such as existing sources in Zambia close to FQMs other operations. The location for this potential limestone quarry is shown in Figure 3.7. Geological investigations are underway to determine the suitability and quantity of material which may be available. One drill hole has been put into the deposit. Should the limestone prove suitable, the necessary environmental and social impact assessment will be carried out in accordance with the legislative requirements of the DRC and also the requirements of the World Bank Group, in line with First Quantum Minerals policies. Initially a limestone mill will be installed at the plant site, but for the production of cobalt metal, quantities of slaked lime will also be required so a lime burning plant will be added.
3.7
Waste Neutralisation
In addition, a small waste stream (2,500 m3/d) will be produced from the reflux step in the process flow sheet, which will be incorporated into the tailings slurry liquor.
(2007) (mg/l)
Calcium Magnesium Sodium Sulfate Chloride Total salts dissolved NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS NS
(mg/l)
(mg/l)
Arsenic Barium Boron Cadmium Chromium, total Chrome VI Copper Nickel Nitrates nitrites Mercury Fluoride, total Lead Iron, total Selenium Uranium Zinc +
1.00 NS NS 0.01 NS
0.30 0.50 NS
NS NS 1000.0
0.3 0.5 NS
(2007) (mg/l)
Total Cyanide WAD Cyanide 1.00 1.0 1.0 0.5
(mg/l)
(mg/l)
<0.50
<0.50
Analysis of test work tailings indicates that the metal concentrations, with the exception of copper, in both the tailings solids and the solution are below the limits specified in the DRC Mining Code and therefore classify as Low Risk. The copper in the TCLP extract from the tailings solids exceeds the 0.3 mg/l limits indicated in Low Risk tailings and the IFC Mining Sector discharge guidelines. The DRC, however, sets relaxed limits for copper in areas where copper is mined specifically, in view of the naturally high background levels of copper in these areas. Comprehensive analyses for volatile organic content of the tailings were carried out with the result that all values were below detection limit. Results of geochemical test work on existing sediments Representative composite samples of waste rock and tailings from existing mining deposits within the KMT Project area were taken and submitted to an accredited laboratory in Johannesburg for geochemical test work. The initial objective of this test work was to determine whether any of these existing mining deposits contained sufficient sulfide to generate acid on oxidation. If so, in the absence of sufficient neutralising material such as calcite or dolomite, the acid formed may have the potential to dissolve heavy metals from mineralised sediments leading to contamination of the surface or ground water bodies affected. The samples were therefore subjected to acid-base accounting (ABA) using the modified Sobek methodology. Results are presented below in table 3.6.
AP:NP Ratio
Calculations on Total Sulfur instead of Total Sulfide are often too conservative Acid Potential divided by Neutralising Potential Net Neutralising Potential is Neutralising Potential minus Acid Potential
The ABA results tabulated above show: none of the sediment samples from the KMT Project area contain sufficient sulfide to generate significant acid on oxidation; all of the samples from the KMT Project area show relatively high neutralizing potential; none of the samples from the KMT Project would be classified as acid generating;
Classification of the tailings as Low Risk A number of samples of tailings produced during metallurgical test work on bulk samples taken from the Kingamyambo Tailings at Kolwezi have been subjected to classification tests, including laboratory leaching for metals and volatile organics and acid-base accounting, as reported in the sections above. In all cases the results confirm the classification of the tailings material as Low Risk, as defined in Annexure XI of the DRC Mining Code. Tailings storage facility (TSF) design
storage facility would require a capacity of approximately 87 million m3 at an in-situ dry density of 1.28 tonnes / m3. The dam will be developed to a maximum elevation of 57 m above the datum level of 1390 metres above mean sea level (mamsl). At current production levels the new tailings will be deposited at about 2.4 million tpa solids. Based on preliminary test work the tailings material is expected to have an average permeability of approximately 1 * 10-5 to 1 * 10-6 cm/s and will restrict the rate of seepage accordingly. A geotechnical investigation has been done and used in the design of the tailings dam. This works, as well as borehole drilling logs in this area show that much of the underlying material is strongly weathered. Recent trends in the USA would be to consider the lining of the tailings dam to prevent seepage draining into the underlying soils and shallow aquifers. In this case the decision has been taken not to line the 420 ha tailings dam on the basis of the following considerations:
The DRC Mining Code stipulates that tailings dams that classify as Low Risk do not require a barrier between the dam and the underlying soils and ground water. The US Bureau of Mines and the US EPA have adopted the Bevill Amendment which classifies the solid wastes from primary copper processing (amongst other mining activities) as high volume-low toxicity wastes exempt from hazardous waste classification. These wastes conform with the US EPA criteria requiring absence of:
- corrosivity - reactivity - ignitability - Extraction toxicity.
The US states of Arizona, Utah, Texas and New Mexico specifically exclude the solid wastes from primary copper processing facilities from their hazardous waste regulation. The question of lining specific tailings dams has not yet been resolved in the European Union, and is currently under investigation. Preliminary testwork on the KMT tailings indicates that the sediments are likely to drain slowly and retain approximately 34% of the slurry water as interstitial water, limiting their capacity to consolidate. The imposition of a basal liner is considered to impede drainage and consolidation further and possibly reduce the stability of the tailings dam.
Tailings storage facility (TSF) layout The conceptual layout of the Tailings storage facility is shown in Figure 3.8 and incorporates the following:
As the material will be hydraulically deposited the material will be saturated. Therefore, in order to control the stability of the dam, an underdrainage system will be provided. The underdrainage system will consist of both a toe drain and an elevated blanket drain. The drains are intended to promote the drying and consolidation of tailings deposited over them and also to prevent the build-up of elevated phreatic surfaces within the TSF. The drains will be constructed of graded drainage stone and sand, perforated drainage pipes and geofabric. Drain outlets will be constructed at regular intervals and will discharge into the solution trench that will be constructed around the perimeter of the facility. The solution trench will in turn be pumped into the tailings decant pond. The tailings delivery system will comprise a delivery line feeding a spigot pipeline with spigots at. appropriate centres The decant solution will be reclaimed directly from the pool in the early phase. This will be via a trench and pump system located on the side of the hill noting that the TSF will not in the early phase have a constructed western wall, as this is provided by the hill upon whose side it is constructed. As the dam level rises and a western wall is required the decant will be revised to a pontoon system. The decant solution is pumped to the plant for re-use with excess discharged to the Luilu River. The dam wall on the northern side will be equipped with a spillway to prevent any overtopping. A runoff diversion trench (to the west of the tailings dam) which will collect and divert clean runoff from up-gradient of the facility until the TSF development exceeds this requirement.
TSF construction The tailings impoundment starter wall will be constructed over the full, final, footprint of the dam. Ongoing wall raising during operations will be by cycloning and/or raising with fill as required. The water retention works, including the tailings dam it self and the storm water control dam is designed to cater for the 1:100 year return period flood leaving a 2 m freeboard. It is anticipated at this stage that the facility will be sited more than 200 m from the nearest natural high water line. It will therefore be well away from any potential area of flooding. The TSF consists of the following works:
slopes of the wall around the tailings dam are 1V:1.5H and IV: 2.5H respectively. The outer side slopes of the wall around the perimeter of the dam are to be covered with topsoil and vegetated. Toe drains and blanket drains Toe drains with a width varying between 3.0 m and 5.0 m will be installed on the inside perimeter of the starter walls. The inner blanket drain is 8m wide and has been constructed on elevated platforms, 2.0 m above the natural ground level.
Catchment paddocks Catchment paddocks are to be constructed on the perimeter of the TSF. These will have an average height of 1 m.
Solution trench A solution trench is to be constructed along the perimeter of the TSF. The solution trench has a base width of 1m and side slopes of 1V:1.5H. The solution trench will convey water collected by the subsoil drains and the water will be pumped to the top of the TSF. In order to minimise seepage losses to the foundation as well as to protect the solution trench from erosion, the trench will be concrete lined. The depth of the solution trench varies according to the topography from a minimum of 1m to a maximum of 3m.
3.7.2
Aqueous Effluent
This issue is described in detail in Chapter 4. Form of effluent The aqueous effluent stream from the KMT process plant is derived from the reflux circuit and will be neutralised with lime to a pH of about 10.5. It will contain the constituents listed below. In the flowsheet selected, the stream is produced at 105 m3/h (about 2,500 m3/d) containing total dissolved solids (TDS) of about 11,000 mg/l, made up as follows: Sodium Calcium Magnesium Sulfate Nil 600 mg/l 1,700 mg/l 8,400 mg/l
Aqueous effluent disposal Neither the DRC Mining Code, nor the IFC effluent discharge guidelines, imposes a limit on dissolved salts discharging to watercourse. FQM has confirmed that this effluent stream will form part of the tailings slurry liquor, whos overall TDS will be about 8,000 mg/l dominated by calcium and magnesium sulfates with traces of insoluble copper and cobalt. This option has been selected above the alternative of discharging this effluent stream into the Luilu River as previously proposed. The river discharge had been justified by the arguments that the Luilu River has been shown to be severely degraded as a result of decades of mining waste discharges, which, however, are diluted to insignificant levels when the Luilu flow merges downstream with the high flow rates in the Lualaba River. However, during the annual wet periods there will be far more water in the tailings pool than can be returned to the plant. This water cannot be stored on the dam for capacity and stability reasons, and must therefore be discharged, at rates peaking at an estimated 1300 m3/h at TDS values between 3000 and 8000 mg/l. The proposal is to discharge this surplus to the Luilu River during wet periods, when it is assumed that it would be diluted by high flows in the river, with no further impact on the already degraded watercourse. Blending estimates indicate that the effect of the Luilu River flowing into the Lualaba River below Nzilo Lake would have a negligible impact on the Lualaba TDS.
waste. The waste will be compacted and covered with suitable material at the end of each working day to prevent windblown litter and to control vectors. The lined waste site or hazardous cell in landfill will be used for solid and organic hazardous waste like drums used to transport hazardous materials, wastes containing acid, oils, greases, medical waste etc.
3.8
Water Management
The tail of the second hydrograph indicated on the 27 August 2004 is an anomaly as the hydrograph falls within 1 hour, which is highly unlikely. It is possible the float (element of the continuous monitor) got stuck in the pipe and dropped from its original height on the 1st September. A more likely scenario is that the tail of the hydrograph was similar to that of the first (28 July 2004) hydrograph. If this is the case, it can be seen that the hydrograph takes 5 days to get back to its original baseflow; on the 18 August 2004 the KOV pit was not pumping water into the Musonoi River and the drop in the water discharge was approximately 3600 m3 /h; This period of monitoring occurs during the dry season, but during the wet season rainfall is high and frequent and it is likely that the tail of the hydrograph following one rainfall event will not have recovered before the next rainfall event.
The water balance for the medium, dry and wet months are presented in Figures 3.11 to 3.13, respectively, and the following conclusions can be drawn from the present day site water balance: The water balance for a medium month indicates the discharge of water that is expected from the Kasobantu Dam through the Nzilo spillway (SW09). The inflow into the Musonoi tailings dam indicates substantially higher flows than those exiting the Kasobantu Dam. Extensive losses of water are encountered along the river where the Musonoi tailings are situated. The discharge of water from the Kasobantu Dam to the Nzilo canal is highly variable from 1.4million m/mth to in excess of 16 million m/mth. Approximately 90,000 m/mth of water enters the Kakifuluwe wetland from the Musonoi River. Baseflow is extensive in this area.
Page 3.26
e 3.8:
Aug
2 258 752 1 808 096 1 634 596 1 634 596 1 687 847 1 634 596 1 634 596 1 634 596 1 634 596
Expected flow in the Musonoi River as it enters the Kolwezi tailings as m3/month
Sep
4 962 722 2 760 645 2 200 075 1 814 765 2 096 181 1 695 644 1 634 596 1 634 596 1 634 596
Oct
7 847 169 5 826 614 3 821 305 3 475 617 3 678 773 3 046 604 2 176 060 1 808 008 1 634 596
Nov
11 803 614 8 193 515 7 095 442 6 084 649 6 198 521 5 475 008 4 012 979 3 152 747 1 634 596
Dec
12 842 494 9 573 306 7 709 310 6 787 700 7 151 555 6 131 910 5 369 742 4 251 306 1 634 596
Jan
11 742 995 9 390 160 7 618 526 6 963 737 7 090 663 6 064 154 5 129 528 4 279 103 4 101 289
Feb
10 922 705 8 504 291 7 705 329 6 474 846 6 485 676 5 230 848 4 349 286 3 492 253 3 336 065
Mar
10 224 597 8 804 887 7 773 995 6 933 132 7 028 017 6 163 204 5 167 004 4 315 739 3 492 988
Apr
6 703 568 5 015 534 4 145 987 3 464 666 3 572 716 2 750 806 2 267 724 1 714 900 1 634 596
May
3 194 972 2 548 693 1 749 132 1 634 596 1 833 267 1 634 596 1 634 596 1 634 596 1 634 596
J
22
1 63
1 63
1 63
1 66
1 63
1 63
1 63
1 63
e 3.9:
Aug
2 533 392 1 687 023 1 443 974 1 443 974 1 535 189 1 443 974 1 443 974 1 443 974 1 443 974
Discharge of water through the Nzilo spillway (from Kasobantu dam) as m3/month
Sep
6 345 137 3 248 869 2 367 252 1 760 621 2 184 211 1 552 705 1 446 150 1 446 150 1 446 150
Oct
10 738 621 7 656 595 4 698 937 4 226 031 4 544 044 3 582 374 2 349 115 1 725 376 1 422 698
Nov
16 452 451 11 112 846 9 488 715 8 031 845 8 168 280 7 101 437 4 929 522 3 657 960 1 450 937
Dec
17 976 515 13 141 143 10 384 155 9 021 024 9 560 387 8 051 062 6 923 759 5 270 703 1 458 867
Jan
16 334 323 12 854 306 10 233 927 9 265 446 9 453 770 7 934 895 6 552 513 5 294 672 5 031 672
Feb
15 360 539 11 563 654 10 381 929 8 561 954 8 583 820 6 721 988 5 418 092 4 150 477 3 919 463
Mar
14 347 382 12 044 891 10 520 125 9 276 427 9 423 454 8 137 646 6 664 192 5 405 107 4 188 197
Apr
8 950 622 6 453 895 5 167 769 4 160 045 4 319 146 3 104 193 2 389 679 1 564 796 1 424 632
May
3 794 729 2 838 835 1 603 269 1 403 355 1 720 118 1 403 355 1 403 355 1 403 355 1 403 355
J
24
1 40
1 40
1 40
1 44
1 40
1 40
1 40
1 40
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3.8.2
Water supply
Water will be used in the reclamation of the tailings and in the process plant with a maximum make-up requirement of approximately 620 m3/h. This requirement will reduce by the volume of water that can be returned from the Tailings storage facility, estimated conservatively at about 60 m3/h, although during the wet season many times that volume will be available for use. A ground water investigation was undertaken to assess the existing ground water resources in the KMT Concession Area and to identify a suitable well-field for water abstraction. Water from the well-field will be pumped to the tailings reclamation area and as make-up to the plant site. Potential water sources are:
The Manga ore body has the best potential for water supply and its potential to supply water is described below. This is currently being further investigated by FQM along with other locations; however, this site appears to be the most promising. The unexpectedly high yields determined for boreholes BH5 and BH6 at Plant Site A near the dambo indicate that this area could be an alternative source for the water supply to the Kolwezi Tailings Project, and this option has also been investigated. The Kingamyambo ore body could also potentially provide a water supply within the KMT concession area, although it is probably within the KOV cone of drawdown.
Manga Ore body A single borehole, BH 1, was drilled within the Manga ore body to investigate the potential for groundwater supply to KMT. The borehole was targeted in the CMN formation (determined from the geological map) within the concession area. The borehole was drilled to a final depth of 91vm and to a final diameter of 165 mm. The final estimated blow yield of 101 m3/h was too strong for the two compressors to lift the water out of the hole and deeper drilling was therefore not possible. Test pumping of BH1 in the Manga ore body was not possible as the maximum abstraction rate for the pump on site was 40 m3/h. Nevertheless, aquifer parameters collated for the Calcaire a Mineraux Noir (CMN) of the Roan Series have been used in the assessment and preliminary design of a well-field using the available data. Chemical analysis of the ground water abstracted on a monthly basis from BH1 and analysed for process use shows water that is typically near-neutral in pH, with low dissolved salts (less than 50 mg/l) and negligibly low concentrations of heavy metals, apart from manganese (1-2 mg/l) and iron (50-70 mg/l). It has been concluded that this area is the most feasible for development of a water supply wellfield for the following reasons: High yielding borehole BH1 shown that at least 100-200m3/h could be abstracted from the CMN formation in this area providing the borehole dimensions are sufficiently large (17 inches in diameter). The sustainability of this abstraction rate has not been fully proven, as it was not possible to test-pump this borehole due to the capacity of the pump on site.
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There are no other users exploiting this aquifer and no villages close to the site. The water quality is good (based on the 12-month dataset) with the exception of the high concentrations of ferrous iron and manganese present. Contamination from other sources is unlikely. The proposed well-field is within the KMT concession area, well placed for monitoring at Kingamyambo Tailings as well as the upper reaches of the Musonoi tailings deposit.
The assumed data from the KOV CMN aquifer, shown in table 3.10, indicate the following drawdown is expected depending on the variables: Table 3.10: Comparison of water drawdown at the Manga ore body under different transmissivity rates
Transmissivity
m /day 30 Dolomitic CMN 400 Altered CMN 0.0001 0.001 0.0001 0.001
2
Storativity
Abstraction rate
m /hour 100 200 100 200
3
At radius of
m 500 500 500 500 44 m 58 4.5 6.8
Drawdown (m)
1 year 10 years 58 m 87 5.6 9 30 years 65 101 6 10
Since the blow yield intercepted in BH1 was more than 100 m3/h from a small diameter hole (8), it is likely that the CMN is altered (rather than dolomitic) in which case a transmissivity of about 400 m2/day is feasible. Depending on the storativity, the expected cone of drawdown at a distance of 200-500m is expected to be only 6 to 10m after 30 years of pumping at this rate. The project requirements are estimated at approximately 620 m3/h ranging from 240 to 620 m3/h, which could be supplied by ground water from an estimated total of 6 boreholes, spaced 500 m apart and operating on a rotational basis. It should be noted that the conclusions itemized above are based on data from a single borehole and the water supply potential has been extrapolated from the current understanding of the hydro geological model. It is intended to investigate the Manga ore body more extensively by drilling a number of suitably sized boreholes and test-pumping these to establish the assured yield with more certainty. At the same time, boreholes that may be used by communities will be monitored to determine whether abstraction from the Manga well-field could impact negatively on other ground water supplies. The occurrence of elevated iron and manganese levels in the ground water will need to be confirmed, and if so, a treatment system to remove these metals will be specified. A number of alternative water supplies are available that could augment the supply from the aquifer:
High quality return water from the new Tailings storage facility will be available as discussed briefly above. Table 3.11 defining the flows leaving the Kasobantu Dam through the outlet to the Nzilo Lake shows that during most months of the year the bulk (or all) of the KMT water requirements could be obtained from the Musonoi River. Monthly samples analysed over the past year
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show the TDS to be consistently in the range 250 to 350 mg/l, and metals to be essentially absent. It should also be noted that other developers, currently assessing the feasibility of re-opening existing mines in the Kolwezi area, are likely to undertake extensive dewatering of open pits and underground workings for the foreseeable future. It is possible that some of this abstracted water could be used by KMT for process purposes, in lieu of the Manga well-field supply. These opportunities will be investigated further. Development of any of these options will mean that the drawdown from the aquifer will be significantly lower and KMT will vigorously pursue these options to ensure a high security of water supply under all seasonal conditions and to limit the use of the aquifer. Water Recycling Water that can be recycled includes
Rainfall on top of the tailings dam; Water recycled within the plant operations.
The measures that are in place to recycle the water are described below: Storm water management The channel on the KOV pit side of the Kingamyambo tailings dam will be diverted away from the Kingamyambo tailings, again to minimise the pollution of clean runoff. Similarly the Musonoi River will be diverted away from the reclamation workings to minimise clean and dirty water mixing. Storm water run-off at the tailings dams (Kingamyambo and Musonoi) will flow towards the sump created for the capture of slurried tailings to be pumped to the plant. At the new tailings dam, clean storm water will be diverted away from the tailings area and discharged to the environment. A storm water control dam at the plant will capture and control run-off from non-contaminated areas. The expected size of the dam will be approximately 200 m x 100 m with a depth varying between 1 and 4m. The following measures have been adopted to reduce non-contaminated run-off: A storm water control dam will be constructed at the plant to collect dirty run-off water emanating from the open plant areas. Oils, grease and non-miscible solvents will be trapped and drummed for disposal in a lined impoundment. Particulate matter in the dirty stormwater will be allowed to settle, and the supernatant will be sampled to determine what further treatment is required before controlled discharge over an extended period in admixture with the plant effluent. Upstream storm water diversion controls will be constructed at the plant and tailings dam to divert clean water away from the dirty water infrastructure. An additional seepage drain will be constructed along the southern boundary of the new tailings dam to minimise pollution of the Kanamwamwa River.
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3.8.3
Water Disposal
Apart from the process plant solids and aqueous effluents the operations will discharge the following water flows. Overflow from the plant storm water dam during very wet periods. This flow will be discharged into the Kasobantu dam and will be typical surface water runoff quality; The plant has the capacity to use between 3000 and 4000 (typically 3300 m3 per day) of return water from the TSF. The data shown graphically below indicates that overflow from the TSP is expected only during the wet season, up to a peak of 1300 m3/h. This water is discharged directly to the Luilu River through a pumped system but may contain elevated levels of suspended solids, which should be settled out before discharge. Daily variations in decant volumes, dictated by rainfall patterns, will mean that in practice the process make-up water will be drawn in varying amounts both from the tailings decant pond, as well as the ground water aquifer, as required.
3.8.4
3.9
Transport
A number of transport routes were investigated for the transport of construction materials and reagents to site and the transport of product from site, from a technical and economic perspective. It is not possible to determine at this stage where each raw material or construction material will be sourced and how it will reach site. However, the preferred route during construction will be the existing route through Kasumbalesa via Likasi to Kolwezi during 2008 and during 2009 from
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Zambia along the 180km road which will be constructed up to a new border crossing between Zambia and DRC some 20 kilometres south of Kolwezi. Other options are outlined below, in 3.9.2. The existing rail and road infrastructure between Kolwezi and Lubumbashi is described below and shown in figure 3.14.
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Road bridges established at Lufira River (98.4 km from Lubumbashi) and Lake Lualaba (281 km from Lubumbashi), with no alternative diversions, place the following cargo restrictions on the project: Max width: 3.2m Max height: 5.0m Max GVM: 65t
The World Bank and the Office Des Routes are actively seeking the involvement of potential road users in the rehabilitation and maintenance of this route. The distinct advantages offered by road vs. rail during the construction phase are: Reliability Flexibility Time and Speed Crisis Management Emergency Freight
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Internal Access and Distribution Roads Apart from the main access road (Road 2), there are a further 10 roads or tracks that make up the retreatment operations internal road network as follows: Road 5 Road 6 Road 7 Road 8A Road 8B Road 8C Road 9 Road 10 Road 12 Access to residue storage facility Lime quarry access road Aggregate quarry haul road Access to pipeline maintenance road: Upper Musonoi reclaim area Access to pipeline maintenance road: Middle Musonoi reclaim area Access to pipeline maintenance road: Lower Musonoi reclaim area Powerline maintenance track Borefield maintenance track Access and pipeline maintenance road to Luilu River
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provided with their own step down substation. Substation buildings are constructed of block work and are provided with air-conditioning units and fire alarm monitors. All the power in this area is hydro-electric sourced and therefore, it would be safe to say that 99% of the electrical power utilisation is clean. Even the steam boilers are electrode boilers using power from the DRC national grid. The acid plant generates steam when in production ensuring efficient power use throughout the plant and minimising the draw from the grid. Furthermore, the plant has been designed to use process stream heat interchange where possible (i.e. heat exchange between the various process streams), ensuring efficient energy utilisation. A total of 13 diesel generators will be used at the plant site, with storage for 48,000 l diesel. This will initially be used during a period of 9 months during the construction phase, but will remain into the operational phase. The generators are the enclosed silent type and will generate between 60 and 300 KVA. Three 1MW sets will be installed for the main plant to provide emergency back up in the event of power outages In addition there will be some very small diesel lighting generators used to illuminate (and ensure safety at) the tailings reclamation works at Kingamyambo.. The main use of diesel will be for the truck fleet which will bring in the required materials and reagents and export the copper cathode and cobalt hydroxide/metal (according to the stage of the project). The vehicle fleet will be owned and operated by FQM (Const/Ops division). Almost all electricity in Katanga is generated by Hydro power dams as outlined below: Congo River : Inga, Nzilo, Nseke. Lufira River: Mwadingusha, Koni Kalemie: Hydro plant Kananga: fuel plant Tshopo River in Kisangani: Hydro plant but does not belong to SNEL.
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this is an overall business plan, which will include security, which reflects an understanding of and compliance with the appropriate parts of the following protocols: Universal Declaration of Human rights (1948). Geneva Convention (1949). Protocols additional to the Geneva Conventions (1977). Chemical Weapons convention (1993). Voluntary principles on security and human rights (2000).
And with specific emphasis on the following: IFC Performance Standards The Equator Principles The Voluntary Principles on Security and Human Rights with regard to the extractive and energy sector. The Conflict Sensitive Business practise Guidance for extractive industries, produced in March 2005 by International Alert.
Security Security at the plant site has been provided for by means of the following measures: Perimeter Gate The plant perimeter and staff housing area will be closed off with 2.4 m high security fencing. Installation of 2 x 6m boom gates on the entry and exit roads for trucks as well as 2 x 4m boom gates for entry and exit of light vehicles. The entrance and exit roads will be widened to allow traffic to split up into trucks and light vehicles. Installation of 2 x double entry and 2 x double exit turnstiles. Construction of a security office at the outer perimeter comprising of access control badging, security and other offices.
All mine personnel not living on site will enter the mine through this gate. All personnel who arrive on site by bus (and any passengers in light vehicles) will debus and walk through the turnstiles. Once the vehicle has been checked by security it can pass through the boom gates and collect its passengers again. Visitors to the mine will be issued with a temporary electronic Visitors ID badge. This badge will be issued from the badging office at the main gate and will be set for a limited date & possibly time period (e.g. a visitor will only be allowed on site access for today for a 3 hour period
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to ensure the visitor does not spend the whole day wandering around the mine site). The access level issued at the main gate will only allow the visitor up to, but not inside, the plant gate. The plant site itself will also be enclosed with 2.4 m high security fencing. Plant Gate Installation of 2 x 6m boom gates on the entry and exit roads. As there will be limited traffic through these gates there is no need for a separate truck and light vehicle entrance and exit gate. Installation of 2 x double entry and 2 x double exit turnstiles. These will be used for time & attendance clocking points. Completion of covered walkway for pedestrian traffic as well as construction of a plant gate building.
When the buses with employees arrive at the plant gate, they will park in the car park. The employees will debus and walk through the turnstiles, continuing on to their various places of work. The plant gate will be used as the main time & attendance clocking point (except for employees who work outside the Plant, these can be clocked at the perimeter gate). Visitors who have been issued an ID badge at the perimeter gate will report in to the main badging office outside the plant gate if they require plant access. Their appointment will be confirmed by telephone. If they are expected on site they will be issued further access (for a limited period) inside the plant. The purpose of the plant gate is to further restrict access onto the site and in the plant area. Vehicle access will be very restricted to those fit to drive within the plant area. Any visitors required to have plant access will be given the necessary induction and PPE issue. Certain areas within the plant will be secured with single type fencing and, in the case of the cobalt electro winning and loading bay with double type fencing. Entire plant site area, external pump stations, construction camp and staff housing facility to be less than 24hr manned contracted guarding. Principles of the Security Function KMT has employed a senior security manager for the DRC to oversee all security policies and implementation. On site on a day-by-day basis the implementation of the security policy will be implemented by the Health and Safety superintendent. KMT is in the process of employing Group 4 Securicor, a world renowned service provider, with a proven track record in management and a full understanding of working in the DRC environment for the provision of manned guarding, associated risk management services and technology-based applications (access control, CCTV and electronic Occurrence Book and reporting). This also includes the ability to select, vet, train, equip and motivate a well disciplined guard force A clearly defined organisational structure and reporting chain.
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Integrate with existing, ongoing local relationships including liaison with local community leaders, police and military. Validation of existing security measures. Detailed security survey to be carried out at all locations. Recommendations for different project phases, commencing with pre-construction and Construction, and implementation of those recommendations. Liaison with the Health, Safety, Environment and Community (HSEC) Manager to ensure sensible coordination of activities and communication to stakeholders Adherence to IFC Performance Standard 4 Adherence to the Equator Principles and the Voluntary Principles for Security and Human Rights Crisis Management, including emergency procedures, in conjunction with the Emergency Preparedness Plan (Annexure C). The ability to react effectively to different circumstances such as fire, injury, accidents. Basic security of individuals and company assets. These would include some electronic security measures. Management of reputation related issues. A clear chain of command in the event of a threat. Integration with social and environmental programmes. Liaison with appropriate NGOs as part of an overall networking plan. Participation in the Katanga Security Managers forum with the other mines active in the region An understanding of the judicial system and legal issues which might impact on the operation such as union and labour law and laws relating to medical care. Journey management.
Personal Security briefings, particularly on arrival. Production of a basic security handbook. Training of household staff as necessary.
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Communications The establishment of a security operations room with 24 hr radio monitoring and reaction. Frequencies and radio allocation. Vehicle radios. Standby independent satellite communications.
Crisis Management and Emergency Response Detailed plans have been drawn up to cover the following potential incidents (see Annex C: security Arrangements), and security personnel will be trained in the response to each of these, as well as having the necessary equipment available and operational: Civil and military disturbance. Breakdown in law and order. Natural disaster. Evacuation planning / site / accommodation. Medical evacuation. Kidnap and ransom. Armed robbery from offices. Armed robbery from residential accommodation. Labour disputes / site invasion / takeover. Malfunction at site involving environmental impact. Arson / sabotage Vehicle accident / breakdown / overdue / carjacking Provision of a kit and equipment. Protection of family units. Accidental / criminal fatalities. Requisition of equipment by government forces or other armed factions.
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Security Management A security strategy is to be agreed in line with corporate policy in order that detailed procedures are recorded in line with best practices. These are to be published and made available. All staff will be trained in their application. The transfer of information is to be determined by clear reporting lines in conjunction with corporate policy. Reporting procedures and templates are to be drawn up to ensure correct, accurate, timely and detailed information is available. This is particularly important in the event of a crisis. A code of ethics and conduct will be established for all security staff. This will include training in human rights. Clear guidelines on the use of force will be formalised and integrated in the training to be undertaken of G4S staff, and shared with any Government security personnel / commanders who may be called in to assist in times of conflict. A continuation training package will be implemented in order that the highest standards are maintained with integrity. Preparation for all phases of emergency response plan to include training and rehearsals at all levels.
Conclusion While the exact formation and numbers of guards are, at this stage, difficult to determine, detailed site surveys and liaison with the project managers will be carried out during the pre-construction phase, to ensure that the necessary measures are in place and the staff trained, as soon as construction begins
3.12 Employment
The project is anticipated to employ about 660 people during operations, of which 20 are anticipated to be expatriate, with 640 local positions. It is anticipated that most of the operational staff will be drawn from the population of Kolwezi. During construction, there will be up to 1300 employees, of whom 400 expats from Indonesia and the Philippines, who will each be twinned with a local worker in order to develop their skills.
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Legal compliance KMT strives to be compliant with the statutes applicable to its employees, namely the Loi No 015/2002 dated October 16, 2002; code du travail, and its application measures. Every year, before January 31, KMT will submit to the Labour Inspector and to the National Labour Office a summary of the numbers of both national and expatriate employees. All non-Congolese working with KMT require a work permit. The taxation that applies to expatriates work permits is defined in the Arrt Ministriel No 013/95 dated January 31, 1995.
Employment contracts Daily contracts apply to employees recruited for daily, small casual-labour requirements. Fixed-term contracts apply to a specified term or ascertainable period, for which the starting and finishing dates are specified. The maximum length of a fixed-term contract is two years. Congolese staff hired on a permanent basis in Kolwezi are offered open-ended contract for an undetermined period of time. Independent contracts are contract agreements which will specify the task to be accomplished and the payment due on successful completion of the task.
Staff regulations and internal regulations These form part and parcel of the fixed-term and open-ended employment contracts of Congolese employees. Staff regulations are to be signed alongside the Employment Contract on recruitment of all staff. Work environment For the purpose of ensuring that staff members are informed about matters concerning their employment, KMT will place notice boards for the display of any notices of or relating to employment.
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Employees on contract will be issued with a KMT Identity Card for identification and security purposes. Work tools are specific to the functions of the position; e.g.: desk, computer, stationery, toolkits, uniforms and protective gear. Uniforms and working tools are the property of KMT, and are to be returned upon termination of employment or when replaced.
Working hours Normal working hours will not exceed nine hours per day and/or 45 hours per week (not including transportation time from and to the work place). All employees shall be required to submit their time worked on approved KMT timecards, which the supervisors shall sign.
Paid leave All staff is entitled to annual leave. Sick leaves are granted upon presentation of a medical certificate signed by an approved doctor. A woman employee, who has become pregnant and has been employed for a continuous period of no less than six months prior to the expected date of birth, is entitled to maternity leave. The woman shall be entitled to 14 consecutive weeks with a maximum of eight taken after childbirth. After completion of three months continuous service, any employee holding a fixed-period contract of more than six months and/or open-ended period contract is entitled to compassionate leave.
Transport policy In addition to the transport allowance given as part of the remuneration package, KMT provides bus transportation on specified routes to all employees bearing identification cards. Employees are not authorized to use their private motor vehicle for KMT work-related purposes and will consequently not be reimbursed for any claims.
Travel policy Travel policy applies when an employee is hired outside the work location or during out-station posting. An employee recruited and hired in Kolwezi is considered a resident of Kolwezi despite his/her place of origin or the residence location of the family. Only employees hired by KMT outside Kolwezi are entitled to the travel allowance. KMT pays for the cost of travel for the employee and his/her immediate family relocation from the residing place to the work place. The same shall apply if and when the contract is terminated.
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Return travel is granted to the employee and his/her immediate family every second year of full service. Employees are entitled to an out-of-station allowance whenever they are required to travel outside Kolwezi on official duty.
Medical and Health Care policy KMT shall guarantee its employees and their immediate families access to proper medical and health care as recommended by KMTs doctor , and in compliance with appropriate DRC legislation, such as: Medical care and emergency treatment on site for employees. Out patient and in patient treatment through medical schemes for employees and their immediate families. Drug reimbursement. Dental care Evacuation in death-threatening situations Accident and occupational illnesses Coverage of HIV/AIDS treatment is discussed below.
Accidents All work-related accidents shall be immediately reported to the appropriate supervisor, regardless of the severity or cause.
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Re-routing of a patient to Kinshasa or outside DRC will be considered only if Lubumbashi Hospital lacks the diagnostic or therapeutic means to treat the patient evacuated from Kolwezi.
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The Human Resources team will put together a set of job descriptions for the 127 positions of the organizational chart. This will provide a framework to make an inventory of required skills and to construct a skill availability survey. During the recruitment process, training programs will be established to train prospective employees in the required skills. Worker housing and other facilities The temporary modular construction camp is being erected south of the plant site, and within walking distance of it. These comprise construction labour accommodation within walking distance of the plant, capable of housing around 600 staff in rooms of up to 5 personnel, and a management camp consisting of 6 one bed-one bath units, 6 three bed-two bath units and 6 three bed-three bath units. Unskilled labour will be sourced from Kolwezi and its surrounds. These facilities will be removed upon completion of the project, and all areas will be rehabilitated in compliance with the Environmental and Social Management Plan. Additional accommodation and a visitors centre may be constructed in the township of Kolwezi at a later date, east of the present built-up area. The site is situated in the new Mutoshi urban area and borders the road Avenue Ungu Ngandu to the east. The total site consists of 14 contiguous plots of 30 m x 50 m each making up a total area of 21,000 m2. All Congolese employees will receive a housing allowance paid together with the monthly salary as required by the Congolese labour law. The housing allowance will be equivalent to 30% of the gross salary. Accommodation will be provided in KMTs furnished housing (either shared compound accommodation for single employees, or a separate house for family posting) for employees hired outside the work location. Accommodation for Lubumbashi-based employees visiting Kolwezi or in transit or temporarily posted in Kolwezi will be booked at a KMT guest house or KMTs preferred accommodation facilities.
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unknown additional grant from USAID, with whom FQM is actively collaborating on HIV/AIDS prevention in the Zambian Copperbelt. The HIV/Aids implementation plan for Kolwezi will contain the following: KMT will undertake orientation sessions in HIV/AIDS which will primarily target the entire workforce and their spouses. These are 2 hourly sessions and they are will be done over a number of days to give chance to almost all the employees to attend. The sessions cover an over view of HIV/AIDS information. The next stage will be the training of peer educators who will be identified during the orientation sessions and become the main stay of HIV/AIDS sensitization both at the work place and the community. The community members are integrated in the Peer education training and all the other trainings thereafter. The training in psychosocial and antiretroviral treatment will then follow. The VCT will be started from the inception of the programme. The company will provide free treatment of opportunistic infections and Anti Retroviral treatment for the employee and their spouses. Positive living training and support will be offered for the HIV-positive employees who are not in need of ART, to delay as much as possible the onset of AIDS.
Employees or potential candidates with HIV/AIDS may work or pursue employment at KMT, as no employee or a candidate to a position will be forced to undergo compulsory HIV testing. Employees living with HIV/AIDS will be treated in exactly the same manner as the other employees and will not be subjected to discriminatory practices because of their HIV/AIDS status. The right of the employee and his/her family members on confidentiality regarding HIV serologic testing, diagnosis and treatment will be respected. Voluntary Counselling Testing (VCT) will be actively promoted to all KMT employees. A reference structure for counselling and testing will be identified in Kolwezi for those employees or immediate family members who request VCT. Information materials will be made available within KMTs onsite medical facilities, and KMT medical staff will be in a position to provide information, guidance and referral to any employee requesting support. If an employees contract is terminated for any reason, KMT commits itself to continue to pay 50% of the cost of treatment for six months. However, in case of new (define) employment, the employee will inform KMTs doctor and KMT will disengage itself from its commitment. In case of death of the employee, immediate family members who are already under treatment shall receive their entitlement to 50% of the cost of treatment for a maximum of a further twelve months after the death.
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initiatives, such as bed net distribution, will be considered. Throughout, a collaborative communitybased approach will be pursued. The KMT clinic will monitor trends in drug resistance, and will ensure a supply of the appropriate drugs. General awareness of the dangers of stagnant water will be built in the HSEC department, and among communities. Research indicates that up to 30% of all lost time in the workplace in locations like Kolwezi is related to malaria infection. Therefore, FQM takes an active role in malaria control during the construction phase as well as during operations. During operations, KMT will take an active roll in malaria control at its operations in the local communities in partnership with government and local authorities in their malaria roll-back program. A representative of Regent Laboratories of South Africa has visited KMT site and concession in March 2008 and has submitted a one year proposal for a comprehensive malaria control program for the construction site, construction camp, housing estate, and communities living inside and adjacent to the concession. The program focus on source reduction larviciding, residual in-door spraying, insecticide treated bed nets, personal protection, spraying equipment, fogging and training. Subject to approval of the proposal, KMT will begin implantation in May/April following consultation with communities and authorities.
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work is expected to take from June 2008 until August 2009. The road to Solwezi should be complete by June/July 2008 although the portion from the DRC/Zambian border to Solwezi make take longer than this. For the aggregate, FQMO will provide aggregate to the Projects Division, which is responsible for co-ordinating and managing the contraction phase (in the place of an EPC contractor), and who will in turn quality check the material and supply the aggregate to the various sub-contractors who require it. At present the aggregate used is being supplied by Gcamines from an existing quarry. Sand will be provided from crusher dust at the aggregate crushing plant and also from an existing source in Kolwezi. Cement will be brought from Ndola in bulk road tankers. In addition to the work being carried out by FQMO, some work will also be done by DEM mining, who has built the plant site access road from the Luilu road northwards along the line previously earmarked for the railway line to the plant site. They will also be building other site roads which will be complete by the end of the dry season 2008 (October/November). Drilling: Comisa and Boart Longyear are carrying out drilling activities for water wells a total of 12 holes will be drilled and tested to establish the quantities of groundwater available in each location. Management camp: CCC and Benco are putting in the bases and Nova will be erecting and finishing the 18 houses, 6 one bed one bath units, 6 three bed two bath units and 6 three bed three bath units. Nova is due to begin construction on in February and have a 15 week contract. They have a team of 6 expatriates and local staff. Security fencing: This is already 95% complete and is being carried out by the FQM Projects division. Removal of tailings pipeline: This old approx 12 inch diameter pipeline runs along the western side of the Musonoi valley and was previously used for spigoting tailings into the Musonoi. The pipes are being removed and reused as drainage sleeves around the FQM construction site. Vehicle fleet during construction This will consist of the following: 20 pickups 4 5 ton or 6 ton trucks 8 tractors, bobcats, loaders etc. 13 cranes
Staffing of the construction works The construction workforce is estimated to be about 1300 maximum, with about 700 local unskilled and semi-skilled labour drawn from Kolwezi and environs, and a maximum of 600 expatriates, with
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a base load of around 480. These will be Filipinos, who will carry out the civil works, and Indonesians, who will be working on the structural steel, plate work and piping. Around 60% of these workers have already worked on FQM projects in Mauritania (Guelb Mughraine), and Zambia/DRC (Frontier and Kansanshi). These skilled workers will be matched with a local worker to provide a buddy system and on-the-job training. This system has been used successfully at other FQM operations. CCC and Benco both have 57 local employees and CCC have one expatriate manager. Local workers will be managed through Bernard Mwape, the HR manager for RPM. Three sets of labour brokers will be used to source workers; one of these has worked with FQM at Frontier. The labour brokers should feed the workers and provide them with PPE (personal protective equipment) but this will be supplemented by FQM where required. As part of its due diligence, FQM will screen these labour brokers in relation to their modus operandi, to ensure that their actions are in keeping with DRC laws and IFC Performance Standard 2 (Labour & Working Conditions). Particular skills are difficult to find locally (such as crane operators) so these will be sourced from Zambia using operators who have previously worked at Frontier. Others from DRC will be trained. Buses will be provided to move local workers from Kolwezi to the plant site where construction activities are centred. This will take the form of 2 x 60-seater buses. Access control and clocking-in will be carried out at the gate to the construction area (which is already access controlled). Health and Safety The responsibility for health and safety during construction is, as far as possible, devolved to the sub contractors but reported back to the FQM Projects Division. Ultimate responsibility for OHS management and incidents on the KMT site resides with FQM. A local safety officer who has previously worked for Phelps Dodge/Freeport MacMoran at Tenke Fungurume is currently employed by FQM. A monthly report will be prepared reporting LTIs and man-hours, reported through the contractors to the manager of FQM Projects or the HSE manager within his organisational structure. FQM typically report (have reported to date?) no fatalities at any of their construction sites and few lost time injuries (LTIs). One of the units at the construction camp will be equipped as a clinic the equipment is already on site waiting to be installed. A further clinic will be opened at the plant site and one in town for employees and dependents. A component of the workers salaries is paid to the clinic in town to allow access for their dependents. Construction programme Agri-auto will be constructing the steel sheds which consist of the warehouse at the plant, the reagent store, the cobalt store, workshops for plant and light vehicles. This company construct their own concrete bases and fixings, although FQM supply the aggregate and some reinforcing. Their
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workforce will consist of 3 expat (Zambian) specialists and a supervisor, and 12 local workers. They will be on site until Dec 2008. Wade Walker is carrying out the electrical works (including the external reticulation for the construction camp) and is due to be on site from mid March 2008 for 2 months. They will use 1 expatriate, 5 skilled Zimbabwean workers and 25 local staff. Conco will build the power line from the Inga-Shaba line to the plant site, including a temporary line to supply the power needed for construction, to be completed by end Mar 08, and the permanent power to be completed by Jun/Jul 2009. They will use an international team of 9 staff plus 8 locals. Lycopodium from Australia is the design and engineering contractor responsible for the main plant site construction, which is due to start in March/April 2008. It will take two months for full mobilisation and 12 months to complete the concrete, a planned 28,000 m3. The building work will be carried out by FQM Projects division. The plant should be commissioned by the end of 2009.
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Figure 3.1: Location of the Kingamyambo and Musonoi tailings deposits and proposed infrastructure
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2,500,000
2,000,000
500,000
1 5 9 13 17 21 25 29 33 37 41 45 49 53 Time (years)
Figure 3.2: Mining Schedule for Kolwezi Tailings Project indicating the source of tailings to be processed. Source: (LQS Ltd, March 2005)
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Figure 3.6:
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Figure 3.7:
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Figure 3.8:
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Figure 3.9: Discharge points from the tailings decant pond and stormwater control dam
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SPILLAGES (m )
01 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 01 01 01 01 01 01 01 01 01 01 01 01 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 /0 8/ 19 7 8/ 19 7 01 8/ 19 7 5 7 8/ 19 8 8/ 19 8 8/ 19 8 8/ 19 8 8/ 19 8 8/ 19 9 8/ 19 9 8/ 19 9 8/ 19 9 8/ 19 9 8/ 20 0 8/ 20 0 9 1 3 5 7 9 1 3 5 7 9 1 3 8/ 19 7 3 8/ 19 7 1 8/ 19 6 9 8/ 19 6 7 8/ 19 6 5 8/ 19 6 3 8/ 19 6 1 8/ 19 5 9 8/ 19 5 7 8/ 19 5 5 8/ 19 5
1,000,000
1,200,000
1,400,000
1,600,000
1,800,000
200,000
400,000
600,000
800,000
01 3 01 01 01 01 01 01 01 01 01 01 01
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