The high density thickened discharge tailings storage facility at Osborne Mine – a case history from inception to closure

Abstract

Chinova Resources Pty Ltd's Osborne Mine is located in Northern Queensland, approximately 800 km inland from the eastern coast. It commenced operations in 1995 with the development of an open pit mine. In 1996, the operation transitioned to underground mining. In 2015, Osborne will have been in operation for 20 years and will have mined 29 Mt of ore. The site has produced 672, 420 t of copper and 673,295 oz of gold. Osborne Mine produces approximately 112,000 t of tailings per month. In 2003, following progressive evaluation and development of a high-density discharge tailings management system, Osborne implemented the first of two trial depositions forming advancing cones of deposited tailings within their TSF2 site. These trials proved successful and, following successful permit applications to the regulators, TSF2 was converted to high-density thickened tailings discharge. The principal benefit of this change was in the reduction of construction costs for confining embankments. However, an additional major benefit lay in a reduction of make-up water volumes. The majority of water loss in the process water circuit occurs in the tailings system as a result of evaporation. High-density thickened discharge provides a means for significantly reducing water losses, since, by recovering and re-using more water at the thickener and in the plant, less water is discharged onto the tailings facility so there is less water available for evaporation. High-density thickened discharge also enabled a significant improvement in operating costs. High-density thickened discharge operations at Osborne have had to be continuously modified and adjusted as ores from satellite mines have been processed to supplement the diminishing Osborne Mine ore. Mineralogical influences of the supplementary ore significantly affect the thickening and beaching characteristics of the tailings slurry, particularly in the most recent operating period. However, through appropriate modifications and adjustments, the benefits of high-density thickened discharge have been retained. The resulting tailings storage facility (TSF) landform is that of a shallow-sloped shedding mound so that there is no need to retain water on the TSF. Chinova has been proactive with ongoing site monitoring and rehabilitation with a view to shedding runoff to the environment. Their site plans include ensuring that the discharge water from the site will meet the stock-water guidelines, and that the erosion gullies forming in TSF cover materials or on the side slopes of confining embankments will not result in exposure of the tailings over 500 years.

Geotechnical effects of polymer treatment on tailings – state of knowledge review

“…Further, the inferred variation to the CSL suggested in Figure 1 is generally consistent with the other testing results on UT and PT material in the same program. These outcomes indicate that the effects of PT on resulting CSL should be considered when critical state techniques (Li et al 2009;McPhail et al 2004) are applied to assess the stability of a steepened tailings beach. Paste 2018, Perth, Australia…”

Feasibility of High-Density and Non-Segregable Niobium Ore Tailings

“…Cooling [10], Kam et al [11], Fourie [1], Mcphail et al [12], and Mudd and Boger [13] reported the high-density slurry advantages, such as reduced dam construction and decommissioning costs, reduce risks of failure, increased in situ density, higher yield stress, lower infiltration and leaching issues, and better water process recovery, avoiding losses with evaporation and possibilities due to the reclaim process reagents.…”

“…Studies have demonstrated the potential for increasing in situ bulk density with a higher solids content in slurry and the non-segregation of particles [1,12]. Solids content necessary to achieve this consistency can be different according to the material, particle size distribution, presence of clays, pH, use of chemicals such as flocculants, and type of water, which can affect the rheological behavior of mineral tailings [14,15].…”

Desaguamento e disposição de rejeitos de nióbio adensados não segregáveis em barragens.

“…Relata ainda ganho de densidade e resistência com a utilização de rejeitos espessados. A redução de infiltração e lixiviação também foram notadas e vantagens na recuperação de água, uma vez que é recuperada no equipamento de desaguamento evitando perdas de evaporação e infiltração (COOLING, 2007;KAM et al, 2011;MCPHAIL et al, 2004).…”