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Mine Water Treatment SOQ

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Mine Water Treatment SOQ

  1. 1. Statement of Qualifications Mine Water Treatment Advanced filtration & separation technologies for incoming and discharge (waste) water streams
  2. 2. 2
  3. 3. 3 Contents Introduction Total Cleanliness Management Enabling a Greener Future Leadership Recognition Representative Projects Global Offices
  4. 4. 4 Pall’s Global Mining Presence Pall Corporation is a filtration, separation and purification leader providing solutions to meet critical mine water treatment objectives of mining customers for open cut and underground installations. With offices around the world, Pall can provide detailed water process chemistry review and offer industry leading membrane technologies and services. These products and services are specifically designed and optimized to meet both the mining customer objectives and to be environmentally compliant to external regulatory controls. For more than 50 years Pall has been a dependable source of innovative technical solutions designed to ensure water chemistry optimization, deliver maximum productivity, and have dependable equipment operating costs. Total Cleanliness Management (TCM) Total Cleanliness Management (TCM) is a comprehensive program specifically designed for each of Pall’s mining customers. TCM begins with an in-depth review/analysis of each customer’s water chemistry. Then we recommend and build a package of selected membrane filtration and separation equipment, diagnostic/monitoring devices, and on-site consulting services that will help the customer achieve the highest process efficiency at the lowest operating cost. Mine Water Issues Pall Corporation defines mine water treatment into two categories: • Incoming water quality or quantity not sufficient for use in the process (e.g. dust suppression water, cooling water, boiler feed water) or for potable water needs ♦ e.g., poor surface water quality: colloids, solids (TSS), microbiology, dissolved solids (TDS), variability • Discharge (waste) water quality (TSS, turbidity, specific ions, etc.). Water needs treatment prior to use / reuse or discharge ♦ e.g., treatment of intrusion / mine water prior use / reuse (turbidity, Fe, Mn) We believe that mining investment in water treatment technologies should be such that the solution enables the mining customer to meet current and future discharge regulatory requirements while meeting high variability and potential changes of raw water / mine water quality. Water in mining comes from several sources: • Surface water (lake, river, sea…) • Ground or spring water • Municipal water (towns water) • Secondary effluent (from biological waste water treatment plants, e.g. municipalities reuse) • Lagoon/pond water (may include run-off water, storm water, intrusion water, groundwater, mining drainage water including Acid Mine Drainage, or dewatering wells) • Tailing storage facilities Depending on where the water is coming from and where the water is used, contaminants in the water can be harmful for the operation (assets and efficiency), staff/people (health) and/or environment (nature).
  5. 5. 5 Depending on the water source, contaminants can be present across the entire range • Suspended solid contaminants can be removed by ♦ Up front settlement of bulk contaminant by pond/lagoon or clarifiers (bulk removal) ♦ Filtration with Pall Aria® membrane filtration system or disposable range of products • Dissolved contaminants can be removed by ♦ Oxidation, coagulation or precipitation followed by an Aria system ♦ Reverse Osmosis (RO) / Nanofiltration (NF)* ♦ Ion Exchange (IX)* or EDI * Note: it is necessary to protect RO, NF and IX with an upstream Aria system Pall’s mine water team can help mining customers: •…with innovative filtration solutions for challenging incoming water or discharge (waste) water streams, allowing mines to meet discharge requirements ♦ … by treating water for reuse (e.g. as process water or to cope with shortages in arid areas) ♦ … become less dependent on external water supplies Contaminants and Pall Corporation’s membrane separation technologies Range where contaminants may exist in a dissolved / suspended state Inorganic salts Organics Colloidal Virus / Bacteria Mineral / General / Mixed Size (µm) Size (µm)0.0001 0.001 0.01 0.1 1.0 10 100 Dissolved Suspended
  6. 6. 6 Setting the Standard, Sharing the Responsibility Pall Corporation recognizes and embraces its role as a global citizen, including an obligation to the environment. Pall is dedicated to helping customers minimize their water and carbon footprints, maximize recycling and waste reduction efforts, and ensure the most efficient utilization of natural resources and raw materials. We are applying the same know-how and dedication to our own operations. Pall’s approach to environmental stewardship is proactive and is anchored in a culture of continuous improvement. We team with customers in ways specific to their industries, providing them with technologically superior products and engineered process solutions that improve and strengthen their businesses while reducing their environmental impacts. Customers worldwide look to us to help them purify and conserve water, address water scarcity, consume less energy, make alternative energy sources possible, and minimize emissions, pollutants, and waste. Pall has integrated aggressive environmental sustainability metrics into our business by using globally accepted greenhouse gas protocols to measure and manage carbon emissions. We are also a partner in the U.S. Environmental Protection Agency’s Climate Leaders program, an industry government partnership committed to developing long-term climate change strategies. We encourage you to visit our Web site at www.pall.com/green for updates on progress, as well as for information about other environmental initiatives. Pall’s approach to environmental stewardship is proactive and anchored in a culture of continuous improvement.
  7. 7. 7 Leadership Recognition NYSE (Since 1992) Pall Corporation is a publicly traded company listed on the New York Stock Exchange under the ticker PLL. Listed companies must continuously meet rigorous financial and governance requirements. http://www.nyse.com Fortune 1000 (Since 1991) Pall is included in the Fortune 1000, an annual list compiled and published by Fortune magazine that ranks the top 1000 U.S. closely held and public corporations by revenue. http://money.cnn.com/magazines/fortune S&P 500 (Since 1987) Pall is included in the S&P 500 index—one of the most commonly used benchmarks for the overall U.S. stock market. The S&P 500 is a capitalization- weighted index published since 1957 of the prices of 500 large-cap common stocks actively traded in the United States. http://www.standardandpoors.com Business Recognition Environmental Recognition ISO 14001 Certification ISO 14001 is the international standard for environmental management systems. Worldwide, all of Pall’s plants have achieved ISO 14001 certification. Certified companies must provide assurance about their ability to satisfy quality requirements and to enhance customer satisfaction in supplier-customer relationships. http://www.iso.org EPA Climate Leaders (Since 2008) Climate Leaders is an EPA industry-government partnership that works with companies to develop comprehensive climate change strategies. Partner companies commit to reducing their impact on the global environment by completing an inventory of their green- house gas emissions, setting aggressive reduction goals, and annually reporting their progress to the U.S. EPA. http://www.epa.gov Carbon Disclosure Project (Since 2008) Pall participates in the Carbon Disclosure Project (CAUP), a global initiative to inventory greenhouse gas (GHUZ) emissions and evaluate the risks and opportunities from climate change on business operations. Companies use their annual GHG inventory to make informed and effective policy decisions to reduce their carbon footprint. http://www.cdproject.net Cleantech Index (Since 2006) Pall is included in the Cleantech Index—the first stock market index intended to reflect the surging demand for clean technology products and services. The index is comprised of companies that are global leaders in Cleantech across a broad range of industry sectors, from alternative energy and energy efficiency to advanced materials and air & water purification. http://cleantech.com FTSE4Good (Since 2001) Pall has been independently assessed according to the FTSE4Good criteria, and has satisfied the requirements to become a constituent of the FTSE4Good Index Series. FTSE4Good is an equity index series that is designed to facilitate investment in companies that meet globally recognized corporate responsibility standards. http://www.ftse.com Technology Recognition Engineering Materials Achievement Award (2010) Pall Corporation won the prestigious Engineering Materials Achievement Award (EMAA) for 2011 for its porous iron aluminide technology. The award, which recognizes outstanding achievements in the field of materials science, is given annually to one company by ASM International, a society dedicated to the development and commercialization of materials that advance production techniques and facilitate innovation. http://www.asminternational.org National Inventors Hall of Fame (2008) Dr. David B. Pall, founder of Pall Corporation, was inducted into the National Inventors Hall of Fame. Dr. Pall’s body of work in the field of filtration science earned him a place among legendary innovators including Alexander Graham Bell, Walt Disney, Thomas Edison and Henry Ford. http://www.invent.org National Medal of Technology (1990) On behalf of Pall Corporation, Dr. Pall received the National Medal of Technology, the highest technology honor in the United States. Other past winners include Microsoft, Applied Materials, Proctor & Gamble and Johnson & Johnson. http://www.uspto.gov
  8. 8. 8 Application: Coal Seam Gas (CSG) Produced Water Treatment Location: Queensland, Australia Solution: Integrated Membrane System (IMS): Microfiltration (MF), Reverse Osmosis (RO) and ancillary skid Capacity: Containerized CSG IMS including: Microfiltration (MF) and Reverse Osmosis (RO) services (with supporting services container) on coal seam gas produced water 12 MLD (3.2 MGD) Status: The design allowed for an initial capacity of 9 MLD (2007), upgraded to 12 MLD in 2008 Coal Seam Gas (CSG) now accounts for approximately 80% of the gas used in Queensland. For many of the CSG fields, water is present over the coal deposit and in the coal cleats or fractures. Gas production is initiated by lowering the pressure in the coal seam, by pumping off the water contained in the cleats, allowing the gas to ‘desorb’ from within the coal and flow to the surface. CSG production will typically involve a large flow of water initially and the water flow will diminish as the gas production ramps up. The water quality is highly variable and differs significantly not only from field-to-field, but also within the field itself from well to well and over the life of the field. It can be moderately brackish to saline, with a wide range of potentially fouling/scaling constituents including high-suspended solid levels, metals, silica, and other ions. The design allowed for an initial capacity of 9 MLD, easily upgradable to 12 MLD (which was done in 2008) and potential expansion to 15 MLD. For this CSG application, Pall provided the MF system including all CIP and pre-treatment facilities configured for containerized installation as part of a mobile water platform fleet for irrigation. The IMS facility was brought online on Dec 23, 2007 and has been operational since that time. In 2008 capacity was increased to 12 MLD. Discharge license conditions have been consistently met, with pH and conductivity being constantly measured and recorded. The Pall MF system continues to operate reliably with little operator involvement. Representative Projects
  9. 9. 9 Application: Potable Water Production Location: Australia, Army Solution: Microfiltration (MF), Reverse Osmosis (RO), and ancillary equipment skid Capacity: 0.4 MLD MF (0.1 MGD) – 0.1 MLD RO permeate Status: • Full Military Spec Design and prototype accredited • First 14 production units complete • Order received for 9 additional units Pall has been contracted to provide the Australian Army (value ~$24 M Aus) with design, fabrication, supply, and full through-life support and maintenance services for 14 specialized MF and RO systems and self-sufficient service units. These units meet high level military specifications (COG, weight, vibration resistance, required documentation, etc.). These customised modular systems were fully designed and fabricated in Pall’s Somersby facility (NSW), and were designed for rapid deployment for military purposes or humanitarian aid to provide purified water from a variety of sources (e.g: seawater with surf harvesting, or inland contaminated surface waters).
  10. 10. 10 Application: Arsenic Removal Location: Gold mine, Nevada, U.S. Solution: Microfiltration (MF) Capacity: 120gpm (0.65MLD) Status: Installed and operating since 2006 Pall Corporation supplied an Aria AP-3 skidded microfiltration (MF) system to a gold mining customer located in Nevada. The skid was designed for 120 gpm flow. Tetra Tech was the engineering firm responsible for the design and construction of the plant. The Pall MF system removed arsenic from a groundwater source following chemical pre-treatment. The overall process consisted of chemical addition of oxidant (sodium hypochlorite) and coagulant (ferric chloride), a Pall Aria AP-3 system, three acid ion exchange vessels (to remove radium), and a salt storage/brine generation tank. Prior to the design phase, Pall Corporation worked with Tetra Tech and conducted a 2 month pilot testing program to determine design criteria for chemical dosages, membrane flux, and to evaluate chemical dosing, water temperature, arsenic oxidation state and pH adjustment. Representative Projects
  11. 11. 11 Application: Arsenic Removal Location: Gold mine, Alaska, U.S. Solution: Microfiltration (MF) Capacity: 800gpm (4.3 MLD) Status: Installed and operating since 2007. Pall Corporation supplied 2x Aria AP-4 skidded microfiltration (MF) systems to a gold mine located in Alaska. Total flow was 800 gpm. Tetra Tech was the engineering firm responsible for the design and construction of the plant. The Pall MF unit treated pit dewatering water containing arsenic concentrations above 170 ppb. Tetra Tech conducted on-site bench scale testing and with Pall process engineers, determined an optimal dosing treatment process for both arsenic and antimony removal. The full scale treatment plant utilizes pre-treatment with ozone and primary settling in two plate clarifiers followed by the two Pall Aria AP-4’s MF skids in parallel. The remote aspects of Alaska led to challenging construction conditions. All piping over 4000 linear feet (1220 m) and tanks were heat traced and insulated. The water treatment plant was successfully integrated into the mine process through a common SCADA system.
  12. 12. 12 Application: Brine Wastewater Treatment Location: Natural gas storage facility, U.S. Solution: Microfiltration (MF), Pall Aria Mobile trailers Capacity: 12MGD (45 MLD) Status: Installation in phases, starting with pilot project of 4x trailers in 2010, to full production usage of 12x trailers in mid 2011 With the rising importance of natural gas as an energy source, significant effort is being given to the development of large underground storage facilities to bridge the gap between natural gas production and the sale of the gas for energy use. These massive storage facilities are created by means of salt cavern leaching. Using heated raw water circulating through an underground well, developers slowly leach large caverns in deep salt pillars that are then utilized for the storage of compressed natural gas. Salt pillars contain not only salt but are laden with clays, sands, and gravels due to geologic processes. Brine extracted during leaching can contain onerous loads of suspended solids. Filtration of these solids to a 2 micron level is a regulatory requirement that must be met before the salt brine can be disposed by injection into a neighboring salt pillar. Current industry practice is to use hydrocyclones followed by disposable filters to remove these sediments. While simple in concept, this traditional process comes at enormous operating costs. Pall Corporation, working with Tetra Tech, optimized waste brine handling for 4 salt caverns that could store over 48 billion cubic feet of natural gas. Following a 4 MGD (15 MLD) pilot test, the project resulted in the building of a full-scale 12 MGD facility. Representative Projects
  13. 13. 13 Application: Coal Seam Gas Produced Water Treatment Location: Queensland, Australia Solution: Integrated Membrane System (IMS): Microfiltration (MF) and Reverse Osmosis (RO) Capacity: 9 MLD (2.3 MGD), upgraded to 12 MLD in 2008 4 x Aria 6CSG MF systems 3 x Aria 3CSG RO skids Status: Installed December, 2007 Upgraded to 12 MLD in 2008 This project involved the design, fabrication, supply, and commissioning of a complete IMS (Integrated Membrane System) for a Coal Seam Gas Development. Due to the remote nature of the site, a high degree of modularized (or skid mounted) systems were required, minimizing on-site labor costs and time. Project scope included pre-strainers, MF skids, RO skids, interconnecting pipe work, MCCs and ancillary equipment (CIP skids, chemical transfer and dosing, compressed air systems, and plant-wide control / SCADA).
  14. 14. 14 Application: • Desalination of Coal Mine Brackish Water • Treatment of River Water for Potable Water Location: Underground Longwall Coal Mine, Australia Solution: • Microfiltration (MF) & Reverse Osmosis (RO) for brackish water • Microfiltration (MF) and dosing for river water Capacity: • 1.28 MLD (0.33 MGD) freshwater permeate by MF & RO desalination (expandable in 2 future stages to 3MLD and then 5 MLD) • Potable water production 0.06 MLD by MF Status: Commissioned in 2011 The dewatering of underground coal mines results in large volumes of brackish water that requires desalination to allow its re-use as process water for machinery cooling and dust suppression in the longwall mining machinery. As the mine expands, the volume of brackish water produced increases and the salinity (TDS) also increases over time. A flexible design approach was taken to minimize initial capital costs. This enabled operation for the first 5 years and allowed expansion to accommodate larger flows and higher TDS feeds via a relatively simple ‘plug and play’ upgrade. 2 x Pall Aria AP4 MF systems remove suspended solids and metal precipitates before desalination by a 2 stage RO skid running at 80% recovery. A separate Aria AP1 MF plant produces potable water from a river water feed. Pall Corporation provided all the equipment and overall process guarantee. Moree Engineering provided civil engineering, electricals, tanks, miscellaneous services, design, and installation. Representative Projects
  15. 15. 15 Application: High Recovery Longwall Coal Mine Pit Waste Water Treatment Plant Location: Underground Longwall Coal mine, Australia Solution: Integrated Membrane System (IMS): Microfiltration (MF) & Reverse Osmosis (RO) Capacity: 2.5 MLD (0.66 MGD) Status: Commissioned in 2009 This mine operates sensitive machinery and equipment that relies on a constant supply of good quality fresh water. To improve the sustainable performance of its operations, Pall Corporation worked with the mine’s partner for sustainable environmental improvement to develop a facility to: 1) Minimize the consumption of mains water and 2) Decrease the salinity of water discharged from mine operations into the local creek and river systems An integrated membrane system (IMS)filtration plant was designed and built at the mine site – the first of its kind to be built for the Australian mining industry. The plant uses a range of technologies, such as microfiltration, weak acid ion exchange resin, and reverse osmosis to desalinate low-level saline waste water that is pumped from underground workings. It is capable of processing 28.9 litres/second (458 GPM) or 2.5 MLD. The plant is equipped with a host of on-line chemical analysis systems to monitor the performance of the facility. The design of the plant and process allows a high (~ 92%) recovery rate such that up to 2.3 MLD of fresh water can be produced. This water is recycled for use in the mine and to reduce the amount of water purchased from the municipal supply. In the first year of the plants operation, the mine’s demand from the mains supply was less than one third that of previous years, resulting in an annual saving of 241 million litres. The water saving earned the mining company the Largest Reduction Award in Sydney Water’s Every Drop Counts Business Programme Awards.
  16. 16. 16 Application: TSF Discharge Waste Stream Recovery Location: Underground Nickel Mine, Manitoba, Canada Solution: Integrated Membrane System (IMS): Microfiltration (MF) & Reverse Osmosis (RO) Capacity: 400gpm (2.2 MLD) Status: Commissioned in 2009 Pall Corporation received an urgent distress call from the local mine management. The mine was in violation of their mine dewatering discharge permit and was ordered by the province to stop discharging water, i.e. to shut down mine operations. Dewatering water was being sent to the tailings storage facility that, because of additional volume from rainfall, was about to burst and discharge into the river. Minimum dewatering flow was 400 gpm. Time had run out and the mine had only 20 days left of available TSF storage. If the mine had shut down operations and stopped the dewatering pumps, the mine shaft would have been flooded and water would have destroyed $50M worth of underground mining equipment. The unacceptable alternative would be to continue to discharge and knowingly violate the permit, which would amount to substantial daily fines. To avoid these outcomes, Pall Corporation worked in conjunction with Tetra Tech to conceptualize, design, build, procure and commission a complete water treatment plant. This project was completed in 19 days and was the fastest build and deployment in Pall’s mining history. News of this fast track deployment success quickly spread throughout the Canadian mining market. Representative Projects
  17. 17. 17 Application: Arsenic Removal Location: Gold mine, Nevada, U.S. Solution: Microfiltration MF Capacity: 0.7 MGD (0.19 MLD) Status: Installed and operating since 2006 Pall Corporation, working with Tetra Tech, designed and constructed a 50 gpm capacity WTP that included coagulation-assisted microfiltration (MF) for arsenic removal from a groundwater source. The process involves chemical addition of oxidant (sodium hypochlorite) and coagulant (ferric chloride) and a Pall Aria AP-2 microfiltration (MF) skid. Prior to design, pilot testing was conducted for 3 months to determine design criteria for chemical dosages, membrane flux,chemical dosing, water temperature, arsenic oxidation state, and pH adjustment. Source water is 150 ppb As and high silica, but low hardness and alkalinity. Operation interface is less than one hour per day.
  18. 18. 18 Application: Wastewater Treatment Location: Gold mine, sub-Sahara Africa Solution: Integrated Membrane System (IMS): Microfiltration (MF) and Reverse Osmosis (RO) Capacity: • Dewatering pit, 2x PAM MF Containers 2.778 MLD (0.73 MGD) • TSF, 2x PAM MF Containers, 1x RO and 1x RO CIP container 2.82 MLD (0,74 MGD) Status: Installed and operating since 2011 Pall Corporation worked with Tetra Tech under an EPC to execute and satisfy a water management challenge at a gold mine in a very remote part of sub-Sahara, Africa. Standard MF containers were supplied and a custom RO container was designed. Membrane technology treated both the dewatering pit and the discharge from the tailings pond that was being discharged into the local river. Also, a side potable water stream was fed to the mine camp and the local village. HMI / SCADA interface was implemented into the current PLC operational protocol of the mine. The operators received detailed water treatment plant training. The mine faced significant water challenges caused by excess process circuit water from their mining operations. They also required the rapid treatment and discharge of accumulated pit water in order to resume mining their open pit operations. Tetra Tech was commissioned to design a two-train water treatment facility to handle the excess water from the TSF and accumulated pit water. Tetra Tech and Pall Corporation developed a detailed treatment process for addressing the complicated water discharges caused by stringent discharge standards (for metals and inorganic constituents). Tetra Tech performed the complete detailed design of the water treatment plant including all surrounding infrastructure. The final plant includes lime/soda ash softening followed by integrated microfiltration (MF) and reverse osmosis (RO) membranes. An innovative technology of forced air thermal evaporation was used to manage the brine waste generated from the reverse osmosis process Being so remote also presented many logistical and security challenges. These were overcome, and the plant is fully operational. Representative Projects
  19. 19. Application: Potable Water Treatment Location: Coal Mine, Russia, Kemerowo Siberia Solution: Microfiltration (MF) Capacity: 0.63 MGD (100 m³/h); AriaTM AP-6 Status: Under construction – start up expected in 2012 This is the first water treatment system sold to a Coal Mining Company in Siberia/Russia for potable water. The superior design of the Pall Aria MF system will provide safe water at all times, independent of variations of the feed quality. This is a vast improvement compared to undefined effluent quality of sandfilters, UV lamps etc., and was the pri- mary reason the customer chose to use Pall membrane-technology. A local partner company was involved to supply the local service. Application: Drinking water for mining-staff Permeate quality: Meets drinking water standard (pathogen removal; Fe/Mn-removal; turbidity free; microbiological clean) to provide water supply for operators, canteen, showers, etc. Feed water: Underground well water Pretreatment: Oxidation (aeration) Siberia’s cold environment (temperatures to -40 °C in winter) and cold water creates challenging design and construction conditions. Pall’s reliable and robust technology, used and approved by the market (ARIA with more than 600 installations), was chosen for its suitability for the purpose of water treatment. 19
  20. 20. Pall Industrial Sales Offices Machinery and Equipment 25 Harbor Park Drive Port Washington, NY 11050 +1 516 484 3600 telephone +1 888 333 7255 toll free US Melbourne - Australia +61 (0)3 9584 8100 telephone +61 (0)3 9584 6647 fax Visit us on the Web at www.pall.com Pall Corporation has offices and plants throughout the world. For Pall representatives in your area, please go to www.pall.com/contact Because of technological developments related to the products, systems, and/or services described herein, the data and procedures are subject to change without notice. Please consult your Pall representative or visit www.pall.com to verify that this information remains valid. © Copyright 2011, Pall Corporation. Pall, , and Ultipleat are trademarks of Pall Corporation. ® indicates a trademark registered in the USA. Filtration. Separation. Solution. and ENABLING A GREENER FUTURE. are service marks of Pall Corporation. MEMWTEN February 2012