Publication information. Executive summary

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1 TABLE OF CONTENTS Water for Mining Publication information ii Executive summary Figure: Global mining water market by expenditure category, 2011 Figure: Global mining water market forecast: 2012 peak, 2014 peak and supercycle models, Market challenges Opportunities Conclusion Units and conversion factors used in this publication 1. Introduction to mining Mining Water for mining Mining methods Surface mining Underground mining 3 Figure 1.1 Water issues associated with surface and underground mining Processing methods 4 Figure 1.2 Mineral ore processing steps Physical separation processing Pyrometallurgy Hydrometallurgy Electrometallurgy Product handling and transport Commodities 9 Figure 1.3 Overview of commodities Copper Copper processing 10 Figure 1.4 Processing streams for copper ores Copper production 11 Figure 1.5 Top 5 copper reserves and largest producers of copper in Figure 1.6 Copper - Share of controlled production by mining companies, Gold Gold processing 12 Figure 1.7 Processing streams for Gold ores Gold production 13 Figure 1.8 Top 5 gold reserves and largest producers of gold in Figure 1.9 Gold - Share of controlled production by mining companies, Nickel Nickel processing 14 Figure 1.10 Processing streams for Nickel sulphide ores 14 Figure 1.11 Processing streams for Nickel laterite ores Nickel production 15 Figure 1.12 Top 5 nickel reserves and largest producers of nickel in Figure 1.13 Nickel - Share of controlled production by mining companies, Zinc Zinc processing 16 Figure 1.14 Processing streams for zinc ores Zinc production 17 Figure 1.15 Top 5 zinc reserves and largest producers of zinc in Figure 1.16 Zinc - Share of controlled production by mining companies, Platinum Platinum processing 17 Figure 1.17 Processing options for Platinum ores Platinum production 18 iii iii iv iv v vi vi vii

2 WATER FOR MINING Figure 1.18 Top 4 PGM reserves and largest producers of platinum in Figure 1.19 Platinum - Share of controlled production by mining companies, Iron ore Iron ore processing 19 Figure 1.20 Processing options for iron ore Iron ore production 20 Figure 1.21 Top 5 iron ore reserves (iron content) and largest producers of iron ore in Figure 1.22 Iron ore - Share of controlled production by mining company, Metal mine geography 20 Figure 1.23 Operating mines in the Americas 21 Figure 1.24 Operating mines in Europe and Africa 22 Figure 1.25 Operating mines in Asia Pacific Non-metal commodities Coal 24 Figure 1.26 Top 5 black coal reserves and largest producers of black coal in Figure 1.27 Top 3 brown coal reserves and largest producers of brown coal in Figure 1.28 Coal processing steps Phosphate rock Processing The washing plant Production 26 Figure 1.29 Top 5 phosphate reserves and largest producers of phosphate 26 Figure 1.30 Phosphate - Share of controlled production by mining company, Heavy media separation plant The flotation plant 27 Figure 1.31 Phosphate ore processing steps Acid rock drainage 28 Figure 1.32 Typical relation to drainage ph 29 Figure 1.33 : Types of drainage produced by sulphide oxidation 29 Figure 1.34 : Generalised conceptual model of sources, pathways and receiving environment at a mine or processing site 30 Figure 1.35 Examples of ARD costs Water volumes for mining and processing Water required for processing methods 31 Figure 1.36 Water consumption volumes for the processing steps for selected metals Water use reported by major mining countries Chile 32 Figure 1.37 Average water consumption per ton of copper ore in Chile, 2000 and Figure 1.38 Projection of total water withdrawal for copper mining in Chile, Australia 33 Figure 1.39 Water use by the Australian mining industry, Canada 33 Figure 1.40 Water use in the Canadian mining industry, Figure 1.41 Intake water treatment in the Canadian mining industry, Figure 1.42 Effluent water treatment in the Canadian mining industry, USA 34 Figure 1.43 Average water use per tonne of crude ore production 34 Figure 1.44 Metal mining water use in the US, Mexico Water use reported by major mining companies Calculating global water withdrawal for mining Drivers for improved water management in mining Water related risks Water scarcity 38 Figure 2.1 Global water scarcity: Ratio of water extraction to total renewable resources 39 Figure 2.2 Locations of currently operating mines Regulations International framework 41 viii

3 TABLE OF CONTENTS Figure 2.3 Global Reporting Initiative water related indicators Introduction to national regulatory frameworks 44 Figure 2.4 Main regulatory requirements in the mining operation life-cycle Chile Governmental organisations Legal framework around water issues in mining 46 Water allocation and environmental permitting 46 Effluent discharge regulations 47 Figure 2.5 Effluent discharge limits according to D.S.90* 48 Mining closure regulations Australia State and territory level agencies and regulations 50 Water allocation and permitting 50 Effluent discharge regulations United States South Africa Canada 54 Figure 2.6 Federal water policies Recovery of valuable metals and the water quality factor Water supply, treatment and reuse in mines: main management options and technologies Water management overview 57 Figure 3.1 Mining operational phases Water management risks Supply Effluent Reuse Mine closure Water balance 59 Figure 3.2 Water balance in a typical mine Water accounting 60 Figure 3.3 Key requirements for generating a water account Water supply, treatment and reuse in mines: main management options and technologies Use of alternative water supply options Factors behind the choice of feedwater 62 Figure 3.4 Water quality suitability for selected processes Desalination mining projects Seawater mining projects in Chile 64 Figure 3.5 Main mining operations using desalination or raw seawater in Chile 64 Figure 3.6 Mining operations considering the use of seawater 65 Case study: Minera Esperanza (Antofagasta Minerals) Desalination mining projects in Australia Australian mining desalination project examples Effluent treatment technologies and disposal Neutralization technologies Conventional lime neutralization 67 Figure 3.7 Conventional lime neutralization process High density sludge (HDS) process Lime precipitation system 68 Figure 3.8 HDS process Limestone neutralization Passive treatment technologies Anaerobic wetland systems Aerobic wetlands Metal removal technologies Sulphide precipitation BioSulphide precipitation process 71 Case study: Mike Horse Mine Water Treatment System (CDM) 71 Figure 3.9 BioSulphide precipitation process ChemSulphide precipitation process 72 ix

4 WATER FOR MINING Figure 3.10 ChemSulphide precipitation process Biogenic sulphide precipitation - THIOTEQ BIOMETEQ biological sulphide precipitation Biological filters - ABMet 73 Case study: Raglan Mine, Quebec, Canada (Xstrata/BioteQ) Fluidised bed reactor - METCLEAN Membrane technologies Microfiltration (MF) and Ultafiltration (UF) Nanofiltration (NF) Reverse osmosis (RO) Ion exchange (IX) Electrodialysis (ED) Electrodialysis reversal (EDR) Bipolar Electrodialysis (BPED) Electrodeionization (EDI) Evaporators, concentrators and crystallisers Brine concentrators Crystallisers Evaporators - Vapour compression distillation (VCD) Evaporators - mechanical vapour recompression (MVR) Multi effect distillation (MED) Dewatering technologies Clarifiers Dissolved air flotation (DAF) ITT Leopold Clari-DAF Filtration and thickening technologies Sand filtration - DynaSand Ceramic vacuum filters Pressure filters Thickeners High rate thickeners Paste thickeners Selenium treatment technology 80 Case study: Selenium remediation using zero-valent iron (ZVI), Liberty Hydro Inc., West Virginia Cyanide treatment technologies Alkaline Chlorination International Nickel Company s (INCO) process Hydrogen peroxide process Acidification Volatilization Recovery (AVR) cyanide recovery process Sulphidization, Acidification, Recycling and Thickening (SART) process 82 Figure 3.11 Sulphidization, Acidification, Recycling and Thickening (SART) process Biological cyanide treatment Effluent disposal Tailings disposal Backfill disposal 85 Figure 3.12 Drainage treatment technology categories Water reuse and recycling Reuse overview 86 Figure 3.13 Worked water resources Effluent water reuse Effluent water recycling and treatment 87 Figure 3.14 Comparison between passive and active treatments Offsite use of treated effluent water Market analysis Market division / segmentation 89 Figure 4.1 Global mining water market by expenditure category, Figure 4.2 Global mining water market by country, Figure 4.3 Global mining water treatment equipment market by equipment type, x

5 TABLE OF CONTENTS 4.5 Key and emerging players Engineering programme management firms Traditional water technology companies Key companies and areas of expertise 91 Figure 4.4 Key and emerging players: Engineering and consultancy sector for water in the mining industry 91 Figure 4.5 Key and emerging players: Supply of water technology for the water in mining industry 94 Figure 4.6 Key and emerging players: Manufacture of specialist equipment for the water in mining industry 95 Figure 4.7 Acquisitions and joint ventures Future market growth 96 Figure 4.8 Selected metal prices, January June Figure 4.9 Global mining water market forecast: 2012 peak, 2014 peak and supercycle models, Figure 4.10 Global mining water market forecast: 2012 peak model by country, Figure 4.11 Global mining water market forecast: 2014 peak model by country, Figure 4.12 Global mining water market forecast: Supercycle model by country, Figure 4.13 Global mining equipment forecast: 2012 peak, 2014 peak and supercycle models, Figure 4.14 Global mining equipment forecast: 2012 peak model by country, Figure 4.15 Global mining equipment forecast: 2014 peak model by country, Figure 4.16 Global mining equipment forecast: Supercycle model by country, Figure 4.17 Australia market summary 101 Figure 4.18 Brazil market summary 102 Figure 4.19 Canada market summary 103 Figure 4.20 Chile market summary 104 Figure 4.21 China market summary 105 Figure 4.22 Indonesia market summary 106 Figure 4.23 Peru market summary 107 Figure 4.24 Russia market summary 108 Figure 4.25 South Africa market summary 109 Figure 4.26 USA market summary 110 Figure 4.27 Rest of the world market summary 111 Figure 4.28 Global market summary Current and future projects Billion dollar projects 113 Figure 4.29 Billion dollar mining projects from the RMD dataset 113 Figure 4.30 Locations of mining projects and currently operating mines Metal-by-metal trends 120 Figure 4.31 Currently operating mines with copper as the main metal 120 Figure 4.32 Forthcoming mining projects: Copper 120 Figure 4.33 Currently operating mines with zinc as the main metal 121 Figure 4.34 Forthcoming mining projects with zinc as the main metal 121 Figure 4.35 Currently operating mines with nickel as the main metal 122 Figure 4.36 Forthcoming mining projects with nickel as the main metal 122 Figure 4.37 Currently operating mines with gold as the main metal 123 Figure 4.38 Forthcoming mining projects with gold as the main metal 123 Figure 4.39 Currently operating mines with iron ore as the main metal 124 Figure 4.40 Forthcoming mining projects with iron ore as the main metal Accessing the market The approach to entering the water for mining market Barriers to market entry Piloting as a vehicle for market entry The players in the water for mining market Technologies dominating the water for mining market Dominance of market players Process solutions versus separate technologies Challenges facing the water for mining market Water for mining market opportunities Overview of market opportunities Opportunities in treating mine effluent 148 xi

6 WATER FOR MINING 6.3 Water reuse opportunities Opportunities in metal recovery Water supply opportunities Market opportunities: Standard effluent treatment Evolution of the mine water effluent treatment market Best positioned companies in the mine water effluent treatment market Market place longevity for conventional effluent treatment technologies Implications of processing lower ore grades on the effluent treatment market The effect of fluctuations in commodities prices on the selection of water management options Market opportunities: Water reuse opportunities Barriers affecting the development of the reuse market Potential opportunities for offsite reuse Potential opportunities for onsite reuse Best positioned companies in the reuse market Market opportunities: Water supply Primary areas of demand for water supply technologies Challenges facing the technologies market for water supply Companies best positioned for the water supply technologies market Mining companies that are customers to the water supply technologies market Market size Collaborations and agreements between market players 175 Interviewees 179 References 181 xii