Waste generation: reduce, reuse, recycle and the role of collaboration

Waste generation: reduce, reuse and recycle and the role

of collaboration

Minas e Minerăçao no Sėculo xxi

14 September 2016 Belo Horizonte

2Delivering solutions through collaboration


© AMIRA International Limited

• Mining industry trends & need for collaboration

• How does industry collaborate?

• What do we mean by waste?

• What is the waste is being generated and where?

• The changing nature of mining and what it means for waste generation

• Reduce, reduce, reuse and recycle

• Challenges abound – why collaborate

• Towards minimalist waste generation

• A roadmap to achieve a clean mine

• AMIRA International – an overview

Contents



Mining Industry Trends & Drivers



Mining Industry Trends & Drivers

Resource base

Capital availability

Cost competitiveness

Sustainability (HSEC)

Supply chain infrastructure constraints

Increased regulation and country risk

Mining deeper and/or at lower grades

Specialist labour and equipment shortages

Business Challenges

Commodity Prices

Top 6 Strategic ImperativesFor Mining Innovation*

Reduce operating costs

Develop and produce better and faster

Reduce capital costs

Find new reserves / resources

Reduce health, safety & environmental risk

Increase the viability of future projects

* Source: Mining State of Play 2014 – Virtual Consulting International – Listed in decreasing order of popularity (score) from a survey of 230 senior decision makers across 100 mining companies & suppliers.

2013 score 2014 score

Value Drivers



While technological innovation has fundamentally transformed

many industries, but mining is lagging

Source:



Mining industry trends and drivers

The mining industry needs to increase its operational maturity in line with other industries that use technology better.

This needs collaboration.

1 – Functional Excellence

2 – Site-wide Integration

3 – Asset/Partner Collaboration

4 – Extended Value Chain

5 – Full Network Connectivity

Mat

urity

& B

enef

its

Source: Farrelly et al (2012). The Network Centric Mine in International Mine Management 2012 conference



How does Industry Collaborate



So how is the mining industry collaborating?

Exploration / Discovery Mining

Closure / ReclamationProcessing

DevelopmentDesign/Construction

Operations

Co

llab

ora

tin

g P

artn

ers

One-to-many± Suppliers with

± research institutions

Mining Value Chain

Not an area suitable for multi-peer

collaborationBUT….

Typically not an area

suitable for multi-peer

collaboration

Open innovation

Internal/Proprietary R&D with ± external research providers ± Suppliers

Peer-to-peer± Suppliers with

research institutions



Open innovation





So how is the mining industry collaborating?

Exploration / Discovery Mining

Closure / ReclamationProcessing


Operations

Co

llab

ora

tin

g P

artn

ers



Mining Value Chain

Not an area suitable for multi-peer

collaborationBUT….

Typically not an area

suitable for multi-peer

collaboration

Open innovation

Internal/Proprietary R&D with ± external research providers ± Suppliers





Open innovation



the Goldcorp Challenge and

recently the Integra Gold Rush

Challenge

AMIRA “co-opetition” modelAMIRA International's “co-opetition” model



What do we mean by waste?



What do mean by waste?

The Organisation for Economic Co-operation and Development defines two types of mine waste:

extraction waste and beneficiation waste

Source: https://stats.oecd.org/glossary * note its not “uneconomic” waste

Waste is all the unwanted* mineral and non-mineral solid, liquid or gaseous material, generated as a result of

exploration, extraction, haulage, processing, and transport of concentrate or metal to market

https://stats.oecd.org/glossary



What is the waste generated and where?



What is the waste generated?

Waste material Description

Overburden Overburden includes the soil and rock that is removed to gain access to the ore deposits at open pit mines.

Waste rock Waste rock is material that contains minerals in concentrations considered to be uneconomic to extract.

Tailings Tailings are finely ground rock and mineral waste products of mineral processing operations.

Slags Slags are non-metallic by-products from metal smelting, and were historically considered to be waste.

Source: http://www.miningfacts.org/Environment/How-are-waste-materials-managed-at-mine-sites/

http://www.miningfacts.org/Environment/How-are-waste-materials-managed-at-mine-sites/



What is the waste generated?

Waste material Description

Mine water Mine water is produced in a number of ways at mine sites, and can vary in its quality and potential for environmental contamination.

Water treatment sludge Sludge is produced at active water treatment plants used at some mine sites, and consists of the solids that had been removed from the water as well as any chemicals that had been added to improve the efficiency of the process.

Gaseous wastes GHG . Gaseous wastes include particulate matter (dust) and sulphur oxides (SOx). The majority of emissions to the atmosphere are produced during high-temperature chemical processing such as smelting, and vary in their composition and potential for environmental contamination.

Source: http://www.miningfacts.org/Environment/How-are-waste-materials-managed-at-mine-sites/

http://www.miningfacts.org/Environment/How-are-waste-materials-managed-at-mine-sites/



Typical waste generated in a copper operation

Source: www3.epa.gov : Picture Los Bronces copper mine

Waste rock

Tailings

Spent Ore from Heap, Dump, and

Vat Leaching

Mine water

SX/EW Sludge

Spent Electrolyte

Spent leaching solution

Spent ore piles

Solution ponds

Dust

Greenhouse gases

Etc

http://www3.epa.gov/epawaste/nonhaz/industrial/special/mining/techdocs/copper/copper1b.pdf



Exploration / DiscoveryMining

Closure / Reclamation

Exploration by prospectors and

companies leads to discoveries that could become

mines.

Discovery depends detailed field

surveys, technical studies and finally

drilling.

Includes pre-feasibility, feasibility

and engineering studies, raising

capital and construction.

1 - 5 years

Includes milling & processing /

metallurgy to produce

concentrate or metal to market

Reclamation of sites to productive use

begins during operation and continues after

closure

Processing

Includes extraction, haulage, and stock

piling


Operations

1 - 10 years or more decade to perpetuity 2 - 100 years

The Generalised Minerals Value Chain: where is waste generated?







mines.



drilling.




1 - 5 years






closure

Processing


piling


Operations


TimeTota

l was

te g

ener

ate

d:

no

t to

sca

le

loga

rith

mic

sca

leThe Generalised Minerals Value Chain: where is waste generated?



loga

rith

mic

sca

le





mines.



drilling.




1 - 5 years






closure

Processing


piling


Operations


TimeTota

l was

te g

ener

ate

d:

no

t to

sca

le

In 2011 Rio Tinto alone generated about 1,535 million tonnes of mineral waste (predominantly waste rock and tailings), and

758,000 tonnes of non-mineral waste. Source: www.riotinto.com


http://www.riotinto.com/sustainabledevelopment2011/pdf/waste_factsheet.pdf



loga

rith

mic

sca

le





mines.



drilling.




1 - 5 years



concentrate or metal



closure

Processing


piling



Operations


TimeTota

l was

te g

ener

ate

d:

no

t to

sca

le

In 2011 Rio Tinto alone generated about 1,535 million tonnes of mineral waste (predominantly waste rock and tailings), and

758,000 tonnes of non-mineral waste. Source: www.riotinto.com

To put this into perspective according

to the World Bank the world generates

about 1,420 million tonnes of urban

waste a year (50% in OECD countries)

http://www.riotinto.com/sustainabledevelopment2011/pdf/waste_factsheet.pdf



The changing nature of mining and

implication for waste generation



Key Trend Implication for waste generation

Average head grades are declining • More gangue to be mined for the same amount of metal, greater haulage required

• increasing energy intensity as more material will need to be processed for the same amount of metal

• more beneficiation waste will be generated

Mining Industry Trends: Implications for waste generation







Ore is becoming more complex • Increasing use of chemicals and other consumables to process ore into concentrate or metal










A shift from open pit to underground operations

• Increasing haulage distances

• Also ore becomes generally harder with depth increasing the energy intensity in comminution









A shift from open pit to underground operations

• Increasing haulage distances

• Also ore becomes generally harder with depth increasing the energy intensity in comminution

Social License to Operate increasingly being threatened

• Society and regulators want zero-footprint mines

• This means eliminating waste, minimising, and maximally reusing and recycling



Reduce, reuse and recycle



Reuse (repurpose) - the new use or application of the total mine waste in its original form for an identified purpose directly without any reprocessing

Recycling - extraction of new valuable resource ingredients, or uses the waste as feedstock and converts the entire mine waste into a new valuable product or application with some reprocessing

Reuse and Recycling of mine waste – not new concepts



Reuse and Recycling of mine waste – not new concepts

Reuse (repurpose) - the new use or application of the total mine waste in its original form for an identified purpose directly without any reprocessing

Recycling - extraction of new valuable resource ingredients, or uses the waste as feedstock and converts the entire mine waste into a new valuable product or application with some reprocessing

WE MUST REFRAME OUR VIEW AND CONSIDER WASTE AS A RESOURCE



Mining wastes Reuse and Recycling options

Waste rocks • Resource of minerals and metals

• Backfill for open voids

• Landscaping material

• Capping material for waste

repositories

• Substrate for revegetation at mine sites

• Aggregate in embankment, road, pavement,

foundation and building construction

• Asphalt component

• Feedstock for cement and concrete

• Sulfidic waste rock as soil additive to neutralize

infertile alkaline agricultural soils

Mine waters • Dust suppression and mineral

processing applications

• Potable water

• Industrial and agricultural use

• Coolant or heating agent

• Generation of electricity using fuel cell

technology

• Engineered solar ponds to capture heat for

electricity generation, heating, or desalination

and distillation of water

• Recovery of metals from AMD waters

Mine drainage

Sludges

• Flocculant/adsorbant to remove

phosphate from sewage and

agricultural effluents

• Extraction of hydrous ferric oxides for paint

pigments

• Extraction of Mn for pottery glaze

Reuse and Recycling options for mining, processing and

metallurgical wastes





Processing wastes Reuse and Recycling options

Tailings • Sand-rich tailings mixed with cement

used as backfill in underground mines

• Clay-rich tailings as an amendment to

sandy soils and for the manufacturing

of bricks, cement, floor tiles, sanitary

ware and porcelains

• Mn-rich tailings used in agro-forestry,

building and construction materials,

coatings, cast resin products, glass,

ceramics and glazes

• Bauxite tailings as sources of alum,

soda

• Cu-rich tailings as extenders for

paints

• Fe-rich tailings mixed with fly ash and

sewage sludge as lightweight

ceramics

• Phlogopite-rich tailings for sewage treatment

• Phosphate-rich tailings for the extraction of

phosphoric acid

• Ultramafic tailings for the production of glass

and rock wool

• Carbon dioxide sequestration in ultramafic

tailings and waste rocks

• Reprocessing to extract minerals and metals

• Energy recovery from compost–coal tailings

mixtures



Metallurgical

wastes

Reuse and Recycling options

Bauxite red mud • Treatment of agricultural and

industrial effluents

• Raw material for glass, tiles, cements,

ceramics, aggregate, bricks and

proppants for hydrofracturing

• Treatment of AMD waters

• CO2 sequestration

Historical base

metal smelting

slags

• Production of concrete and cement

• Use as fi ll, ballast, abrasive and

aggregate

• Extraction of metals (e.g. Cu, Pb, Zn, Ag, Au)





The challenges abound



Challenges abound

1. Despite much effort in reuse and recycling over the last few decades the majority of mining waste is stored in an unsustainable way-> Ultimately the aim must be waste prevention or minimisation, but how?



Challenges abound


2. Many recycling and reuse options at scale are not economic -> Much remains to be done to develop more effective recycling and reuse options that are economic



Challenges abound


2. Many recycling and reuse options at scale are not economic -> Much remains to be done to develop more effective recycling and reuse options that are economic

3. Not all waste is the same – one mine’s waste is different to another > More work needs to be done to characterise the waste streams – the quantification, distribution and nature of the chemistry / mineralogy. Is it possible to develop recycling and reuse solutions that are not mine specific?



Challenges abound

4. Hard waste such tailings still contain valuable minerals -> We need to develop cost effective solutions to process ultra low grade waste and extract the valuable minerals



Challenges abound


5. Many waste streams contains chemicals toxic to humans, fauna and flora -> There is a need to develop cheap processes to extract toxic chemicals and turn them into benign materials



Challenges abound


5. Many waste streams contains chemicals toxic to humans, fauna and flora -> There is a need to develop cheap processes to extract toxic chemicals and turn them into benign materials

6. Designing mines to prevent and minimise waste -> We need to know more about our ore body at the feasibility stage to be able to predict the nature and volume of the expected waste to enable the mine design to be optimised to eliminate what can be eliminated or reduced to the absolute minimum what cannot?



Challenges abound

7. Minimizing the space required to store mining waste -> We need cost-effective means of filtering and dry stacking of tailings



Challenges abound


8. Monitoring of exiting waste repositories-> We need to develop predictive tools and reliable, field-tested modelling of long-term waste behaviour



Challenges abound


8. Monitoring of exiting waste repositories-> We need to develop predictive tools and reliable, field-tested modelling of long-term waste behaviour

9. Maintaining social license to operate -> We must build fail-safe storage systems capable of withstanding once in a thousand year event . Companies are now under increasing pressure to “guarantee” that there will be no adverse affects to people, society and the environment during the life of the mine and post-closure



Why collaborate?

Solving the waste problem is not a competitive issue - it’s a whole of industry risk issue and requires cooperation

Collaboration works because even though companies are competitors, there are always synergies and strengths that can be leveraged

In a globalised economy it is difficult for companies to achieve excellence and competitive advantage across a wide range of disciplines

Solutions are increasingly captured outside a company's immediate environment

With the boom over, R&D is now subject to availability of scarce financial resources, spurring the need for collaboration



Towards a minimalist waste scenario



The minimalist waste mine

Waste generation, disposal and management is a major business risk for the industry

Mining industry’s future will depend on its ability to evolve quickly as possible towards a zero-waste state .

This ideal final state is unlikely to be achieved however, until in-situ extraction becomes a reality, and even then the generation of waste will not be entirely eliminated

In the interim it is possible to make big strides in making mines as “clean” as possible by reducing or eliminating waste where possible, repurposing waste and sustainably manage what waste is produced?



The minimalist waste mine: A roadmap?

Perhaps what we need is a global roadmapping initiative to layout a path to achieve a minimalist waste mine, a “Clean Mine”

This will involve the following elements:• An industry developed strategic vision of what a “Clean Mine” should look like

• A well defined set of goals required to achieve the vision

• Identification of the current status. To this end a review of the nature and volume of waste generated in mines and the strategies currently used to minimise, store, re-use or eliminate waste will be commissioned

• Identification of the technical and other risks, and knowledge/capability gaps

• An industry endorsed goal-based plan of R&D activities required to mitigate risks and fill gaps based on a consensus of key priorities

• A focus on pre-competitive collaborative partnerships between companies, suppliers, research organisations and government agencies



AMIRA International: an overview



AMIRA International: enabling collaboration

AMIRA International is a private sector, not-for-profit , member-based

organisation

We are a facilitator, broker and manager of collaborative projects designed

to address industry challenges and needs; both technical and non-technical

Our members include explorers, producers and equipment, technology and

service suppliers from around the world

We are independent which means we can engage with solution providers

throughout the world, but ensure that local partners are part of the team

We have global reach: currently have offices in the USA, Chile , South Africa

with head office in Australia

We have a 57 year history of success



AMIRA International’s two pillars

SUPPORTING THE GLOBAL MINING INDUSTRY VIA OUR TWO

SERVICE-DELIVERY PILLARS

TECHNOLOGY-

CENTRED

COLLABORATIVE

RESEARCH

ENTERPRISE

DEVELOPMENT,

INNOVATION &

IMPLEMENTATION

PILLAR 1 PILLAR 2

WE BROKER, COORDINATE AND DELIVER A BROAD RANGE OF COLLABORATION-BASED

SOLUTIONS

FOR TECHNOLOGICAL CENTRED CHALLENGES & ENTERPRISE DEVELOPMENT INNOVATION

AND IMPLEMENTATION



AMIRA International: our members



AMIRA International’s collaborative models

Co-opetition Model(Collaboration with peers,

who could be direct

competitors)

Sponsor A

Sponsor B

Sponsor C

Researcher A

Researcher B

Researcher C

Sponsor A

Sponsor B

Sponsor C

Researcher A

Researcher B

Researcher C

Sponsor

Researcher A

Researcher B

Researcher C

Non-competitor

Collaborative Model(Collaboration with peers

who are not direct

competitors)

One-on-one

Collaborative Model (includes managing

existing proprietary

projects for our

members)



The AMIRA Collaborative model in action: Example of Pillar 1

Example of the “co-opetition” collaborative model



The AMIRA Collaborative model in action: Example of Pillar 1

Project: P9P - The Optimisation of Mineral Processes by Modeling & Simulation

Sponsors: Alcoa, Anglo American, AngloGold Ashanti, Barrick Gold, BHP Billiton, Glencore , Teck Resources, LKAB, Lonmin, Newmont, MMG, Newcrest, Rio Tinto, Vale,

COREM, FLSmidth Minerals, Magotteaux, Metso, Outotec, Polysius, Russell Mineral Equipment, Senmin, and Tenova Bateman

Researchers: University of Queensland (JKMRC), Chalmers University of Technology (Sweden), Hacettepe University (Turkey), Universidade Federal do Rio de Janeiro (Brazil), University of Cape Town (South Africa), and CRC ORE

Example of the “co-opetition” collaborative model



Nature of AMIRA International's projects

Exploration Mining

Mineral

processing /

metallurgy

Sustainability

De

mo

nst

rati

on

an

d

Tech

nic

al D

e-r

iski

ng 7:

Implementation

Improvement

Proven technology.

Technology fully integrated into intended operation system.

The technology has successfully operated with acceptable

performance and reliability.

6:

Implementation

Support

Technology installed. Technology is ready for implementation

Full-scale prototype in intended environment has shown

acceptable performance and reliability over a period of time, and

may already be successfully operational in other operating

environments.

De

velo

pm

en

t

5: Scale-up,

Trial/Demo

Technology integration tested.

Full-scale prototype built and integrated into intended operating

system with full interface and functionally tests.

4: Pilot

Technology qualified for first use.

Full-scale prototype built and technology qualified through testing

in intended environment, simulated or actual.

New hardware/software is now ready for first use and testing.

3: Proof of

Concept

New technology tested.

Prototype built and functionality demonstrated through testing

over a limited range of operating conditions.

Re

sear

ch

2: Laboratory

Concept validated.

Concept design or novel features of design validated through

model or small scale testing in laboratory environment.

Evidence that technology can meet specified acceptance criteria

with additional testing.

1: Science

Concept demonstrated.

Basic functionality demonstrated by analysis.

Technology is likely to meet specified objectives with additional

testing.





• New discovery technologies• Improved ore genesis models• Developing vectors to ore• Undertaking regional studies• New data compilations• Data Metallogenica

• Improving Comminution• Enhancing flotation recovery• Improving extraction selectivity• Towards maximising reagent and water

recovery• Increased revenue from improved product

quality & product recovery• Integration of mining & processing• Optimising resource characterisation for

optimal production & recovery

• Improved environmental management

Mineral Processing & Metallurgy

• Enhancing Productivity

• Mine Safety- zero deaths

• Reduced operating costs


-------Operations------

Sustainability: Licence to Operate; New management practices

Roadmaps:Alumina, Copper, Drilling, Exploration undercover, In-

situ extraction, Heap-leach

AMIRA International’s projects



AMIRA International’s global reach

Countries with Research Providers

Countries with Sponsors/Members

AMIRA Offices



AMIRA International is willing to partner

The majority of the big challenges that mining companies are facing are

global in scope and would benefit from a global approach

AMIRA International is a open to collaboration with government agencies

and industry associations to address the big challenges facing the mining

sector

We are well connected with broad networks in industry and academia and

have many years of experience on how to build collaborative partnerships

between industry , solution providers and government


WITH COLLABORATIONGREAT THINGS

RESULT

Com a Colaboração, Grandes Coisas Resultado

CollaborerC’est Aller Vers le Succès

合作共赢

Con la ColaboraciónGrandes Cosas Resultan

Obrigado

Services

Waste generation: reduce, reuse, recycle and the role of collaboration