koodaideri project - mining newspilbara iron company (services) pty ltd level 18, central park...

Level 18, Central Park 152-158 St Georges Terrace Perth WA 6000 © Copyright 2018 Rio Tinto

www.worleyparsons.com

RIO TINTO PROJECTS

Koodaideri Project Koodaideri Processing Plant Works Approval Application

Licence Amendment Supporting Documentation Works Approval – Pelican Pelican Camp Waste Water Treatment Plant Supporting Documentation

Koodaideri Exploration Pelican Camp – L8562/2011/1

Project No 201012-00702

Document No. KD-9900-H-REP-00005

20 December 2018

DocuSign Envelope ID: 62ED1C2C-A9FF-4707-B31B-CD6786EB587ADocuSign Envelope ID: D48B096D-ED6E-47A6-85A7-F37F96FE3078

Koodaideri Project – KD-9900-H-REP-00005

Rev Description Original

Review WorleyParsons

Approval Date

Customer Approval

Date

0 Issued for Use 20-Dec-18 20-Dec-18

D Pearse N Simcock B McLernon J Whitburn

KD-9900-H-REP-00005_0.DOCX

ii

Disclaimer

This report has been prepared on behalf of and for the exclusive use of Rio Tinto Projects, and is subject to and

issued in accordance with the agreement between Rio Tinto Projects and WorleyParsons. WorleyParsons

accepts no liability or responsibility whatsoever for it in respect of any use of or reliance upon this report by any

third party. Copying this report without the permission of Rio Tinto Projects or WorleyParsons is not permitted.


RTIO-HSE-0327750

Works Approval Application Supporting

Documentation

Koodaideri Iron Ore Mine

December 2018

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Disclaimer and Limitation

This report has been prepared by Rio Tinto Iron Ore (Rio Tinto), on behalf of Pilbara Iron

Company (Services) Pty Ltd, specifically for the Koodaideri Iron Ore Mine. Neither the report

nor its contents may be referred to without the express approval of Rio Tinto, unless the report

has been released for referral and assessment of proposals.

Document Status

Rev Author Reviewer/s Date Approved for Issue

Signed Date

1 Worley Parsons

Leisa Turner, Sean Savage

20 Dec 2018 20/12/2018


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TABLE OF CONTENTS

Disclaimer ............................................................................................................................. 2

1 Licensee Information ............................................................................................ 1

1.1 Occupier Details ...................................................................................................... 1

2 Premises Details .................................................................................................... 2

2.1 Prescribed Activity Overview ................................................................................... 2

2.2 Legal Land Description ............................................................................................ 2

2.3 Location and Siting .................................................................................................. 2

2.4 Topography ............................................................................................................. 8

2.5 Water Resources ..................................................................................................... 8

2.6 Hydrogeology .......................................................................................................... 8

2.7 Geology ................................................................................................................... 8

2.8 Fauna ...................................................................................................................... 9

2.9 Vegetation and Flora ............................................................................................... 9

2.10 Stakeholder and Community Consultation ............................................................... 9

3 Prescribed Premises Category ........................................................................... 11

3.1 Current Environmental Protection Act 1986 (Part V) Licences / Works Approvals . 11

3.2 Other Approvals / Licences ................................................................................... 12

4 Process Description ............................................................................................ 14

4.1 Overview ............................................................................................................... 14

4.2 Design and Operation ........................................................................................... 14

4.3 Timescale for Construction / Operation ................................................................. 22

4.4 Commissioning and Reporting ............................................................................... 22

5 Risk Identification and Assessment .................................................................. 23

6 Emission Management ........................................................................................ 27

6.1 Air Emissions (excluding dust) ............................................................................... 27

6.2 Dust Emissions ..................................................................................................... 27

6.3 Noise ..................................................................................................................... 29

6.4 Odour Emissions ................................................................................................... 30

6.5 Light Emissions ..................................................................................................... 31

6.6 Discharge to Water ................................................................................................ 31

6.7 Discharges to Land ............................................................................................... 32

6.8 Hydrocarbon Management .................................................................................... 34

6.9 Solid/Liquid Waste ................................................................................................. 34

6.10 Flora and Fauna .................................................................................................... 35

7 Rehabilitation and Closure ................................................................................. 36

8 Project Costs ....................................................................................................... 36


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9 Summary of Commitments ................................................................................. 37

A Drawings .............................................................................................................. 40

TABLES

Table 2-1 Coordinates (MGA Zone 50) of the Koodaideri Mine Proposed Prescribed Premise Boundary ............................................................................................................ 6

Table 2-2 Sensitive Land Uses and distance from prescribed activity ................................... 6

Table 2-3 Specified ecosystems ........................................................................................... 7

Table 2-4: Other landscape features, relevant factors or receptors ....................................... 7

Table 3-1 Proposed prescribed premise categories .......................................................... 11

Table 3-2 Prescribed premise category details under Part V licence L8562/2011/1 .......... 11

Table 4-1 Inputs to the process plant .................................................................................. 17

Table 4-2 Outputs from the process plant ........................................................................... 17

Table 5-1: Risk Rating Matrix ............................................................................................. 23

Table 5-2: Consequence Matrix ......................................................................................... 24

Table 5-3: Likelihood Matrix ............................................................................................... 24

Table 5-4: Risk Assessment .............................................................................................. 25

Table 8.7-1: Project Costs ................................................................................................... 36

FIGURES

Figure 2-1: Koodaideri Iron Ore Mine Location ...................................................................... 3

Figure 2-2: Koodaideri Project Location ................................................................................ 4

Figure 2-3: Koodaideri Proposed Prescribed Premises Boundary ......................................... 5

Figure 4-1: Koodaideri Processing Plant Flow Sheet........................................................... 16

Figure 4-2: Koodaideri Primary Crusher .............................................................................. 18

Figure 4-3: Secondary Crushing Facility.............................................................................. 18

Figure 4-4: Product Screening Facility ................................................................................ 19

Figure 4-5: Stockyard Cross-Section ................................................................................... 20

Figure 4-6: Surge bin outlet and charge gates removal method .......................................... 21

APPENDICES

A Drawings .............................................................................................................. 40


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Abbreviations

BWT Below Water Table

CEMP Construction Environmental Management Plan

DWER Department of Water and Environmental Regulation

DMIRS Department of Mines, Industry Regulation and Safety

EPA Environmental Protection Authority

EPBC Act Environment Protection and Biodiversity Conservation Act 1999 (Commonwealth)

EPAS EPA Services (branch of DWER)

HG High-grade

HSEQ Health, Safety, Environment and Quality Management System

km Kilometre

m Metres

PDWSA Public Drinking Water Source Area

PER Public Environmental Review

PLNB Pilbara Leaf-nosed Bat

ROM Run of Mine

SOP Saleable Ore Product

TLO Train Load-out

WFSF Waste Fines Storage Facility WRC Western rail Corridor


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1 Licensee Information

1.1 Occupier Details

The occupier (the Licensee) of the land subject to this works approval application is:

Pilbara Iron Company (Services) Pty Ltd Level 18, Central Park 152-158 St Georges Tce Perth WA 6000 ACN: 107 210 248 The Proponent is Pilbara Iron Company (Services) Pty Ltd, wholly owned subsidiary of Rio Tinto. The proposed works are being undertaken in the Shire of East Pilbara and Shire of Ashburton. The contact person for the licence amendment is as follows: Sean Savage Superintendent, Government Approvals Rio Tinto Level 18, Central Park 152-158 St Georges Terrace Perth WA 6000 Telephone: (0)8 6213 1254 M: (0)467 776 204 Email: [email protected]


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2 Premises Details

2.1 Prescribed Activity Overview

This application is for the proposed construction and commissioning of an iron ore processing

facility comprising a primary crusher, screenhouse, secondary crusher, stockyard, train

loadout and related conveyor and ancillary systems at the Koodaideri Mine site. The

application also includes two mobile crushing and two mobile screening plants to be used

during construction only.

2.2 Legal Land Description

The Koodaideri Iron Ore mine (The Project) and processing facility is located on AML70/00252

(ML252SA) held by Mount Bruce Mining Pty Ltd and the pending Special Rail Licence being

obtained by Hamersley Iron Pty Limited (a subsidiary of Rio Tinto) pursuant to clause 10N(6)

of the Hamersley Range State Agreement. Minor facilities will also be located on pending

L47/00701 held by Mount Bruce Mining Pty Ltd.

Pilbara Iron Company (Services) Pty Ltd (a subsidiary of Rio Tinto) provides extensive

corporate and site services to Rio Tinto owned entities (including Hamersley Iron Pty Limited

and Mount Bruce Mining Pty Ltd) in the Pilbara, including the operation of Rio Tinto mines.

Pilbara Iron Company (Services) Pty Ltd is therefore the licence holder for the Koodaideri

mine.

2.3 Location and Siting

2.3.1 Location Context

The Koodaideri Iron Ore mine is located approximately 110 kilometres (km) northwest of

Newman in the Pilbara region of Western Australia (Figure 2-1).

The premises are located on the northern margins of the Hamersley Range and includes the

level plains immediately north of the range. The Hamersley Range escarpment is aligned in

a west-north-west to east-south-east direction, rising approximately 120 metres (m) above the

plain in the vicinity of the premises site. The proposed processing plant lies approximately 22

km to the east of the Karijini National Park and the Fortescue Marsh is located approximately

7km north of the site (Figure 2-2).

Table 2-1 lists the approximate boundary coordinates of the Koodaideri iron ore proposed

prescribed premise boundary. The proposed processing plant will have a footprint area of

approximately 54 ha within lease AML70/00252 (ML252SA) pending Special Rail Licence and

pending L47/00701 as shown in Figure 2-3. The two mobile crushing and two mobile screening

plants will also be located in the same area.


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Figure 2-1: Koodaideri Iron Ore Mine Location


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Figure 2-2: Koodaideri Project Location


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Figure 2-3: Koodaideri Proposed Prescribed Premises Boundary


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Table 2-1 Coordinates (MGA Zone 50) of the Koodaideri Mine Proposed Prescribed Premise Boundary

2.3.2 Sensitive Land Uses

The distances to residential and sensitive receptors are detailed in Table 2-2. The closest

residential area to the premises is the township of Newman 110 km to the south-east, which

had a population of 6,162 in 2014 (Australian Bureau of Statistics, 2016).

The Premises Village is 7.5 km to the south east of the facility and within the Premises

boundary, however as this facility is operated by the Licence Holder the Premises Village is

not considered to be a sensitive land use or receptor.

Table 2-2 Sensitive Land Uses and distance from prescribed activity

Sensitive Land Uses Distance from Prescribed Activity

Closest residential zoned premises is

Marillana Station Homestead

33 km from the eastern edge of the prescribed

premises boundary.

Closest recreation zoned premises Approximately 22 km from the premises to the

eastern boundary of Karijini National Park.

Fortescue Marsh Approximately 8 km north of the premises to the

nearest mapped boundary.

2.3.3 Specified Ecosystems

The distances (within a 30 km radius) to specified ecosystems are shown in Table 2-3.

ID Easting (m) Northing (m)

1 707,332 7,511,974

2 706,744 7,510,695

3 704,841 7,511,566

4 702,359 7,506,423

5 702,521 7,506,347

6 702,434 7,506,168

7 714,549 7,500,559

8 717,148 7,505,934

9 714,713 7,507,048

10 712,570 7,509,684

11 707,332 7,511,974


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Table 2-3 Specified ecosystems

Specified ecosystems Distance from Prescribed Premises

Parks and Wildlife tenure Approximately 22 km from the premises to the eastern

boundary of Karijini National Park.

Public Drinking Water Source

Area (PDWSA)

There are no PDWSAs located within 30 km of the

premises.

RAMSAR wetland – Fortescue

Marsh

Approximately 8km north of the premises to the nearest

mapped boundary.

Geomorphic Wetlands No geomorphic wetlands are located within 30 km of the

premises.

Threatened Ecological

Communities and Priority

Ecological Communities

The premises boundary intersects with the buffer zone of

the Priority 1 Fortescue Marsh Priority Ecological

Community

Declared Rare Flora There are no Declared Rare Flora within the Premises.

Lepidium catapycnon (previously Declared Rare Flora,

now Priority 4) is located adjacent to the Premises.

2.3.4 Other environmental receptors

Environmental receptors relevant to the premises are provided in Table 2-4.

Table 2-4: Other landscape features, relevant factors or receptors

Other receptors or areas of concern Location

Koodaideri Spring Located 4.1 km from the processing plant.

Pilbara Orange Leaf-nosed bat

(Rhinonicteris aurantius)

A colonised adit is located approximately 2.5 km

south west from the primary crusher

Northern quoll (Dasyurus hallacatus) Recorded in the Project Area.

Pilbara Olive python (Liasis olivaceus

barroni)

Recorded in the Project Area.

Trogolofauna Zones Located within the mine pit area and not within

the footprint of the prescribed premises

boundary.


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2.4 Topography

The Project mine site is located on the northern margins of the Hamersley Range and includes

the level plains immediately north of the range. The Hamersley Range escarpment is aligned

in a west-north-west to east-south-east direction and rises to approximately 120 m above the

plain level in the vicinity of the Project mine site. The ground level falls towards the Fortescue

River Basin to the north-east. The portion of the Hamersley Range containing the proposed

prescribed premises location is rugged and rocky, giving rise to an irregular network of

ephemeral streams. The plateau containing the ore resources is incised by a series of gullies

that drain into ephemeral creeks on the plains below.

2.5 Water Resources

The mine processing area lies within the Upper Fortescue River catchment. All of the creek

systems within the Upper Fortescue River catchment are ephemeral. Creekline flows are

generated following significant rainfall events, which generally occur between December and

July. Sub-catchments south of the Fortescue River Valley (including the headwaters of the

Fortescue River, Weeli Wolli Creek, and to a lesser extent Coondiner Creek, Mindy Creek and

other smaller creeks) contribute surface water and sediments into the Fortescue Marsh.

The Fortescue Marsh is a nationally and internationally important wetland, and is located to

the north of the Project development area. At its closest, the premises boundary is

approximately 8 km from the mapped boundary of the Fortescue Marsh.

The Koodaideri deposits are intercepted by deeply incised gullies that characterise the

Hamersley Ranges. Surface water drainage occurs within defined water courses during and

immediately following large, extended duration or high intensity rainfall events. High surface

water infiltration is expected to occur within alluvial creek beds on the lower slopes of the

Hamersley Range and adjacent plains. Surface water runoff in the mine processing area

commences via weakly defined tributaries in shallow bedrock/gravelly soils that then drain into

thicker alluvium/colluvium sequences in the incised valley systems. Water courses in the

incised valleys facilitate ephemeral surface water flows typically after large or intense rainfall

events. Smaller rainfall events are likely to generate sub-surface flow in the loosely

consolidated gravelly stream beds. Stream drainage systems gradually multiply and become

shallower due to flat relief as they continue northwards towards the Fortescue Marsh.

2.6 Hydrogeology

Local groundwater is fresh and is approximately 70 m below ground level in the area of the Processing Plant. Water quality is fresh with electrical conductivity between 412 and 420 µS/cm. There are no nearby users of groundwater in the area.

2.7 Geology

The Project area lies within the Hamersley Range which is principally comprised of rocks of

the Brockman Iron Formation. Further north is the broad expanse of the Fortescue Valley,

which was formed by the preferential erosion of the Wittenoom Formation and includes deep

layers of Cainozoic sediments.

The Koodaideri mine area contains martite-geothite mineralisation predominantly within the

Dales Gorge Member of the Brockman Iron Formation, with lesser mineralisation in the Joffre


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Member. A variable thickness hydrated capping overlies the deposits, which is permeated with

numerous cavities. The orebody is underlain by the Mount McRae Shale and Mount Sylvia

Formations.

2.8 Fauna

Several species of conservation significance are found within the overall project development

footprint. Impacts on the Pilbara Leaf-nosed Bat (PLNB), Pilbara Olive Python and Northern

Quoll have been assessed and will be managed through relevant conditions in MS999. In

terms of Short Range Endemics species, large exclusion zones have been implemented to

protect trogolofauna in the Project area in accordance with MS999.

The habitat types present in the Processing Plant development footprint are considered to be

well represented in the local and regional area. The same land systems are found outside the

Development Envelope, including within the nearby KNP.

Koodaideri spring and the K75W adit/cave system are important habitat for Pilbara Leaf-nosed

Bat, Pilbara Olive Python and Northern Quoll and have been designated as development

exclusion zones to minimise the risk of impacting on this important fauna habitat.

2.9 Vegetation and Flora

Vegetation communities within the immediate area consist of mixed Acacia species, Hakea

chordophylla, and Grevillea wickhamii, tall open shrubland over Triodia lanigera, T. pungens

and open hummock grassland.

There are two flora species of elevated conservation value within the overall development

area: Lepidium catapycnon and Synostemon hamersleyensis. The closest of these species to

the processing plant is located 1200 m from the primary crusher. Neither species will be

impacted by the construction or operation of the processing plant and all recorded populations

are protected by development exclusion areas.

The vegetation of the Koodaideri Spring Gorge is of conservation significance as it provides

key habitat for a number of fauna species including the Pilbara Leaf-nosed Bat, Pilbara Olive

Python and Northern Quoll. As required by MS 999 an exclusion zone has been implemented

to protect Koodaideri Spring Gorge and an approved adaptive management plan implemented

to monitor and respond to any changes in the hydrology of Koodaideri spring.

2.10 Stakeholder and Community Consultation

2.10.1 Community Consultation

Rio Tinto has a long-term commitment to working with Pilbara communities. Specific

consultation strategies and initiatives are outlined within the Annual Sustainable Development

Report.

All stakeholders consulted during the preparation of the Public Environmental Review (PER)

were provided with details of the Koodaideri project key characteristics, including mining,

processing and infrastructure requirements, and the environmental studies undertaken. This


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consultation process provided stakeholders with details of the works for this Works Approval

application.

Key government agencies actively consulted with during the preparation of the PER include:

• EPA; • Department of Water and Environmental Regulation (DWER); and • Department of Mines, Industry Regulation and Safety (DMIRS). • Local government organisations (Shires of Ashburton and East Pilbara)

Key non-government stakeholders who were consulted during the preparation of the PER include:

• Youngaleena Aboriginal Community; • Banjima People; • Yindjibarndi People; • Mulga Downs Station; • Mt Florence Station; and • Coolawanyah Station.

Rio Tinto has sought to keep relevant stakeholders up-to-date with studies relating to planned mining activities.

2.10.2 Aboriginal Heritage

The Koodaideri Mine Plant Area is located within the traditional lands of the Banjima People.

The identification and management of cultural heritage within the traditional lands of the

Banjima Traditional owners is in accordance with the principles and practices outlined within

Rio Tinto’s Communities and Social Performance Guidelines, the Rio Tinto Cultural Heritage

Group Procedure.

In relation to this works approval, detailed Aboriginal heritage surveys, both archaeological

and ethnographical, have been undertaken with approved representatives from native title

claimant groups in the proposed development footprint.

There are no heritage sites within the vicinity of the screen house or stockyard. Six aboriginal

heritage sites have been identified within 1 km of the proposed primary crusher. All of the sites

at risk of impact are the subject of a Section 18 application under the Aboriginal Heritage Act

1972. One site is located within the footprint of K58W ROM Pad with another site within 30 m

of the K58W ROM Pad. Two sites are within the design of a heavy vehicle haul road. The

remaining two sites will not be impacted by the proposed works and will be fenced in

accordance with Rio Tinto’s Heritage Site Fencing Procedure (RTIO-HSE-0121790).

.


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3 Prescribed Premises Category

The proposed facility is considered to be an activity defined by Schedule 1 of the

Environmental Protection Regulations 1987 (as amended) and detailed below in Table 3-1.

DWER have advised during project scoping discussions that the processing plant should be

constructed and commissioned under a works approval, followed by an amendment to existing

operating licence L8562/2011/1 (Koodaideri Exploration Camp). The mobile crushing and

screening plant will be installed, commissioned and operated under the same works approval

as the activity is required immediately for construction works to commence and involves

minimal commissioning. This approach was discussed and agreed during scoping meetings

with DWER.

The mine plant is expected to process 43 million tonnes per year of iron ore by crushing and

screening coarse ore to a saleable product. The mobile crushing and screening plant is

required during the construction of the mine plant to facilitate earthworks.

Table 3-1 Proposed prescribed premise categories

3.1 Current Environmental Protection Act 1986 (Part V) Licences / Works Approvals

The Licensee currently holds Part V Operating Licence L8562/2011/1 (expiry date

18/03/2030), with categories shown in Table 3-2. The current licence for the Koodaideri

Exploration Camp includes a putrescible landfill, two waste water treatment plants and

associated sprayfields Once works for the mine plant are completed this licence will be

amended to include the operation of the mine plant (Category 5) and ongoing use of mobile

crushing and screening plants (Category 12) as required.

Table 3-2 Prescribed premise category details under Part V licence L8562/2011/1

Category

number

Category Description Category Premises Production or

Design Capacity

5 Processing or beneficiation of metallic or non-metallic ore

>50,000 tonnes per year 43 million tonnes per year

12 Mobile crushing and screening plant.

>50,000 tonnes per year 10 million tonnes per year

Category

number

Category Description Category Premises Production or

Design Capacity

54 Sewage facility 100 cubic metres or more per

day

418.5 cubic metres per day

64 Class II putrescible

landfill site

20 tonnes or more per year 2000 tonnes per year


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3.2 Other Approvals / Licences

3.2.1 Part IV of the Environmental Protection Act 1986

Background

Rio Tinto referred a proposal to the Environmental Protection Authority (EPA) on 28 May 2012

to develop and operate an open pit iron ore mine, rail corridor and associated infrastructure at

the Premises.

The level of assessment was set by the EPA as a PER. The PER was reviewed by the EPA

and the Report and Recommendations of the EPA (EPA Report 1533) were submitted to the

Minister for Environment for approval. Approval was granted through Ministerial Statement

999 on 10 March 2015 for the project to be implemented.

The proposal was also referred to the former Department of Sustainability, Environment,

Water, Population and Communities (DSEWPaC) (now the Department of Environment and

Energy) for consideration under the Commonwealth Environment Protection and Biodiversity

Conservation Act 1999 (EPBC Act) on 5 June 2012. DSEWPaC determined that the proposal

was a ‘controlled action’ and subject to a bilateral assessment coordinated by the Government

of WA. The proposal was approved under the EPBC Act on 9 May 2015 through instrument

reference EPBC 2012/6422.

Ministerial Statement 999

Ministerial approval was granted 10 March 2015 under Ministerial Statement 999 to construct

and operate an iron ore mining area and associated infrastructure at the Premises. This

included the construction and operation of a rail corridor, high voltage power transmission line,

airstrip and accommodation facilities.

Relevant to Part V of the Environmental Protection Act 1986, EPA’s assessment (EPA Report

1533) determined that the impacts from the Project could be adequately managed and issued

Ministerial Statement 999 with conditions to ensure that:

(a) The proposal is implemented in a manner that maintains the Pilbara Leaf-nosed

Bat colony which resides within the K75W adit/cave system;

(b) Troglofauna are protected by excluding mining and infrastructure placement within

a significant portion of troglofauna habitat;

(c) Mine construction and operational activities are carried out in a manner that

minimises impacts to the Northern Quoll;

(d) Mining and infrastructure is sited in a manner that avoids the Declared Rare Flora,

Hamersley Lepidium;

(e) The proposal is implemented so that it does not affect the viability of the Priority 1,

Sauropus sp. Koodaideri detritals; and

(f) Mining activities do not impact the hydrological regime or water quality of the

Koodaideri Spring Gorge.


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Conditions relating the management of asbestos related risk are relevant to the construction

of the Rail corridor through the Wittenoom Asbestos Management Area and are not directly

relevant to construction of the mine site processing plant.

3.2.2 Rights in Water and Irrigation Act 1914

The following Licences to Take Groundwater have been issued under the Rights in Water and

Irrigation Act 1914 (RiWI Act) for the Project.

Table 3-3 Koodaideri 5C licences

Licence Number Volume (kL) Expiry Date

GWL 158473(6) 45,000 3 Sept 2023

GWL 164672(7) 95,000 14 Oct 2023

GWL 171847(3) 45,000 15 Sept 2027

GWL 174242 15,000 1 Sept 2023

GWL 177962(3) 212,000 6 Sept 2028

Groundwater abstraction and quality will continue to be managed in accordance with the

existing Groundwater Licences and associated Groundwater Operating Strategies, and any

amendments and new licences as required. An application to increase the abstraction limit for

GWL174242 for water supply purposes is being progressed with the DWER-Water branch.

Bed and banks permits are not required as the Project is being constructed on land that is the

subject of a State Agreement as described in section 3.2.3 below and any potential significant

impact on major drainage lines has been assessed as part of the Part IV environmental

approval process.

3.2.3 State Agreement and Mining Act 1978

The development of the Project is subject to the provisions on the Iron Ore (Mount Bruce) Agreement Act 1972.

Other forms of Mining Act tenure have also been obtained to facilitate supporting

infrastructure. Activities related to this application are purely located on State Agreement Act

tenure ML252SA and pending Miscellaneous Licence L47/00701.


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4 Process Description

4.1 Overview

The Koodaideri Iron Ore Mine will produce 43 million tonnes per annum (Mtpa) of Saleable

Ore Product (SOP) as lump and fines from coarse ore feed.

In order to process coarse ore feed into saleable ore product, the Koodaideri processing plant

will include facilities for crushing, screening, stockpiling and loading onto rail transport.

Key inputs to the processing plant include iron ore (high phosphorus Brockman ore – goethite),

diesel fuel, electrical power and process water (obtained from local licensed groundwater

source).

Key outputs include iron ore product (lump and fines), noise, dust, light and greenhouse gas

emissions.

Mobile crushing and screening units will be required to support mine earthworks. When

constructed, the Koodaideri processing plant will operate 24 hours per day, 7 days per week.

The life of mine is expected to be more than 30 years.

Construction of the Koodaideri processing plant is expected to commence in Quarter 1, 2019

and be completed in Quarter 2, 2021. Commissioning is expected to commence in Quarter 1

2021.

4.2 Design and Operation

4.2.1 Plant Layout

The following drawings show the overall site layout and are attached to this document as Appendix B:

KD-0000-F-DRG-00001 Process Plant – Process Flow Diagram

1000-EG-DWG-0003 Overall Site Building Set Out – General Arrangement

1000-EG-DWG-0004 Overall Site Building Set Out (1 of 6)






4.2.2 Process Flow

The plant flowsheet is shown schematically in Figure 4.1 and in more detail in Appendix B.

Run of Mine (ROM) ore will be delivered by haul truck to a primary gyratory crusher located to

the north west of the K58W pit (as shown in Figure 3.1). The high-grade (HG) primary crushed

ore will be processed through a dry crushing and screening plant to produce HG lump and HG

fines product.


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Seven double-deck banana screens will provide the required production throughput and

achieve the required product specifications, which will divide the ore into three streams: lump

product, fines product and oversize material.

Oversize material will be conveyed to the secondary crusher surge bin. The secondary crusher

surge bin will have a total live capacity of 860 tonnes and incorporate two outlet hoppers,

isolation gates and belt feeders, each providing feed to a cone secondary crusher. The design

throughput of each secondary crusher is 3,600 tph.

The fines and lump products from the process plant will be conveyed to their respective fines

and lump stockpiles. Representative samples of each ore stream are taken at six minute

increments and sub-sampled prior to conveying directly to a fully automated laboratory cell.

The laboratory cell will provide the metallurgical and analytical / chemical assays for the

process. The laboratory will also manually process the mine and exploration samples with

laboratory rejects conveyed back to the lump stockyard feed conveyor

Final product will be conveyed and stacked separately onto lump and fine product stockpiles for later reclaiming by a bucket wheel reclaimer to a train load-out (TLO) facility.

The process plant features the construction of the following major facilities:

Primary Crusher apron sized for up to 300 tonne class haul trucks;

Dual truck tipping points and ROM dump hopper of 600 tonne live capacity and discharge surge bin of 600 tonne;

Direct-feed crushing facility complete with dump hopper, gyratory crusher, service crane, rock breaker and discharge apron feeder onto the overland conveyor;

Conveyors feeding a coarse ore fixed stacker;

Primary crushed ore stockpile with 25,000 tonne live storage and reclaim with two apron feeders;

7-bay screening plant with shuttle fed, bins, feeders and screens;

Allowance for a future 8th product screening bay in the design;

Two bay secondary crusher facility with bins, belt feeders and MP1250 type secondary crushers;

Sample plants – cutters, conveyors, and equipment for sampling lump and fines;

Stockyard with two slewing and luffing stackers and a rotary reclaimer; and

Volumetric train load-out.

The major facilities are linked by conveyors capable of providing an average 43 Mtpa SOP. More detail on the major facilities is provided in the following sections.

The processing plant is serviced by air, water, and dust suppression and collection systems.


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Figure 4-1: Koodaideri Processing Plant Flow Sheet


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4.2.3 Process Plant Production Capacity

During normal operations the plant will have the capacity to process 43 Mtpa of coarse ore. Table 4-1 summarises the maximum input to the process based on continuous operation for 24 hours.

Table 4-1 Inputs to the process plant

Inputs Rate Unit of Measure

ROM ore 43,000,000 Tonnes / annum

Raw Water 6.15 GL / annum

Table 4.2 summarises the maximum outputs from the process plant.

Table 4-2 Outputs from the process plant

Outputs Rate Unit of Measure

Fines Product 1,600 Tonnes / hour

Lump Product 1,800 Tonnes / hour

4.2.4 Primary Crushing

A dual tip direct-fed primary gyratory crusher will be located on the north-western boundary

of the K58W mine area (Figure 4-2). The primary crushing facility comprises the following

key equipment:

ROM dump hopper;

Maintenance crane;

ROM Bin Rockbreaker;

Primary gyratory crusher assembly;

Primary crusher discharge surge bin

Apron feeder;

Crusher discharge conveyor;

Conveyor weightometer, tramp metal detector and magnet;

Ducted dust collection system;

Primary crusher sump;

Dust suppression, and fire protection system; and

Compressed air system and water services.


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A dedicated oil lubrication system for the gyratory crusher will be provided which will also

incorporate the primary crusher’s hydroset hydraulic power pack as it utilises the same oil

reservoir.

Figure 4-2: Koodaideri Primary Crusher

4.2.5 Secondary Crushing

The Secondary Crushing Facility receives oversize material from Product Screening Facility

and re-crushes the material prior to it being conveyed back to the Product Screening Facility

for re-screening. There will be two secondary cone crushers each with a design capacity of

3,300 t/h (wet). Figure 4-3 shows the general arrangement of the secondary crushing facility.

Figure 4-3: Secondary Crushing Facility


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4.2.6 Product Screening

The Product Screening Facility will fed via a shuttle head conveyor to seven feed bins that

report to seven vibrating feeders integrated with the double-deck banana screens. Each

screen design capacity on medium ore is 1,800 tph (wet).The oversize material from the

screening plant will be conveyed to the secondary crushing facility, re-crushed and returned

to the feed bins and rescreened.

The fines and lump products from the process plant will be conveyed to their respective fines

and lump stockpiles. Representative samples of each ore stream are taken at six minute

increments and sub-sampled prior to conveying directly to a fully automated laboratory cell.

Figure 4-4 shows the cross-sectional arrangement of the Product Screening Facility.

Figure 4-4: Product Screening Facility

4.2.7 Stockyard and Reclaimer

The product stockyard will be located north of the process plant and south of the Roy Hill-

Munjina Road. It will consist of two rows of three 200,000-tonne (nominal) SOP longitudinal-

type stockpiles, one row for lump and one row for fines products.

The product stockyard has two slewing and luffing stackers of 5,700 tph capacity, one for fines

and one for lump products. The stockyard will also have a single slewing and luffing boom-

type bucket wheel reclaimer with an average stockpile reclaim capacity of 4,690 m3/h. The

reclaimer will reclaim either lump or fines to the train load-out system.

The stockyard cross sectional arrangement is shown in Figure 4-5 and general Arrangement

is shown in Appendix B. The stockyard will receive ore from the lump and fines stackers and

consists of two excavated canyons approximately 1,000 m in length. Each canyon

accommodates 3 x 200,000-tonne fines SOP stockpiles, and 3 x 200,000-tonne lump SOP

stockpiles.


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The stockyard will be serviced by dust suppression water cannons which operate

automatically. The water cannons will be linked to the site weather management systems

and will be automatically activated in sequence based on stockpile height, evaporation rate,

wind speed and wind direction.

.

Figure 4-5: Stockyard Cross-Section

4.2.8 Train Load-Out

The TLO is shown in Figure 4-6 consists of a 1,500 tonne surge bin supplying ore to the train

loading gate. The loading gate will load the ore cars volumetrically and will be capable of

loading lump or fines product at a nominal design rate of 11,500 t/h.

Nominally, product trains will consist of 240 cars with a transport capacity of 29,520 to 30,480

tonnes per train. The system, including the bucket wheel reclaimer and the reclaim conveyor,

is designed to maintain a minimum average loading rate of 9,100 tph for all products and load

a train in 200 minutes (first ore car to last ore car).

An under-rail clean-out vault will be located directly beneath the train load-out bin. Any spillage

from the load-out discharge will be allowed to fall through the grating beneath the rail and into

the tunnel below. A loader will be required to periodically remove the spillage material from

the tunnel.

A load optimisation system is included which utilises volumetric scanning and loaded ore car

track weighers to enable the control system to adjust the mass or ore and profile of the ore

being loaded.


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Figure 4-6: Surge bin outlet and charge gates removal method

4.2.9 Mobile Crushing and Screening Plant

As part of the processing plant construction, suitable material is required to be sourced from

adjacent borrow pits. Prospective borrow areas have been identified on AML70/00252

ML252SA and L47/00701 to provide suitable quantities of material for construction

earthworks. This borrow material, in addition to other select cuttings from the processing plant

footprint area, will be processed through a mobile crushing and/ or a mobile screening plant.

The mobile crushing and screening plant components proposed to be used is a Terex Finlay

J1480 Jaw Crusher“and Terex Finlay – Heavy Duty Screen 883”. Basic specifications are

provided in Appendix C. It should be noted that this specific make of plant is subject to change

based on the contractor availability, however if a different make is used, it will be of similar

specification and with the same environmental controls.

The mobile crushing and screening plants will be located within the prescribed premises in

areas previously cleared for the sourcing of borrow material, so no additional clearing will be

required. As borrow material used in the crushing and screening plant is exhausted, the

mobile plant will be transported to the next cleared borrow pit area within the prescribed

premises. This process will continue as required throughout the duration of construction.

The mobile crushing plant works by placing material into the feed hopper via an excavator of

front end loader. The plant is preconfigured for use so the only modification required during

commissioning are the setting of the crusher aperture to deliver product of the required size,

and testing of dust suppression systems. The target particle size (screen setting) is

approximately 40mm. Product material is stockpiled for transport to the relevant construction

site.


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4.3 Timescale for Construction / Operation

Based on the current schedule it is expected that construction of the mine processing plant will begin in Quarter 1, 2019 will be completed in Quarter 4, 2021. The facility is expected to be operational for approximately 30 years. Once construction of the processing plant is completed and prior to commissioning, a compliance document detailing compliance with commitments made in this works approval application will be submitted to DWER as per the works approval conditions. The mobile crushing and screening plants will initially be on site for up to 2 years to support the Project construction activities. At the completion of construction work for the processing plant, the mobile facilities (or similar) may be required for other purposes, for example, to provide stemming for blasting purposes.

4.4 Commissioning and Reporting

4.4.1 Processing Plant

Once construction activities are completed at the mine processing plant, commissioning

activities will begin and are expected to be completed by Quarter 1 2022. In general, the basic

scope of commissioning and handover activities for the processing plant can be designated

by the following six stages:

Stage 1: Construction Verification – verify construction completion to design intent.

Stage 2: Pre-commissioning – functional testing of energised equipment.

Stage 3: No-load Commissioning – dynamic testing of operating systems without process

materials.

Stage 4: Load Commissioning – running the facilities with feedstock and incremental load

tuning. Note during this phase the plant will be running under operational conditions and hence

the risk of emissions and means of mitigation are almost identical.

Stage 5: Care custody and Control – operations and maintenance teams will seek to rectify

any operating issues and aim to achieve stable performance from the new plant.

Stage 6: Performance Verification – ramp up production rate and confirm achievement of

designed through-put.

The licensee seeks to undertake all stages of the commissioning under the works approval,

with Stages 1 to 3, including first fill of all lubricants and running of all process plant equipment

(including conveyors, sizers, feeders, crushers, scrubbers, cyclones, and balanced machines)

undertaken prior to submitting a compliance document and application for a licence.

Upon submission of the compliance document, the licensee will undertake Stages 4 to 6, load

commissioning (i.e. ‘wet commissioning’) and performance verification prior to submitting a

commissioning report and submitting an application to obtain a licence to operate.


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Stages 4 to 6 are expected to take up to 12 months; hence an 18 month commissioning period

is requested to enable commissioning to occur and an amendment to the existing licence to

operate to be obtained.

4.4.2 Mobile Crushing and Screening Plant

The mobile crushing and screening plants will arrive on site ready for commissioning.

Commissioning entails setting the crusher jam aperture to produce material of the desired size

and installing the screens required to produce materials of the desired size. During

commissioning, dust suppression sprays will be tested to ensure functionality. The

commissioning period will be completed within three months of mobilising the crushing and

screening plant to site.

It is requested that commissioning and operation of the mobile crushing and screening plant

be undertaken under the Works Approval (i.e. without the need to obtain an initial licence

amendment within months of the works approval being obtained).Category 12 for ongoing use

of mobile plant following construction of the processing plant would be added to the operating

licence at the same time as the amendment to add Category 5 (for the processing plant).

5 Risk Identification and Assessment

A risk assessment has been prepared to identify the potential emissions from the proposed

activities and the potential sources, pathways and receptors of those emissions, and proposed

controls to manage potential emissions to determine a risk rating. The risk assessment has

been based on the DWER Guidance Statement: Risk Assessments (released by the then

named Department of Environmental Regulation in 2017) and the Rio Tinto risk assessment

process, based on the following risk rating matrix (Table 5-1):

Table 5-1: Risk Rating Matrix

Consequence

Likelihood Slight Minor Moderate Major Severe

Almost Certain Medium High High Extreme Extreme

Likely Medium Medium High High Extreme

Possible Low Medium Medium High Extreme

Unlikely Low Medium Medium Medium High

Rare Low Low Medium Medium High

Risk = consequence x likelihood

The following criteria (DWER 2017) are used to determine the consequence and likelihood of a risk event occurring (Table 5-2 and Table 5-3).


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Table 5-2: Consequence Matrix

Consequence Consequence description

Environment Health

Severe

On-site impacts: catastrophic

Off-site impacts (local scale): high level

Off-site impacts (wider scale): mid level

Mid to long term or permanent impact to an

area of high conservation value or special

significance

Loss of life

Adverse health effects: high level or

ongoing medical treatment

Local scale impacts: permanent loss of

amenity

Major

On-site impacts: high level

Off-site impacts (local scale): mid level

Off-site impacts (wider scale): low level

Short term impact to an area of high

conservation value or special significance

Adverse health effects: mid-level or

frequent medical treatment

Local scale impacts: high level impact to

amenity

Moderate

On-site impacts: mid level

Off-site impacts local scale: low level

Off-site impacts wider scale: minimal

Adverse health effects: low level or

occasional medical treatment

Local scale impacts: mid-level impact to

amenity

Minor

On-site impacts: low level

Off-site impacts (local scale): minimal

Off-site impacts (wider scale): not detectable

Local scale impacts: low level impact to

amenity

Slight On-site impacts: minimal Local scale impacts: minimal impacts to

amenity

Table 5-3: Likelihood Matrix

Likelihood Likelihood description

Almost certain The risk event is expected to occur in most circumstances.

Likely The risk event will probably occur in most circumstances.

Possible The risk event could occur at some time.

Unlikely The risk event will probably not occur in most circumstances.

Rare The risk event may only occur in exceptional circumstances.

The potential emissions, sources, pathways and receptors that have been identified for the

construction, commissioning and operation of the proposed facilities are outlined in Table 5-4

Risk Assessment. This table also identifies the potential impacts, proposed controls and

associated risk ratings. A detailed risk assessment will be undertaken for any activity which

has been identified as having a ‘Medium’ risk rating or higher (Section 6). Detailed risk

assessment includes:

A description of the potential emissions, sources, pathways and receptors.

Any controls that have been identified for the risk event.

An assessment of the consequence and likelihood.

Risk rating.


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Table 5-4: Risk Assessment

Source Potential

Emission Pathway Potential Receptors Potential Impacts Proposed Controls Consequence Likelihood Risk Rating

Detailed Assessment

Required?

Category 5:

Processing of

ore

Category 12:

Screening etc.

of material

Construction of

crushing and

screening

equipment

Dust Air (windborne)

No sensitive land uses in proximity – Fortescue Marsh 8 km away, no residential premises

Vegetation including vegetation adjacent to mining areas

Dust impacts on surrounding

vegetation, including reduced

ability for photosynthesis due to

smothering

Health and amenity: None, given

the distance to the nearest

receptor

Dust suppression (water sprays, water trucks, control

of vehicle movements / restricted speeds)

Rehabilitation of disturbed areas

Minor Rare Low

Risk pathway is low, detailed

assessment is not required.

However, further detail on

controls provided in Section

6.2d

Noise Air (windborne)

Nocturnal native fauna, including

the Pilbara Leaf Nose Bat

(PLNB)

Residential: None, the nearest

receptors are the Koodaideri

Village, offices and mining

operations.

Noise / Vibration impacts on

fauna habitat, including potential

roosting sites for bats



receptor

A specific PLNB Environmental Management Plan has

been developed as required under MS999

Environmental Protection (Noise) Regulations 1997

Moderate Possible Medium

No, managed by MS 999. However, further detail on


6.3

Light Air Nocturnal native fauna, including

the PLNB

Disruption in PLNB roosting

patterns

Construction activities limited to daytime hours

Lighting limited to the minimum required to maintain

site safety and security.

Directional lighting will be used to minimise stray light

emission.


been developed as required under MS999.

Minor Possible Medium



6.5

Discharge of

washwater or

process water

potentially

hydrocarbon

contaminated

and / or

sediment

laden

Discharge to Water Surface water bodies

(Fortescue Marsh 8km away)

No pathway to surface waters

due to distance and topography

No planned discharge of water from site

Potentially contaminated waters managed on site via

bunds and surface diversions

Minor Rare Low





6.6

Discharge to Land

Terrestrial ecosystems

Groundwater

Potential contamination of soil

and groundwater due to

presence of iron, hydrocarbons

and chemicals within

stormwater, leaks and spills.

Clean stormwater run-off and potentially sediment

loaded run-off from the plant are separated to the

extent achievable by applying Rio Tinto Standard

specification SS-N102 Sediment Control and

Separation, with the site graded to direct stormwater

away from the process plant.

Any potential hydrocarbon / sediment laden water will

be retained onsite by use of diversions and bunds

Minor Possible Medium Detailed assessment

provided in Section 6.7.

Operation of

crushing and

screening

equipment,

movement of ore

product between

these and the

stockyards via

conveyors.

Dust Air (windborne)

No sensitive land uses in proximity (Fortescue Marsh 8km away)

Vegetation including vegetation adjacent to mining areas

Dust impacts on surrounding

vegetation, including reduced

ability for photosynthesis due to

smothering



receptor

Dust suppression on trafficable areas including water

sprays, water trucks, control of vehicle movements /

restricted speeds

ROM dump hopper dust suppression through high

pressure water fogging combined with a water spray

curtain system at the ROM feed hopper and coarse

ore stockpile

Two baghouse dust collection systems

Sprays on conveyor transfer points

Stockyard will have automatic water cannons located

on both sides of the stockpiles at 50 m intervals.

Stacker boom conveyors will be fitted with head-end

sprays and dust shrouds

Conveyors covered except in stockyard

Rehabilitation of disturbed areas



Noise Air (windborne)

Nocturnal native fauna, including

the PLNB

Residential: None, the nearest

receptors are the Koodaideri

Village, offices and mining

operations.

Interruption of natural PLNB

activities



receptor



Environmental Protection (Noise) Regulations 1997

Moderate Possible Medium



6.3


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Source Potential

Emission Pathway Potential Receptors Potential Impacts Proposed Controls Consequence Likelihood Risk Rating

Detailed Assessment

Required?

Light Air Nocturnal native fauna, including

the PLNB

Disruption in PLNB roosting

patterns

Plant lighting design will comply with Australian

standards for safe work.

Lighting design will ensure light is directed to work

areas and minimal light spill occurs.

Walkways and platforms that require permanent

lighting at night will have shrouded lenses and LED’s

with optics that direct lighting only onto walkways and

platforms with minimal “spill” to reduce light spill.






6.5

Discharge of

washwater or

process water

potentially

hydrocarbon

contaminated

or / sediment

laden

Discharge to Water Surface water bodies

(Fortescue Marsh 8km away)

No pathway to surface waters

due to distance and topography

No planned discharge of water from site

Potentially contaminated waters retained onsite via

bunds and surface diversions

Minor Rare Low





6.6

Discharge to Land Terrestrial ecosystems

Groundwater

Potential contamination of soil

and groundwater due to

presence of iron, hydrocarbons

and chemicals within

stormwater, leaks and spills.

Diversion of clean surface water around the work area

Stormwater will be collected in open drains which then

discharge to sedimentation ponds.

Plant drainage will flow to an earthen sedimentation /

silt pond designed to treat a peak 1:10 year rainfall

event.

Concrete hardstand under main processing areas with

sediment/silt traps

Drive in sumps installed to collect sediment

Oily water separators (centrifugal type) to separate out

hydrocarbons from surface water.



Non-

prescribed

activity

Hydrocarbon

storage (under

requirement for

licensing).

Discharge of

hydrocarbons /

hydrocarbon

contaminated

water to Land

Discharge to Land Terrestrial ecosystems

Hydrocarbon spills causing soil

contamination, potential

seepage to groundwater

resulting in reduction in water

quality beyond its beneficial /

post closure use and adverse

impacts to the health and

survival of vegetation dependent

upon groundwater

Australian Standard AS1940 - Storage and handling of

flammable and combustible liquids

Storage in bunded areas / secondary containment

Appropriate labelling of storage areas

Provision of spill response equipment


Detailed assessment and


6.8

General

construction /

putrescible waste

during

construction

Solid / Liquid

Waste Discharge to Land

Terrestrial ecosystems /

Surface Water / Groundwater

Seepage of landfill leachate

leading to groundwater

contamination beyond its

beneficial / post-closure use,

and adverse impacts to the

health and survival of vegetation

dependent upon groundwater

Waste material that is suitable for re-use or recycling

will be separated from landfill waste and sent off-site

for treatment or recycling as practicable.

Non-recyclables will be disposed of in approved site

landfill.

Existing landfill conditions on L8562/2011/1

Slight Possible Low



Further detail on controls

provided in Section 6.4


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6 Emission Management

Rio Tinto (WA) has a Health, Safety, Environment and Quality Management System (HSEQ) that ensures environmental controls are developed for key environmental aspects, legal compliance is maintained and continuous improvement is achieved through a formal review process.

6.1 Air Emissions (excluding dust)

There is not expected to be significant air emissions, generated during the construction, commissioning and operation of the mine processing plant and mobile crushing and screening plants.

During construction, commissioning and operations the generation of smoke and gaseous emissions will be limited to the operation of construction machinery including earthmoving machinery, minor temporary power generation and the mobile crushing and screening plants. The mine processing plant will be electrically powered via the high voltage power transmission line.

6.2 Dust Emissions

6.2.1 Description of risk event

Construction – Fixed Crushing / Screening Plant Dust emissions during construction are typically associated with clearing, earthworks and vehicle movement on unsealed roads. There are no sensitive land uses in proximity of the construction activities, with Fortescue Marsh 8 km away and no residential premises within 25 km. Other potential environmental receptors that could be impacted by dust emissions during construction include vegetation adjacent to mining areas. This includes potential for vegetation to have a reduced ability for photosynthesis due to smothering. Operation – Fixed Crushing / Screening Plant Potential dust emissions during the operation of the processing plant are typically point source emissions. Dust emissions are typically generated from a range of point sources including:

ROM area during ore loading and unloading;

ore processing (crushing and screening);

conveyors and conveyor transfer points;

stockpiles where dust lift off from the surface may occur in windy conditions;

stockpiling and reclaiming of ore product; and

frequent light and heavy vehicle movement on unsealed roadways.


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6.2.2 Proposed environmental controls

Construction – Fixed Crushing / Screening Plant The dispersed and temporary nature of dust emissions during construction requires a broad range of controls to be applied including:

Water carts will be used during clearing and construction activities and in areas with

frequent vehicle movement on unsealed roads. The application of water increases the

specific mass of the soil particles and to increase bonding between the soil particles,

minimising the dust generated.

In some transport corridors, dust suppressant additives will be applied through water

carts to assist with dust control.

Site clearing and rehabilitation will be managed to ensure that areas are only cleared

as required and progressive rehabilitation is implemented as construction activities are

completed.

Weather forecasts will be monitored to ensure the availability of adequate water carts

if there is a risk of windy conditions.

Dust emissions during construction will be managed in accordance with the Koodaideri Project Construction Environmental Management Plan (CEMP). Operation – Fixed Crushing / Screening Plant The controls for managing dust in the processing plant will include:

ROM dump hopper dust suppression through high pressure water fogging combined

with a water spray curtain system at the ROM feed hopper and coarse ore stockpile.

This control will raise the overall moisture content and minimise dust generation in

downstream processing.

Provision has been made for water spray addition points at the discharge from the

apron feeders, transfer points and at the head end of the primary crusher discharge

conveyor.

Dust extraction: Two dust collectors will be installed, one between the coarse ore

stockpile and secondary crusher, and a second at the screening plant. Dust collectors

are ducted to a typical baghouse dust collection system. Where possible, collected

dust will be processed using an agglomerator with product being discharged back onto

the process system.

Conveyors handling material with a low moisture content will be fitted with spray booths

for dust suppression at most transfer points. This includes the primary crushed ore

conveyor, dry screen feed conveyor, lump stacking conveyor, and fines stacking

conveyor.

All conveyors are covered except in the stockyard to reduce dust lift off.

Drop heights at all conveyor transfer points have been minimised where possible

throughout the process plant design.

The stockyard will be serviced by automatic water cannons on either side of the

stockpiles. The water cannons will be linked to the site weather management systems

and will be automatically activated in sequence based on stockpile height, evaporation

rate, wind speed and wind direction.


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Stacker boom conveyors will be fitted with head-end sprays and dust shrouds.

The reclaimer bucket wheel will have dust suppression sprays and conveyor sprays

fitted.

Regular housekeeping will be undertaken to collect and remove material that may

present a potential dust risk from around conveyors and loading/unloading areas.

Water flow rates will be calculated and four hourly moisture samples will be taken from

the product belt to measure moisture content of the ore. This allows adjustments to the

moisture content to minimise dust while not adding too much water to the ore and

creating runoff from the stockpiles.

Monitoring of dust levels will be conducted on a real‐time basis in the processing plant to provide data that can be used to reduce overall dust levels and help adjust moisture management to match feed‐specific requirements. The main focus of this monitoring is to mitigate any potential impact on the health and safety of employees, which has the added benefit of assisting to reduce overall dust generated by the plant. Specific monitoring regarding impact to a specific environmental receptor is not required given the significant distances involved.

All water flows will be recorded in the plant control system. Over time the analytics algorithms will correlate water addition, environmental data, ore properties and dust emission data to arrive at optimal dust suppression strategies.

Mobile Crushing and Screening Plants

Dust emissions from the proposed mobile crushing and screening plants are point source emissions that will be managed through the use of dust suppression sprays. The mobile plant will arrive on site with an installed system of dust suppression sprays that will be plumbed in to a site water supply. Dust from mobile plants shall also be managed by:

Spraying the feed stockpile with water prior to being fed into the screen.

Use of dust suppression on stockpiles as necessary.

Water carts to dampen work areas, access roads and stockpiles to minimise dust lift-

off during storage and handling of borrow and screened material as required.

If fitted, use of hydraulically angle-adjustable stockpiling conveyors to minimise drop

heights.

If fitted, belt sprayers will be employed to dampen crushed material as necessary.

Implementation of the CEMP requires regular documented inspections to be undertaken to ensure the dust suppression system is fully functional during operation.

6.2.3 Residual risk to environment

The licensee believes that with the lack of sensitive receptors in the region and the significant number of proposed controls to be implemented, the risk to the environment from potential dust emissions at Koodaideri is low.

6.3 Noise

Noise emissions during construction will be distributed across the site, predominantly mobile and limited to daylight hours. The main source of noise emissions will be earthmoving and construction machinery and on-site power generation.


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During construction noise emissions will be managed under the CEMP. The CEMP controls apply equally to the proposed mobile crushing and screening plant. Controls may include:

• Fitting vehicles and stationary items of equipment with exhaust mufflers;

• Screening or enclosing stationary items of equipment with acoustic enclosures to

reduce operating nose levels.

• Requiring contractors to comply with the Environmental Protection (Noise)

Regulations 1997.

• Construction works must be carried out in accordance with Section 6 of Australian

Standard 2436-1981 “Guide to Noise control on Construction, Maintenance and

Demolition Sites” and the Environmental Protection (Noise) Regulations 1997 (WA)

• A Blast Management Plan must be prepared for all blasting activities and include

an assessment of proximity to sensitive receptors, including nearby communities,

heritage rock shelters and bat cave locations

Once operational the processing plant will operate on a continuous 24 hours per day basis. During mining operations noise sources include:

• Running conveyors – start and stop alarms, rollers, drives and belt interaction

(continuous operation).

• Plant major equipment – primary and secondary crushers, vibrating screens,

stackers, reclaimers and train load out.

• Miscellaneous equipment – air compressors, blowers, transformers (continuous

operation).

• Mobile plant and vehicles – reverse warning alarms and other warning alarms

(irregular).

• ROM Bin Rock Breaker - intermittent use.

There is one sensitive noise receptor being the K75W Adit/Cave system which provides

roosting habitat for a PLNB Colony. The impact on PLNB has been assessed under Part IV

of the Environmental Protection Act 1986 and relevant conditions written into MS 999. A

specific PLNB Environmental Management Plan has been developed by Rio Tinto on the

advice of DWER and approved by the Office of the EPA. This plan includes monitoring for

threshold noise and vibration limits at the entrance to the K75W Adit/Cave system that will

trigger further additional responses.

Noise and vibration are not expected to be significant issues during the construction or

operation of the primary crusher, conveyors and processing plant. The risk related to noise

emissions is low (other than as discussed above regarding PLNBs). The noise emission

profile and risk is well understood and as described above there are significant controls applied

to monitoring and managing noise at Koodaideri.

6.4 Odour Emissions

No significant odour emissions are expected to be produced from the construction or operation of the Koodaideri processing plant or mobile crushing and screening plants.


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6.5 Light Emissions

Light emissions during construction of the processing plant are expected to be minimal. Construction activities will not be conducted at night and so night lighting will be limited to the minimum required to maintain site safety and security. Directional lighting will be used to minimise stray light emission.

When constructed and commissioned the processing plant will be operate on a continuous 24 hour basis. Night lighting in and around the processing plant, accommodation areas, offices and workshops is required in accordance with Australian standards for safe work.

The following controls will be implemented to manage light emissions:

• Plant lighting design will comply with Australian standards for safe work.

• Lighting design will be modelled prior to installation to ensure light is directed to

work areas and minimal light spill occurs.

• Walkways and platforms that require permanent lighting at night will have shrouded

lenses and LED’s with optics that direct lighting only onto walkways and platforms

with minimal “spill” to reduce light spill.

All nocturnal native fauna are potentially sensitive receptors to stray light emission. The project impact on Pilbara Leaf Nosed Bats has been assessed under Part IV of the Environmental Protection Act 1986 and relevant conditions written into MS 999. A specific PLNB Environmental Management Plan has been developed by Rio Tinto and approved by the Office of the EPA which includes commitments to limit light spill and to prevent development in PLNB exclusion zones. The risk to the environment related to light emissions (other than as described for the PLNB) at Koodaideri from the processing plant and mobile crushing and screening plant is therefore considered low.

6.6 Discharge to Water

There are no planned discharges to water during construction or operation of the processing plant or the mobile crushing and screening plants.

The closest surface water expression to the processing plant is Koodaideri Spring Gorge, approximately 4 km and up-gradient. The Fortescue Marsh is located approximately 8 km from the premises boundary. Impacts to either Koodaideri Spring Gorge or the Fortescue Marsh are not expected during operation or construction of the processing plant or mobile crushing and screening plants. Controls in addition to those required by MS999 are not considered necessary as the risk to environmental receptors is low.


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6.7 Discharges to Land

6.7.1 Description of risk event

Construction – Fixed Crushing / Screening Plant

The potential for contamination of soil and groundwater exists due to the possible presence of

iron, hydrocarbons and chemicals within stormwater, leaks and spills associated with the

construction of the fixed crushing and screening infrastructure.

Local groundwater is fresh and is approximately 70 m below ground level in the area where

the Processing Plant is to be constructed.

Operation – Fixed Crushing / Screening Plant

The potential for contamination of soil and groundwater exists due to the presence of iron,

hydrocarbons and chemicals within stormwater, leaks and spills, associated with the operation

of the fixed crushing and screening infrastructure.

Local groundwater is fresh and is approximately 70 m below ground level in the area of the

Processing Plant.

6.7.2 Proposed environmental controls

Construction – Fixed Crushing / Screening Plant

The environmental controls proposed to mitigate any potential impact on the environment during construction of the fixed crushing and screening infrastructure include:

• Diversion of clean surface water around the work area.

• Secondary containment of all chemical and hydrocarbon storage across the entire

site.

• Approval process prior to mobilising any chemicals to site.

• Drainage sumps to settle out sediments prior to discharge from the plant area.

• No permitted release of any potentially contaminated site water that has not been

checked for hydrocarbon contaminants.

Operation – Fixed Crushing / Screening Plant

The processing area will be constructed to enable the separation of clean stormwater run-off

and potentially sediment laden run-off to the extent achievable by applying Rio Tinto Standard

specification SS-N102 Sediment Control and Separation. The area surrounding the crushing

plant and conveyor transfer points will be compacted structural fill. Stormwater will be collected

in open drains which then discharge to sedimentation ponds. The plant drainage will flow to

an earthen sedimentation / silt pond designed to treat a peak 1:10 year rainfall event. The area

under the primary and secondary crushing plant and conveyor transfer points will be concrete

slab, graded such that washdown water will be collected in concrete sediment/silt traps.

Washdown water from conveyors will be collected in concrete sumps and either removed by

pumping out, or allowed to evaporate depending on climatic conditions and volumes reporting

to sumps. Drive in sumps will be installed around the plant site and all wash down from


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concrete slabs placed under the operating plant will be directed into these sumps. The bulk of

solids will settle in the drive in pits of these sumps while the liquid containing particles will be

pumped into silt traps. Fine solids will settle in these silt traps prior to release of the clean

water. Both the drive in sumps and silt traps will be debogged using bobcats and front end

loaders. Sumps will be installed at the Primary Crusher, Transfer Station TF0101, Transfer

Station TF0313, Transfer Station TF0316, COS, Product Screen Area North, Product Screen

Area South, Secondary Crusher, Secondary Sampling Area, Reclaim Conveyor Drive Station

and the Train Loadout. Sumps are designed to be drive-in to allow removal of sediment. These

are depicted in the drawings provided in Attachment B. No other waste water is expected to

be generated in the crusher/conveyor circuit.

The levee and drain structures installed to prevent the ingress of surface water in to the mining

operations will also be used to contain runoff water from around the plant and other

infrastructure. There are no sensitive receptors that could potentially be impacted by

contaminated surface water in the vicinity of the processing plant infrastructure. The Fortescue

Marsh is approximately 8 km from the facilities and the Koodaideri Spring Gorge is 4km away

and upgradient. Regardless, a range of controls will be implemented to ensure any potential

risk to the environment is minimised including:

• Diversion of clean surface water around the work area.

• Secondary containment of all chemical and hydrocarbon storage across the entire

site.

• Approval process prior to mobilising any chemicals to site.

• Drainage sumps to settle out sediments prior to discharge from the plant area.

• Oily water separators (centrifugal type) to separate out hydrocarbons from surface

water.

• No permitted release of any potentially contaminated site water that has not been

checked for hydrocarbon contaminants.

Mobile Crushing and Screening Plants

There are no contaminated discharges to land expected from the construction and operation of the mobile crushing or screening plants. The plant is mobile and will be located within existing cleared borrow pit areas so that any dust laden water is retained within the confines of the borrow pit. Clean surface water will be diverted around the work area by use of bunding where practicable. Mobile plants shall also be situated in a suitable location such that they are located at least 50 meters from any permanent water body.

6.7.3 Residual risk to environment

The risk to the environment from discharges to land from the processing plant and mobile crushing and screening plant is considered low given the distance to any sensitive receptor (see Table 2-2 and Table 2-3), and the significant controls to be implemented.


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6.8 Hydrocarbon Management

Hydrocarbons stored on site during the Project construction will be predominantly diesel fuel, lubricants (new and used oil) and hydraulic fluids. There will typically be up to four 110 kL diesel storage tanks and up to six 55kL diesel storage tanks on site at any one time. A range of minor chemical storage facilities will be located on site typically containing a range of packaged chemicals in 50 litre containers and 220L drums. Hydrocarbons will be stored in the contractor laydown work areas. All bulk hydrocarbon storage will comply with DMIRS licensing requirements. All chemicals and hydrocarbons used during construction will be secondarily contained in bunded storage areas, approved chemical cabinets or dual skinned tanks. All chemicals and hydrocarbons will be managed under the Construction Environmental Management Plan (CEMP) and will be in accordance with Dangerous Goods Safety (Storage and Handling of non–explosive) Regulations 2007 and AS1940:2004 The storage and handling of flammable and combustible liquids. Site environmental management requirements include:

• All storage tanks and transfer points will be above ground and secondarily

contained in accordance with AS1940:2004;

• Vehicle refuelling will occur over compacted, lined earthen pad or a concrete

hardstand area (with the exception of field based machinery refuelling where a drip

tray will be used at the transfer point);

• All piping will be above ground where practicable. Where hydrocarbon piping is

below ground it will be secondary contained and have visual inspection pits for any

leaks in accordance with Rio Tinto standard specifications.

• All tanks will be secondarily contained;

• Substances in small volume packages (nominally 20 litres or less) will be stored in

a self bunded chemical cabinet or in a bunded area;

• Containers and drums may be stored temporarily on self bunded pallets or in a

HDPE lined earthen bund. The capacity of the bunding must be at least 100

percent of the volume of the largest container plus 25 percent of the storage

capacity up 10,000 litres as per AS1940:2004 s4.4.3; and

• Spill kits suitable for the stored material being stored will be co-located with all

chemical storage areas.

6.9 Solid/Liquid Waste

There are no liquid waste by-products generated by the Processing plant during construction or operation. Solid industrial and domestic waste will be generated during the construction and operation of the ore processing area. Waste material that is suitable for re-use or recycling will be separated from landfill waste and sent off-site for treatment or recycling as practicable. Non-recyclables will be disposed of in the licensed site landfill.


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All Controlled Waste will be removed from site via an appropriately licensed controlled waste carrier and relevant records including tracking notes maintained on site for audit and inspection purposes. All waste handling procedures will be in accordance with the CEMP during construction and the RTIO Health Safety Environment and Quality (HSEQ) Management System during operations.

6.10 Flora and Fauna

New clearing is required for the construction of the Processing Plant, associated infrastructure

and site access. Ministerial Statement 999 approves up to 7911 ha of clearing for the mine

and Processing Plant Area, with all clearing associated with this proposal being covered by

this approval. Of this 7911 hectares approximately 54 ha will be required for the footprint of

the Processing Plant.

Construction and operation of the Processing Plant and related infrastructure has the potential

to impact on certain conservation significant flora and fauna. In particular MS 999 specifies

conditions relating to the management of impacts on the PLNB, Northern Quoll, certain

Troglofauna zones and two flora species Hamersley Lepidium (Lepidium catapycnon) and

Sauropus sp. Koodaideri detritals now known as Synostemon hamersleyensis.

The Rio Tinto Approval Request and Ground Disturbance permitting process will be used to

directly control all land clearing and ground disturbing activities on site. Issuing permits

involves extensive analysis using GIS data acquired through professional botanical and

ecological surveys. The commencement of work under approved permits requires formal

survey, delineation of clearing limits, direct supervision of land clearing activities, mandatory

land disturbance training and extensive reporting including survey pick and assessment via

GIS applications.

Site specific controls relating to the management of impacts to PLNB committed to in the PLNB

management plan include:

• Implementing the approved PLNB management plan;

• Implementing an exclusion zone around the K75W Adit/cave System to minimise

noise and vibration impacts;

• Implementing exclusion zones around the Koodaideri Spring Gorge Foraging

habitat;

• Undertaking monitoring in accordance with the approved PLNB; and

• Ensuring lighting is designed in accordance with Australian Standards

requirements for plant and some infrastructure.

Site specific controls relating to the management of impacts to Northern Quoll required under

MS 999 include:

• Implementing the approved Northern Quoll Management plan;

• Undertaking surveys to identify Northern quoll habitat, presence and abundance

within the mine plant development envelope;


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• Having the Northern Quoll management plan prepared and approved prior to the

commencement of ground-disturbing activities within 50 metres of the mapped

Northern quoll foraging and denning habitat; and

• Implementing protocols and procedures to monitor Northern Quoll presence and

abundance adjacent to the mine pit within the Mine/Plant Area Development

Envelope during construction and operation.

Additional general site-wide controls relating to fauna management include:

• General personnel and contractors are prohibited from feeding or handling nay

wildlife in the Project area;

• Trained Fauna Handlers will be on site to manage fauna interaction issues;

• A fauna interaction register will be maintained on site;

• All open pits and trenches are required to include fauna egress facilities or

preferably prevent fauna access to the extent possible;

• Water sources (i.e. turkeys nests) will be fenced so that non-native fauna are not

attracted to the area;

• All waste food material is contained in closed bins onsite; and

• Site communications will periodically feature conservation significant fauna to

assist with educating the workforce on fauna management requirements.

7 Rehabilitation and Closure

After construction works are completed, areas that have been cleared and no longer required for operational use will be rehabilitated. On completion of the required mining operations all structures associated with Koodaideri will be removed from the site and the area rehabilitated. The closure of infrastructure and activities the subject of this works approval will follow the approved mine closure plan for the Koodaideri Mine. The closure plan will evolve over time and will be updated regularly as required under Ministerial Statement 999.

8 Project Costs

Costs associated with the construction of the proposed facilities are detailed below:

Table 8.7-1: Project Costs

Project Description Projected Cost $AUD

Primary Crushing, Transfer Station and Conveyors $ 98,977,302

Crushed Ore Conveyor and Storage $ 62,188,758

Secondary Crushing, Screening, Conveyors and Substations $ 198,946,574

Product Sample Station and Conveyors $ 13,388,483

Stockyard, Stackers, Reclaimer and Conveyors $ 189,289,543

Train Load Out $ 26,559,913

Total Cost (excl, GST) $ 589,350,573


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9 Summary of Commitments

Environmental factor

Potential impacts Proposed management Section number

Commitment

Dust emissions

Dust impacts on surrounding vegetation, including reduced ability for photosynthesis due to smothering.

Dust suppression (water

sprays, water trucks, control of

vehicle movements / restricted

speeds)

Rehabilitation of disturbed

areas

6.2.2

Automated water cannons installed in stockyard.

Dust suppression systems installed in mobile crushing and screening

plant.

Water spray addition points at the discharge from the apron feeders,

transfer points and at the head end of the primary crusher discharge

conveyor.

Two dust collectors will be installed, one between the coarse ore stockpile

and secondary crusher, and a second at the screening plant.

Conveyors handling material with a low moisture content will be fitted with

spray booths for dust suppression at most transfer points, including the

primary crushed ore conveyor, dry screen feed conveyor, lump stacking

conveyor, and fines stacking conveyor.

All conveyors are covered except in the stockyard to reduce dust lift off.

The stockyard will be serviced by automatic water cannons on either side

of the stockpiles.

Stacker boom conveyors will be fitted with head-end sprays and dust

shrouds.


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Commitment

Noise emissions Noise / Vibration impacts on fauna habitat, including potential roosting sites for bats

Implement the approved

Pilbara Leaf Nosed Bat

Environmental Management

Plan

6.3

Fitting vehicles and stationary items of equipment with exhaust mufflers;

Screening or enclosing stationary items of equipment with acoustic

enclosures to reduce operating nose levels.

Requiring contractors to comply with the Environmental Protection (Noise)

Regulations 1997.

Construction works must be carried out in accordance with Section 6 of

Australian Standard 2436-1981 “Guide to Noise control on Construction,

Maintenance and Demolition Sites” and the Environmental Protection

(Noise) Regulations 1997 (WA)

Implementation of Blast Management Plans for all blasting activities and

include an assessment of proximity to sensitive receptors, including

nearby communities, heritage rock shelters and bat cave locations

Prevent development in Pilbara Leaf Nosed Bat exclusion zones

Light Emissions Disruption to nocturnal fauna Disruption in PLNB roosting patterns

Implement the approved

Pilbara Leaf Nosed Bat

Environmental Management

Plan

6.5

Plant lighting design will comply with Australian standards for safe work.

Lighting design will ensure light is directed to work areas and minimal light

spill occurs.

Walkways and platforms that require permanent lighting at night will have

shrouded lenses and LED’s with optics that direct lighting only onto

walkways and platforms with minimal “spill” to reduce light spill.

Prevent development in Pilbara Leaf Nosed Bat exclusion zones

Discharge to Land

Potential contamination of soil and groundwater exists due to the possible presence of iron, hydrocarbons and chemicals within stormwater, leaks and spills associated with the construction of the fixed crushing and screening infrastructure.

Secondarily contain storage of

hydrocarbons and other

chemicals.

Separate all clean and

potentially contaminated water

sources.

6.7.2

Diversion of clean surface water around the work area to the extent

achievable by applying Rio Tinto Standard specification SS-N102

Sediment Control and Separation

Secondary containment of all chemical and hydrocarbon storage across

the entire site.

Approval process prior to mobilising any chemicals to site.

Drainage sumps to settle out sediments prior to discharge from the plant

area.

No permitted release of any potentially contaminated site water that has

not been checked for hydrocarbon contaminants.


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Commitment

Hydrocarbon Storage

Potential contamination of soil and groundwater exists due to the possible presence of hydrocarbons within stormwater.

All chemicals and

hydrocarbons used during

construction will be secondarily

contained in bunded storage

areas, approved chemical

cabinets or dual skinned tanks.

6.8

All storage tanks and transfer points will be above ground and secondarily

contained in accordance with AS1940:2004;

Vehicle refuelling will occur over compacted, lined earthen pad or a

concrete hardstand area (with the exception of field based machinery

refuelling where a drip tray will be used at the transfer point);

All piping will be above ground;

All tanks will be secondarily contained;

Substances in small volume packages (nominally 20 litres or less) will be

stored in a self bunded chemical cabinet or in a bunded area;

Containers and drums may be stored temporarily on self bunded pallets

or in a HDPE lined earthen bund. The capacity of the bunding must be at

least 100 percent of the volume of the largest container plus 25 percent of

the storage capacity up 10,000 litres as per AS1940:2004 s4.4.3; and

Spill kits suitable for the stored material being stored will be co-located

with all chemical storage areas.

Specially protected fauna

Land clearing impacts on Northern Quoll and Pilbara Leaf Nosed Bat

Implementation of the Northern

Quoll and Pilbara Leaf Nosed

Bat management Plans

6.10

Implementing the approved PLNB management plan;

Implementing an exclusion zone around the K75W Adit/cave System to

minimise noise and vibration impacts;

Implementing exclusion zones around the Koodaideri Spring Gorge

Foraging habitat;

Undertaking monitoring in accordance with the approved PLNB; and

Ensuring lighting is designed in accordance with Australian Standards

requirements for plant and some infrastructure.

Implementing the approved Northern Quoll Management plan;

Undertaking surveys to identify Northern quoll habitat, presence and

abundance within the mine plant development envelope;

Having the Northern Quoll management plan prepared and approved

prior to the commencement of ground-disturbing activities within 50

metres of the mapped Northern quoll foraging and denning habitat; and

Implementing protocols and procedures to monitor Northern Quoll

presence and abundance adjacent to the mine pit within the Mine/Plant

Area Development Envelope during construction and operation.

Specially protected flora

Land clearing impacts on Hamersley Lepidium (Lepidium catapycnon) and Sauropus sp. Koodaideri detritals now known as Synostemon hamersleyensis

Avoid direct disturbance of

known populations 6.10

Implementation of the Rio Tinto Approval Request and Ground

Disturbance Permitting system.


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Appendices

A Drawings

KD-0000-F-DRG-00001 Process Plant – Process Flow Diagram

1000-EG-DWG-0003 Overall Site Building Set Out – General Arrangement







TEREX J-1840 Jaw Crusher Specification Sheet and Layout

TEREX 883 Mobile Screening Plant Specification Sheet and Layout


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TEREX J-1840 Jaw Crusher


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TEREX 883 Mobile Screening Plant


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