2010 Annual Tailings Plan Submission Syncrude Mildred Lake
Transcription
2010 Annual Tailings Plan Submission Syncrude Mildred Lake
2010 Annual Tailings Plan Submission Syncrude Mildred Lake (Leases 17 and 22) Submitted to: Energy Resources Conservation Board Submitted by: Syncrude Canada Ltd. Fort McMurray, Alberta September 30, 2010 Table of Contents 1 2 3 4 5 6 Introduction________________________________________________________ 1 1.1 Current Operations (Leases 17/22) __________________________________ 1 Tailings and Mining Plans ____________________________________________ 4 2.1 Tailings Management Strategy _____________________________________ 4 2.2 Dedicated Disposal Area (DDA) Strategy ____________________________ 5 2.2.1 Current Operations...........................................................................................7 2.2.2 Future Dedicated Disposal Areas.....................................................................7 2.2.3 Additional Activities......................................................................................10 2.2.4 Fines Management .........................................................................................10 2.3 Reconciliation to Approved Plan __________________________________ 11 2.4 Opportunities Under Consideration ________________________________ 11 Planning Details ___________________________________________________ 12 3.1 Mining_______________________________________________________ 12 3.2 Tailings ______________________________________________________ 14 3.2.1 Mildred Lake Settling Basin: .........................................................................16 3.2.2 West In-Pit: ....................................................................................................16 3.2.3 East In-Pit: .....................................................................................................16 3.2.4 Southwest In-Pit:............................................................................................16 3.2.5 Southwest Sand Storage:................................................................................17 3.2.6 North Mine South Pond Storage:...................................................................17 3.2.7 North Mine Center Pond Storage:..................................................................17 3.2.8 North Mine End Pit Lake...............................................................................17 3.3 Key Milestones ________________________________________________ 18 Construction Details ________________________________________________ 25 4.1 Southwest Sand Storage _________________________________________ 26 4.2 North-South Dyke and East-West Dyke 1 ___________________________ 29 4.3 East-West Dyke 2 ______________________________________________ 29 Site Wide Material Balance __________________________________________ 32 Water Chemistry ___________________________________________________ 36 6.1 Mildred Lake Settling Basin ______________________________________ 36 6.2 Southwest Sand Storage Facility __________________________________ 36 6.3 In-Pit Tailings Facilities _________________________________________ 37 List of Figures Figure 1.1 Figure 1.2 Figure 2.1 Figure 2.2 Figure 2.3 Figure 3.1 Figure 3.2 Figure 3.3 Figure 3.4 Figure 3.5 Figure 3.6 Figure 3.7 Figure 4.1 Figure 4.2 Figure 4.3 Figure 4.4 Overall Syncrude Process Flow ________________________________ 2 Location Map and Simplified PFD for Mildred Lake Facilities________ 3 Tailings Containment Chart for Mildred Lake _____________________ 6 Mildred Lake Proposed DDA Locations _________________________ 9 MFT Inventory Curve _______________________________________ 10 North Mine Development Sequence____________________________ 13 2010 Status Map ___________________________________________ 19 2012 Status Map ___________________________________________ 20 2013 Status Map ___________________________________________ 21 2015 Status Map ___________________________________________ 22 2018 Status Map ___________________________________________ 23 2023 Status Map ___________________________________________ 24 North South Dyke Asbuilt (year end 2009) ______________________ 30 North-South Dyke Typical Design Cross Section _________________ 30 East-West Dyke 1 Asbuilt (year end 2009) ______________________ 31 East-West Dyke 1 Typical Design Cross Section__________________ 31 List of Tables Table 2.1 Table 3.1 Table 3.2 Table 3.3 Table 4.1 Table 4.2 Table 4.3 Table 4.4 Table 4.5 Table 5.1 Table 5.2 Table 5.3 Key Tailings Planning Assumptions_______________________________ 5 Mine Plan Ore Summary ______________________________________ 12 Mine Plan Waste Summary ____________________________________ 14 Mildred Lake Tailings Production Summary _______________________ 15 Mine Waste Construction Material Schedule _______________________ 25 Mine Waste Disposal Schedule _________________________________ 26 Tailings Disposal Schedule_____________________________________ 27 Tailings Disposal Schedule (continued) ___________________________ 28 Structure Construction Schedule_________________________________ 29 Site Wide Material Balance - Sand Management ____________________ 33 Site Wide Material Balance - Fines Management ___________________ 34 Site Wide Material Balance - Water Management ___________________ 35 List of Acronyms AENV bbl bcm BMD BML CDA CT C&R DDA EIP EPL ERCB E/W Dyke FFT FGD IB ID masl Mbbls Mbcm MFT MFTT ML MLETB MLR MLSB Mm3 Mt NEP NMCP NMSP N/S Dyke NWQ OB O/F PFD RCW R&D SCT SEP Sg SW SWIP SWSS TFT TV:BIP µm U/F WIP Alberta Environment Barrel Bank Cubic Metre Base Mine Dam (name replacement of Plant Site Protection Dam) Base Mine Lake Canadian Dam Association Composite Tailings Conservation and Reclamation Dedicated Disposal Area East In-Pit End Pit Lake Energy Resources Conservation Board East-West Dyke 1 and 2 Fluid Fine Tailings Flue Gas Desulphurization Interburden Interim Directive Metres Above Sea Level Million Barrels Million bank cubic metres Mature Fine Tailings Mature Fine Tailings Transfer Mildred Lake Mildred Lake East Toe Berm Mildred Lake Reservoir Mildred Lake Settling Basin Million Cubic Metres Million Tonnes Northeast Pond (referring to the north portion of the EIP) North Mine Center Pit North Mine South Pit North-South Dyke Northwest Quadrant (of the Mildred Lake Base Mine) Overburden Overflow (referring to the CT Plant hydrocyclone overflow stream) Process Flow Diagram Recycle Water Research and Development Straight Coarse Tailings (or conventional coarse tailings) Southeast Pond (referring to the south portion of the EIP) Specific Gravity Southwest Southwest In-Pit Southwest Sand Storage Thin FineTailings Total Volume to Bitumen In Place Micrometer Underflow (referring to the CT Plant hydrocyclone underflow stream) West In-Pit Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake 1 Introduction The 2010 Annual Tailings Plan for the Mildred Lake project is submitted in compliance with Section 4.5.1 of Directive 074: Tailings Performance Criteria and Requirements for Oil Sands Mining Schemes. The Mildred Lake project currently operates under ERCB Approval No. 8573. For ease of reference, a concordance table for Appendix E of Directive 074 is included in Appendix 1. 1.1 Current Operations (Leases 17/22) Syncrude’s oil sands activities at Mildred Lake include mining, extraction, froth treatment, and bitumen upgrading. Processing at the Mildred Lake upgrader results in the production of a bottomless, light sweet synthetic crude oil. Figure 1.1 provides a schematic of the integrated Syncrude operation. Oil sand mining at the Mildred Lake site uses truck and shovel surface mining technology. The mining sequence consists of ore body and mineable pit delineation, tree clearing, surface and basal aquifer dewatering as required, reclamation material removal, overburden stripping, oil sand mining, in-pit placement of tailings and overburden, and reclamation material placement. At present, approximately 105 million tonnes of ore is mined annually at the Mildred Lake site. The majority of the ore is mixed with hot water and delivered to primary extraction using hydrotransport technology. Dry auxiliary production is transported by conveyor to primary extraction. Separation of bitumen from oil sands is accomplished through warm water extraction and froth treatment processes. The final bitumen product is a relatively clean heavy hydrocarbon used as feedstock to the Syncrude upgrader. Tailings, the materials remaining after bitumen is extracted from oil sands, is a mixture of sand, silt, clay, water, and residual hydrocarbon. Tailings are distributed hydraulically via a network of pipelines to a number of in-pit and out-of-pit placement areas. Syncrude currently operates two out-of-pit tailings deposition areas at Mildred Lake: the Mildred Lake Settling Basin (MLSB) and the Southwest Sand Storage (SWSS) facility. Dykes are also constructed to subdivide mined out areas to utilize those areas for tailings placement. Syncrude currently operates three in-pit tailings deposition areas at the Mildred Lake site; the East In-Pit (EIP), West In-Pit (WIP), and Southwest In-Pit (SWIP) tailings disposal facilities. A location map and simplified process flow diagram of tailings systems currently in place at the Mildred Lake site are included in Figure 1.2. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 1 of 39 PLANT UTILITIES Figure 1.1 Process Athabasca River Water Overall Syncrude Process Flow Byproduct Utilities Steam Geological structure Generator at Mildred Lake and Aurora mines Treated Sanitary Sewage Oil sand Midred Lake’s Base Mine Utility Boiler Potable Potable Water Water Oil Sand Slurry Dump pocket Geological structure Pipeline terminals and refineries Mildred Lake’s Auxiliary Production System Oil Sand Slurry Stack Geological structure Mildred Lake’s North Mine hydrotransport Coke Cells CO Boiler Screens Precipitator Water Treatment Primary Separation To be replaced by SER Project facilities by 2009 Bitumen Froth by 2011 Bitumen Froth Cyclofeeder Coke Silos PSV Froth Blended product to pipeline Diluent Geological structure Inclined Plate Settler Aurora’s north operation Aurora North operation Mine Hydrotransport Fluid Cokers DRU Aurora’s Settling Basin (ASB) at Aurora Aurora’s north operation North operation Centrifuge Froth Tailings Vacuum Distillation Unit Geological structure Southwest Sand Storage (SWSS) Sulphur stock pile Mildred Lake Tailings Settling Basin (MLSB) LC-Finer Aurora South operation’s Aurora’s south operation’s tailings placement area Syncrude Canada Ltd. Sulphur Water to Utilities For Recycling Aurora’s south operation Aurora South operation Mine Hydrotransport MINING Synthetic crude oil storage and blending Hydrotreaters Tailings Oil Recovery Hydrogen Plant Natural Gas EXTRACTION 2010 Directive 074 Submission: Mildred Lake UPGRADING DISTRIBUTION Page 2 of 39 Figure 1.2 Location Map and Simplified PFD for Mildred Lake Facilities Highway 63 Str 73 Coke Lines MLSB Plt 6c Plt 6A&B MLR RCW Plt 6 Plt 5 W2 Dump W1 Dump COF S6 691 S2 CT 690 WIP Barge EIP MFT Barge S5 WIP 791 SWIP SSF Dredges SEP Dredge Barge SEP Return to WIP TTSWIP Dredges S4 S3 SWSS S1 790 Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 3 of 39 2 Tailings and Mining Plans 2.1 Tailings Management Strategy Tailings are stored in both out-of-pit and in-pit facilities. As the mine face advances and containment dykes are constructed, in-pit storage space is made available and tailings storage facilities are established. Syncrude’s tailings disposal plan is integrated throughout all mine areas to optimize the use of available storage capacity. The objectives of the tailings management strategy are to maximize the use of in-pit capacity for CT and fluid containment, minimize fluid transfer requirements, and ensure a reliable recycle water (RCW) supply for plant operations. The Tailings Plan depends on large dykes to provide containment. These dykes are licensed dam structures and are designed to ensure geotechnical stability, per Canadian Dam Association (CDA) and Alberta Dam Safety Branch standards. Dyke designs may include the use of overburden, tailings sand, or a combination of both. Overburden dykes are constructed using mobile equipment for material placement, while sand dykes use standard tailings slurry cell construction techniques. Overburden dyke construction often entails ‘zonation’ of material through the dyke cross section to maximize utilization of available overburden material types. Both types of structures are closely monitored to ensure the geotechnical design criteria are met. Commercial scale Composite Tailings (CT) operation commenced at Syncrude in 2000 with CT deposition in the EIP facility. CT remains one of the primary technologies for mature fine tailings1 (MFT) management at Syncrude and is instrumental in achieving targeted end of mine life MFT inventories. MFT volumes reported at the ML lease have a range of fines by weight of approximately 10% to 70% with an overall average site fines by weight of approximately 45%. To produce CT, coarse tailings are pipelined from the extraction plant to the CT plant, where they are cycloned to produce a densified coarse tailings stream. The densified coarse tailings stream is combined with MFT and gypsum to form CT. The CT product is then transported hydraulically to the designated tailings disposal facility. Once deposited in the pond, the mixture dewaters relatively rapidly, leaving a soft deposit that is capped using coarse tailings sand to create a trafficable surface for reclamation. Syncrude is in the process of implementing MFT centrifuging technology to complement CT as a fines management technology to reduce MFT inventory volumes to those assumed in the Mildred Lake C&R Plan. Centrifuging MFT accelerates the release of water from the MFT deposit and produces a soft, clay-rich soil termed “centrifuge cake”. There are two main types of deposition areas proposed for centrifuge cake: as an internal component of out-of-pit overburden structures and within tailings placement areas. Technology development and deposition planning are being advanced; plans for centrifuge cake deposition and reclamation will be updated as new information becomes available. Syncrude proposes to prepare the resulting centrifuge cake deposits for reclamation as a dry landscape feature by capping with sand or overburden as required. The implementation of MFT centrifuging technology is proposed to be executed in two stages; a commercial scale demonstration to begin in 2012, followed by the commercial facility in 2015. 1 Syncrude uses the terms mature fine tailings (MFT) and fluid fine tailings (FFT) interchangeably to refer to a fluid deposit composed primarily of tailings fines (<44 micrometers) and water. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 4 of 39 The current C&R Plan assumes the establishment of two end pit lakes (EPL) at the Mildred Lake site. The first EPL, namely Base Mine Lake (BML) is currently nearing completion and will be commissioned during 2012. BML will serve as a demonstration of water capped MFT technology as a viable reclamation component of the closure landscape. A second EPL will be created at the north end of the North Mine when mining operations are completed at the Mildred Lake site. Reclamation of coarse tailings areas, sand capped CT deposits, and centrifuge cake deposits will create dry terrestrial landforms that will direct surface drainage towards either BML or EPL before ultimately joining the regional watershed. Key tailings planning assumptions are included in table 2.1. The containment chart shown in Figure 2.1 summarizes total tailings production by type and containment availability for the Mildred Lake site. Table 2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 2.2 Key Tailings Planning Assumptions Item TVBIP ratio Extraction recovery CT sand to fines ratio Water inventory (year end 2009) MFT inventory (year end 2009) BML commissioning Straight coarse tails slurry Sg Flotation tails slurry Sg (Stream 73) Froth tails slurry Sg (Plant 6) CT slurry Sg Beach above water slope Beach below water slope CT slope MFT projected consolidation Unit % Mm3 Mm3 Tonnes/m3 Tonnes/m3 Tonnes/m3 Tonnes/m3 % % % % Mildred Lake 14:1 89.5% - 93.1% 4:1 83 426 2012 1.4 1.15 1.12 1.60 1% 4% 0.5 44.7% - 49.0% Dedicated Disposal Area (DDA) Strategy The fines management technology portfolio for the Mildred Lake site includes Composite Tailings (CT), MFT centrifuging, and MFT water capping in an end-of-pit lake (EPL) facility. Syncrude’s management strategy prioritizes deposition of MFT and engineered tailings deposits in mined out pits. Syncrude continues to optimize placement plans to create dedicated disposal areas for engineered tailings deposits concordant with the fines sequestration objectives of ERCB Directive 074. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 5 of 39 2030 2028 2026 2024 2022 2020 2018 2016 2014 2012 2010 2008 Tailings Containment Chart for Mildred Lake 2006 Figure 2.1 2300 2300 2150 2000 Cumulative Tailings Growth (Mm3) 2150 5 Mm3/yr centrifuge cake in W4 (2015 -2020) 1850 EPL 2000 1850 NMCP SWSS draw dow n 1700 1700 1550 1550 NMSP-E 1400 1400 NMSP-W 1250 1250 SWSS 1100 1100 950 950 BML 800 800 Note: To better represent the modeled volumes, sand, CT and Coke volumes have been zeroed at year end 2009 and 350Mm3 of the total MFT volume is not shown for readability. 650 500 650 500 2030 2028 2026 2024 2022 2020 2018 2016 2014 2012 2010 2008 350 2006 350 Years Sand Syncrude Canada Ltd. CT centrifuge cake MFT above 350Mm3 2010 Directive 074 Submission: Mildred Lake Coke RCW Contingency Containment Page 6 of 39 2.2.1 Current Operations Syncrude is currently utilizing the EIP and SWIP facilities for the deposition of CT. The EIP facility is a large beach deposit comprised of CT interlayered with coarse tailings. A sand cap is currently being placed over the CT / coarse tailings beach deposit to attain adequate bearing capacity for placement of reclamation material. CT deposition in the EIP is expected to be completed in 2011 and ongoing sand capping operations are scheduled to be completed by 2013, with fluid removal completed in 2014. SWIP is divided into several discrete deposit areas. Overburden berms have been constructed with intent to isolate coarse tailings used to construct the upstream sand filter for the South West Dam, from other materials being stored in the SWIP facility. Initial CT deposition was directed to an isolated cell at the north end of SWIP (SWIP Jr.). Thin fine tails will be pumped off of the deposit into the main pond area of the SWIP facility. The isolated cell is now full; CT deposition has begun at the south end of the main SWIP area. Depending on turbidity, water will be returned to the RCW pond to support plant operations or to Mildred Lake Settling Basin (MLSB) for further clarification. SWIP is being utilized and monitored as a test for the design and operation of a dedicated disposal area. Learnings from this pond will be incorporated into the design, plans, and fines measurement programs for future DDAs. 2.2.2 Future Dedicated Disposal Areas Future areas being considered for designation as DDAs are shown in Figure 2.2. Planning details are subject to change as the overall placement plan and technology is optimized. DDA plans will be submitted to the ERCB two years prior to the start of construction for each DDA, as required by Directive 074. DDA-1 will be in the SWIP tailings facility for CT placement. Overall containment is provided by in-situ ground to the west and south, and by the SW Dam to the East of the pond. An upstream sand filter is to be constructed out of coarse tailings to meet the geotechnical design criteria for the SW Dam. Some coarse tailings will be interlayered within the CT beach due to operating constraints and time required to react to changing plant operating conditions. A DDA plan for DDA-1 will be provided to the ERCB by September 30, 2010. DDA-2 is proposed to be established within the valley formed by the existing W1 overburden dump and the north slope of the Southwest Sand Storage (SWSS). This area is being designed as a placement area for centrifuge cake. The deposit formed will be open-ended towards the SWSS facility at higher elevations and will include centrifuge cake on final SWSS beaches. DDA-2 will serve as the main deposit area for centrifuge cake from the MFT centrifuging commercial scale demonstration and, pending acceptable geotechnical performance, further deposition from the commercial plant. A DDA plan for DDA-2 will be provided to the ERCB in Q4 2010. DDA-3a and DDA-3b is proposed to be established on MLSB toe berms and may be required for supplemental volume of centrifuge cake deposition to support the total volume required for the MFT centrifuging commercial demonstration project starting in 2012. If required, a DDA plan for DDA-3 will be provided to the ERCB in Q4 2010. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 7 of 39 DDA-4 will be located within the mined out North Mine South Pit (NMSP), and will be developed in stages. The North-South Dyke will contain the initial deposition of CT in North Mine South Pit – West (NMSP-W) starting in 2013. CT deposition will continue within the pit area until NMSP-E becomes available in 2015. Containment for NMSP-E is provided by the NS Dyke to the West, in-situ ground to the south, the Sulphur platform and T-Dam to the east, and the East West Dyke 1 to the north. NMSP-W and NMSP-E eventually join to become one deposit area (NMSP). At the end of mining, the NMSP does not achieve final planned closure topography with coarse tailings and CT; therefore this DDA will progress further with the deposition of centrifuge cake to complete the closure topography. DDA-5 will be located within the out of pit W4 Dump overburden structure. An approximate 5m base lift and ribs will be built with overburden, which will allow for centrifuged cake to be deposited between the ribs. This design is currently under review. DDA-6 will be located within the North Mine Center Pit (NMCP) for the placement of centrifuge cake on the base of feed. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 8 of 39 2.2.3 Additional Activities Fines management remains a focus for research and development (R&D) efforts at Syncrude. R&D activities are concentrated on continuous improvement and reclamation for the proposed fines management technologies (CT, MFT centrifuging and MFT water capping) as well as continued exploration of new alternatives. Depending on the success of this work, the future DDA plans may be adjusted to include new technologies or adjustments to design and operating procedures. Continued monitoring and research on sand capping and reclamation performance is being conducted on EIP. As results become available, designs for SWIP and NMSP may be adjusted as required. 2.2.4 Fines Management Figure 2.3 displays estimated MFT inventory for the Mildred Lake Project assuming both continued reliance on CT and the staged implementation of MFT centrifuging technology. The use of MFT centrifuging technology in addition to CT will allow Syncrude to reduce MFT inventories at the end of mine life to levels contemplated in the approved C&R Plan. The remaining fluid fines inventory at the end of mine life will be stored in two End Pit Lakes (EPL); namely the Base Mine Lake and the North Mine EPL. Figure 2.3 MFT Inventory Curve 600 400 3 MFT volume (Mm ) 500 300 200 100 Historical Modeled Projections 0 1970 1980 1990 2000 2010 2020 2030 2040 2050 Year End Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 10 of 39 2.3 Reconciliation to Approved Plan The tailings management strategy outlined in this submission remains unchanged from the 2009 tailings plan submission. The mining rate has been increased resulting in changes in timing for tailings placement; however, the projected MFT inventory curve remains unchanged. This plan also includes a change in mining TVBIP ratio from 12 to 14. The tailings plan included in this submission supports the landform and drainage features included in the C&R Plan approved by AENV in 2007. 2.4 Opportunities Under Consideration Syncrude will be updating its tailings management plans to reflect business/strategic decisions being made. Opportunities currently under consideration that would potentially result in changes to future tailings plans include: • Update of plans to reflect field results from ongoing centrifuge pilot plants. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 11 of 39 3 Planning Details 3.1 Mining The North Mine overburden development sequence is shown on Figure 3.1, with corresponding ore production rates provided in Table 3.1. Table 3.1 also includes ore quality parameters derived from the Syncrude geology block model. The North Mine advances west and north until 2012 in order to expose dyke footprint areas in preparation for in-pit tailings, while allowing for ore blending and dyke construction. After 2012 the west area is complete and the mine progresses to the north. At the planned mining rates, North Mine resource depletion is scheduled for 2023. The overburden and interburden disposal schedule is shown in Table 3.2. Table 3.1 Mine Plan Ore Summary Grade Water Solids Fines (<44u m) Coarse solids (>44u m) % (weight) % (weight) % (weight) % (weight) % (weight) 10.6% 10.5% 10.8% 10.0% 10.1% 9.7% 9.9% 9.9% 10.1% 10.3% 10.9% 10.8% 11.1% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 3.6% 85.7% 85.9% 85.6% 86.4% 86.2% 86.6% 86.5% 86.5% 86.3% 86.1% 85.5% 85.5% 85.2% 23.9% 23.4% 22.5% 25.1% 26.7% 26.4% 24.3% 25.0% 22.1% 21.0% 18.7% 19.7% 18.8% 76.1% 76.6% 77.5% 74.9% 73.3% 73.6% 75.7% 75.0% 77.9% 79.0% 81.3% 80.3% 81.2% Ore Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 Million Tonnes 120.8 125.3 124.7 129.4 129.3 124.4 120.0 120.0 120.0 120.0 120.0 120.0 53.2 Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Recovered Bitumen Barrels (per ID 20017) 71.9 73.3 75.1 71.2 72.4 65.8 64.7 64.9 66.9 68.7 73.3 72.9 33.2 Page 12 of 39 Figure 3.1 North Mine Development Sequence 20 23 2 022 2 02 1 2 020 20 19 201 8 2 015 20 17 20 14 201 6 2 013 2 012 20 15 2 01 2 201 4 20 11 20 13 201 2 201 1 20 11 PROJECT: 2010 ANNUAL TAILINGS PLAN TITLE: Mine Development Sequen ce DESIGN CADD CHECK REVIEW Syncrude Canada Ltd. SCALE: N/A REV 0 2010 Directive 074 Submission: Mildred Lake FIGURE 3. 1 Page 13 of 39 Table 3.2 Year Mine Plan Waste Summary Overburden (OB) Interburden (IB) Total OBIB Plant Rejects Million BCM Million BCM Million BCM Million BCM 76.7 77.6 67.6 58.0 65.3 54.1 56.4 70.7 74.2 99.9 92.5 87.8 24.7 7.3 5.4 1.5 8.2 11.3 19.9 25.0 20.2 17.5 18.7 17.5 14.7 10.3 84.0 83.0 69.1 66.2 76.6 74.0 81.4 90.9 91.7 118.6 110.0 102.5 35.0 3.4 3.2 2.8 1.7 1.6 1.3 1.2 1.2 1.2 1.2 1.2 1.2 1.2 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 Note: Reclamation material and miscellaneous rejects are not included above 3.2 Tailings The tailings production schedule is shown in Table 3.3. The tailings volumes shown in the table represent final deposit volumes. Active tailings placement facilities currently include the MLSB and SWSS out-of-pit facilities and the WIP, EIP, and SWIP in-pit facilities. The tailings disposal sequence at the Mildred Lake site balances fluid containment needs and dyke construction, while incorporating key closure initiatives. The tailings disposal schedule is closely integrated with the mine plan; in-pit tailings storage space is utilized as soon as it becomes available. The integrated tailings plan considers the requirement for four different pond functions: CT deposition, MFT storage, coke storage and process water storage and clarification. The tailings plan is based on the following key assumptions: • • • • • Sand allocation consistent with the following priorities: o Containment construction (including construction of upstream sand filters on overburden dykes), o Geotechnical beaching requirements, o CT capping, and o Maximization of CT production with remaining sand. Use of additional fluid containment at the SWSS facility as it becomes available WIP transitions to BML in 2012; Tailings placement in NMSP-W commencing in 2013; and in NMSP-E in 2015 Staged implementation of MFT centrifuging technology begins in 2012 with a commercial scale demonstration. Tailings deposit types and volumes for each facility are included in Table 4.3. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 14 of 39 Table 3.3 Year Mildred Lake Tailings Production Summary Mildred Mildred Aurora Lake Fines Lake Froth Fines Production to Rejects Million Tonnes/y Million Tonnes/y Million Tonnes/y Cyclone Overflow Coarse Tailings Cell 3 Beach 3 Mm /y Mm /y CT Total 3 Mm /y 3 Mm /y 3 Mm /y Froth Flotation Treatment Tailings Tailings 3 Mm /y 3 Mm /y Coke Centrifuge Cake (@ 65% by wt.) 3 Mm /y 3 Mm /y 2011 120.8 0.9 1.5 8.4 38.3 46.7 0.5 7.0 1.8 2.1 3.1 2012 125.3 1.0 1.5 4.0 44.5 48.5 0.5 7.7 1.9 2.2 3.4 1.1 2013 124.7 0.9 1.5 2.0 46.6 48.5 0.5 7.5 1.9 2.2 3.4 1.1 2014 129.4 1.0 1.7 0.8 33.8 34.6 1.5 22.2 2.0 2.3 3.6 2.4 2015 129.3 1.0 1.7 34.0 34.0 1.5 21.5 2.0 2.3 3.7 7.7 2016 124.4 0.9 1.6 33.0 33.0 1.4 20.9 1.9 2.2 4.1 7.8 2017 120.0 0.9 1.7 32.4 32.4 1.4 20.8 1.8 2.2 4.6 7.8 2018 120.0 0.9 1.6 32.2 32.2 1.4 20.6 1.8 2.2 5.0 7.9 2019 120.0 0.9 1.7 32.8 32.8 1.4 21.5 1.8 2.1 5.6 8.0 2020 120.0 0.9 1.6 33.0 33.0 1.4 21.8 1.8 2.1 5.8 8.0 2021 120.0 0.9 1.6 33.2 33.2 1.4 22.4 1.8 2.1 5.9 8.1 2022 120.0 0.9 1.6 33.1 33.1 1.4 22.1 1.8 2.1 6.0 6.8 2023 53.2 0.4 1.5 24.9 24.9 0.8 0.9 4.9 6.8 2024 1.5 0.4 4.1 5.4 2025 1.5 0.4 4.1 5.4 2026 1.7 0.5 5.1 5.4 2027 1.5 0.4 5.6 5.4 2028 1.6 0.4 5.7 5.4 2029 1.5 0.4 5.7 5.4 2030 1.5 0.4 5.6 5.4 2031 1.6 0.5 5.8 5.4 2032 1.7 0.5 5.7 5.4 2033 1.6 0.5 5.6 5.4 2034 1.6 0.5 5.6 5.4 2035 1.6 0.5 5.7 5.4 2036 1.5 0.4 5.6 5.4 2037 1.6 0.5 5.9 5.4 2038 1.2 0.3 6.6 5.4 2039 5.1 5.4 2040 5.2 5.4 2041 5.3 5.4 2042 5.2 5.4 2043 5.3 5.4 2044 4.1 5.4 2045 2.8 5.4 2046 2.7 Note: all tailings volumes shown represent deposit volumes. * Fines Capture = (Weight of fines in CT + Weight of fines in centrifuge cake) / (Weight of fines in ore - Weight of fines in rejects) Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake MFT Water (Cumulative) (Cumulative) Mm 3 452.2 463.2 473.0 482.7 486.3 488.9 488.0 487.8 483.8 478.2 469.7 466.9 463.0 457.2 451.3 445.7 439.8 434.1 428.2 422.4 416.8 411.1 405.4 399.7 394.0 388.2 382.6 376.2 368.4 360.5 352.7 344.8 336.9 329.1 321.2 319.4 Mm 3 83.8 117.4 129.8 143.2 153.8 169.5 175.4 170.3 189.4 182.0 178.0 179.6 201.2 241.1 257.2 295.9 277.9 264.5 243.2 231.2 210.5 197.9 189.3 176.3 155.4 144.5 145.6 146.6 147.6 148.5 149.4 150.3 151.1 151.9 187.7 185.8 Fines Capture * (by CT and centrifuge cake) Annually as % of fines in Feed 9.3% 14.7% 14.8% 34.6% 50.1% 52.1% 59.0% 57.3% 66.9% 71.7% 83.1% 71.1% 83.1% - Annually Cumulative Million Tonnes/y Million Tonnes 2.2 3.6 3.4 9.4 14.4 14.3 14.4 14.4 14.7 14.9 15.1 13.7 6.7 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 - 4.3 7.9 11.3 20.6 35.1 49.4 63.8 78.1 92.8 107.7 122.9 136.6 143.3 148.7 154.1 159.5 164.9 170.3 175.7 181.1 186.5 191.9 197.3 202.7 208.1 213.5 218.9 224.2 229.6 235.0 240.4 245.8 251.2 256.6 262.0 262.0 Page 15 of 39 3.2.1 Mildred Lake Settling Basin: The MLSB is used primarily as a fluid storage facility. It currently provides storage for MFT, coke, flotation tailings (Stream 73), froth treatment tailings (Plant 6), and recycle water for plant operations. Annual MFT transfers out of the facility are required to maintain an adequate recycle water layer and the overall fluid elevation within the design freeboard allowance for the structure. Coke deposition will continue along the west side of MLSB until approximately 2018. Stream 73 and Plant 6 tailings placement will continue along the south and east side of MLSB for an indefinite duration, maximizing beach infilling volume. MLSB is planned to remain a primary source of recycle water for plant operation for an indefinite duration. Post mining, MLSB will continue to be the source of MFT for MFT centrifuging and the remaining fluid (MFT and water) will be transferred to the North Mine EPL at closure. 3.2.2 West In-Pit: WIP will be converted to BML in 2012. Annual MFT transfers from MLSB to WIP are required to establish the required MFT inventory for the planned end pit lake commercial demonstration. WIP remains a primary source of recycle water for plant operation until the commissioning of BML in 2012. The creation of BML effectively removes WIP from the tailings circuit at the Mildred Lake site. To function as planned, BML must support fresh water inflows as well as an outflow. Initially, the outflow will be absorbed within overall fluid balance and reused as recycle water for bitumen production purposes. 3.2.3 East In-Pit: EIP is currently an active deposition area for CT and coarse tailings beach. In 2010, the EIP will have reached its final CT containment capacity. The EIP area will be capped using hydraulically placed coarse tailings sand in preparation for reclamation and closure of the facility. Sand capping began at the north end of the facility in 2008 and is scheduled to be completed in 2013, with final fluid transfer in 2014. CT deposition and subsequent sand capping are being advanced from north to south to permit progressive reclamation of the facility. 3.2.4 Southwest In-Pit: The SWIP facility has commenced operation in 2007, with the transfer of MFT into the facility. CT placement in SWIP began in 2010. Subsequent to the completion of CT placement in the EIP, SWIP will become the primary deposition area for CT. In addition to CT placement, some coarse tailings beaching is required to create an upstream sand filter along the Southwest Dam on the east side of SWIP in order to meet geotechnical design requirements. SWIP will also provide temporary storage for MFT to ensure a sustained MFT supply to the CT plant as the WIP is converted to BML in 2012. As BML is commissioned, SWIP will replace WIP as a primary source of recycle water for plant operations. SWIP will be capped with sand starting approximately in 2018 in preparation for reclamation and closure of the facility as a dry landscape unit. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 16 of 39 3.2.5 Southwest Sand Storage: Syncrude has obtained approval to modify the SWSS dyke design to create interim fluid containment capacity within the approved SWSS facility footprint. MFT accumulation at the SWSS will be maximized in 2015. MFT will subsequently be removed from the SWSS facility as sufficient tailings storage space becomes available for fluid containment in the North Mine. Removal of the MFT out of the SWSS facility by fluid transfer or through the MFT centrifuging process will be completed in 2023. All fluids will be transferred out of the SWSS, the dyke will be breached for closure and reclamation of the structure as a dry landscape feature. 3.2.6 North Mine South Pond Storage: The North Mine in-pit tailings dykes are to be constructed using overburden material. The construction of the North Mine North-South Dyke began in 2007 and is to be completed in 2014. The North-South Dyke is an intermediate dyke partitioning the NMSP to allow for earliest tailings disposal in the North Mine area. The North Mine East-West Dyke 1 will also be constructed within the North Mine to complete containment for the NMSP. Tailings deposition in the NMSP will commence in 2013. The smaller west portion of the NMSP facility will be developed first (protected by the North-South Dyke) with the east portion of the NMSP following as the primary in-pit space available. The NMSP will be utilized for the storage of CT and coarse tailings materials. That facility will also provide MFT storage and serve as a recycle pond to meet plant recycle water demand. Further details on proposed DDA development in the NMSP are included in Section 2.2.2. In the last few years of active mining, the plans for the NMSP are to transfer any remaining fluids to the NMCP, and to sand cap the CT deposit in NMSP. Once complete, however, the final sand-capped surface does not achieve the closure design surface that will allow drainage of the NMSP towards BML, therefore the remainder of the MFT, above and beyond what can be stored in BML and EPL, will be centrifuged and deposited on NMSP. Once complete, the area will be reclaimed as a dry landscape feature. 3.2.7 North Mine Center Pond Storage: Deposition of tailings in the NMCP will be initiated as deposition in the NMSP nears completion. The primary function of the NMCP will be as MFT and coke storage, as mine operations at the Mildred Lake site near completion. It will also become the MFT feed source for the centrifuge plant. At completion, any remaining fluid from the NMCP will be transferred to the North Mine EPL. NMCP provides a deposition location for all the coke from the continued operation of the Upgrading facilities (approximately to 2077). 3.2.8 North Mine End Pit Lake The North Mine EPL is planned to be the final mining area at the Mildred Lake site. Once mining is complete, MFT will be transferred into the EPL from the NMCP and MLSB. The facility will be developed as a water capped MFT deposit, subject to the validation of the EPL concept through the BML demonstration. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 17 of 39 3.3 Key Milestones The integrated mining/tailings plan is illustrated for the years 2010, 2012, 2013, 2015, 2018 and 2023 in Figures 3.2 to 3.7. Fluid elevations are posted at relevant locations. Active tailings placement areas in 2010 (Figure 3.2) are MLSB, SWSS, EIP, WIP and SWIP. The N/S dyke and E/W dyke 1 are being constructed in preparation for future tailings containment in North Mine. The W1 dump is the main location for hauling nonconstruction mine waste. In 2012 (Figure 3.3), progress is shown in building N/S dyke and E/W dyke 1 and continued use of the active tailings placement areas. WIP has been isolated and the BML demonstration has been initiated. W4 dump footprint has been established and it becomes the major location for non-construction mine waste. Centrifuge cake deposition begins at the north end of SWSS and on the MLSB beaches. The 2013 status (Figure 3.4) shows that the EIP has been sand capped in preparation for closure of the facility. The N/S dyke is being completed and coarse tailings beach and CT are being placed in NMSP-W. The E/W dyke 1 is progressing in preparation for future tailings containment. By 2015 (Figure 3.5), the E/W dyke 1 is mostly completed and CT and coarse tailings beach are being placed in NMPS-E. Centrifuge cake deposition has started in the W4 Dump and on NMSP beaches. The W4 Dump is the primary location for nonconstruction mine waste. Figure 3.6 shows that by 2018 E/W Dyke 2 has begun and centrifuge cake is being placed on the NMCP base of feed as mining advances as well as in the W4 Dump & NMSP beaches. Coke placement has moved into NMCP. North mine ore and waste removal is complete in 2023 (Figure 3.7). Tailings storage requirements continue at the ML lease until 2045 due to Aurora North production (2038), continued centrifuge cake deposition in the NMSP until 2045, and coke storage (50 years available capacity). Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 18 of 39 4 Construction Details The North Mine waste availability by construction material type and specification is as shown in Table 4.1. The high spec. volume available is 35% of the total Kc-clay bench and 42% of the total Kcw/marine oilsand and interburden mine benches. The medium spec. volume available is 80% of remaining upper overburden benches. Mine benches are designed to maximize the availability of material types that are suitable for required geotechnical specifications of planned structures. The volume planned for placement in structures is also shown by material type. The limited availabilities on total construction material to meet minimum required geotechnical specifications account for weather and operational restrictions that prevent placement in structures. Table 4.1 Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 Mine Waste Construction Material Schedule High Spec. Available Planned (42%IB,Kcw, use 35%Kc) MBCM MBCM 10.7 9.7 21.0 10.2 15.2 7.5 17.3 12.2 19.5 8.2 14.2 2.1 16.4 6.1 16.0 15.9 16.7 14.6 22.4 4.1 20.2 20.9 8.4 2.4 Medium Spec. Available Planned (80% use remaining) MBCM MBCM 61.5 15.2 49.6 22.0 44.8 27.8 40.8 33.4 45.6 4.5 47.8 2.1 51.9 29.2 59.9 30.1 60.0 35.9 76.9 24.2 71.8 0.9 65.3 21.2 1.1 Low Spec. TOTAL WASTE Available Planned use Available Planned use MBCM 15.1 15.6 11.9 9.8 13.0 13.3 14.2 16.2 16.2 20.5 19.2 17.5 6.5 MBCM 1.1 1.4 7.0 6.8 5.1 6.6 0.2 MBCM 87.3 86.2 71.9 67.9 78.1 75.3 82.5 92.1 92.9 119.8 111.2 103.7 36.1 MBCM 26.0 33.6 35.3 52.6 19.5 9.3 35.3 46.0 50.5 34.9 0.9 3.7 High spec material that is not scheduled to dykes in the last 3 years of mining will be available for elements of the closure plan as required and incorporated into the plan as identified (ex. waterways or canals that need to be constructed and/or lined). The North Mine Waste Disposal Schedule by placement area is shown in Table 4.2. Miscellaneous material (misc.) includes BML Littoral Zone, Industrial Landfill, Flue Gas Desulphurization (FGD) Landfill, NWQ Diverter Dam, Hwy 63 Bridge Area/BMD, and OB Berms required to support Upstream Sand filters for In-pit overburden dykes. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 25 of 39 Table 4.2 Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 Mine Waste Disposal Schedule Dyke Construction E/W E/W Dyke 1 Dyke 2 MBCM MBCM MBCM 3.2 17.7 6.0 26.4 37.5 47.7 16.6 7.1 36.1 45.9 50.4 34.8 0.9 - Waste Dumps W1 700 600 W4 NIP Misc. Total Waste MBCM 45.0 - MBCM 10.0 0.3 - MBCM - MBCM 45.4 34.2 15.3 58.0 65.7 46.1 45.9 14.5 34.5 36.0 MBCM 27.7 84.7 107.1 69.1 - MBCM 11.50 8.2 0.2 4.9 3.5 2.5 0.4 0.3 0.3 0.3 3.2 0.2 0.2 MBCM 87.4 86.3 71.9 67.9 78.1 75.3 82.6 92.1 92.9 119.8 111.2 103.8 36.2 N/S Dyke The tailings disposal schedule by placement area is shown in Tables 4.3 and 4.4. The breakdown is by storage facility and material type. Values represent incremental deposit volumes from 2010 onward (MFT and water are net volumes). 4.1 Southwest Sand Storage Construction of the centerline dyke at the SWSS facility will be achieved through conventional cell construction techniques using coarse tailings material. Centerline dyke volume (crest elevation of 400 masl) is approximately 27 Mm3 with an estimated beach volume of 70 Mm3, based on an average 28% cell capture for cell construction. The construction of the dyke will be accomplished in four lifts from 2010 (390 masl) to 2013 (400 masl). Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 26 of 39 Table 4.3 Tailings Disposal Schedule Southwest Sand Storage (SWSS) Mildred Lake Settling Basin (MLSB) Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 2039 2040 2041 2042 2043 2044 2045 2046 Plant 6 Tailings 2.1 2.2 2.2 2.3 2.3 2.2 2.2 2.2 2.1 2.1 2.1 2.1 0.9 0.4 0.4 0.5 0.4 0.4 0.4 0.4 0.5 0.5 0.5 0.5 0.5 0.4 0.5 0.3 0.0 0.0 0.0 0.0 0.0 0.0 0.0 0.0 Stream 73 Coke MFT Water SCT MFT Water 1.8 1.9 1.9 2.0 2.0 1.9 1.8 1.8 1.8 1.8 1.8 1.8 0.8 - 3.1 3.4 3.4 3.6 3.7 4.1 4.6 5.0 - 177.9 170.3 162.8 154.9 147.0 146.7 138.1 129.1 125.1 121.1 117.1 113.2 114.4 114.0 113.6 113.1 112.7 112.2 111.8 111.4 110.9 110.4 110.0 109.5 109.1 103.1 97.3 90.9 80.9 63.8 56.8 49.8 42.8 35.7 28.7 27.6 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 30.0 25.0 25.0 25.0 30.0 26.6 26.6 26.6 26.6 26.6 48.6 32.0 26.6 26.7 20.3 13.1 - 60.0 72.3 84.6 93.8 104.8 103.7 87.7 71.8 56.1 40.5 25.1 10.0 - 10.0 14.0 16.0 14.0 14.0 14.0 14.0 14.0 14.0 14.0 10.0 2.0 - MLSB toe berm & SWSS/W1 Valley *Centrifuge Cake 1.1 1.1 2.4 - West In-Pit (WIP) Cyclone O/F 0.5 - East In-Pit (EIP) MFT Water CT SCT MFT Water 199.9 204.2 198.4 193.6 189.4 185.7 182.2 179.0 176.0 173.3 170.8 168.4 166.2 164.1 162.2 160.3 158.6 156.9 155.4 153.8 152.4 151.1 149.9 148.6 147.4 146.3 145.3 144.3 143.3 142.3 141.5 140.6 139.7 139.0 138.2 137.4 21.8 36.7 42.5 47.2 51.4 55.2 58.7 61.9 64.8 67.5 70.1 72.4 74.7 76.8 78.7 80.6 82.3 84.0 85.5 87.0 88.4 89.8 91.0 92.3 93.4 94.5 95.6 96.6 97.6 98.5 99.4 100.3 101.1 101.9 102.7 103.4 - 8.4 9.2 10.3 - 1.0 1.0 1.0 - 2.0 1.5 1.5 - 3 Note: all numbers are in million m and represent Incremental deposit volumes from 2008 onward (MFT and water are net volumes) * North Mine North Pond (NMNP) is called End of Pit Lake (EPL) * Centrifuge cake volumes are reported at 65% solids by weight Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 27 of 39 Table 4.4 Tailings Disposal Schedule (continued) Southwest In-Pit (SWIP) North Mine South Pond (NMSP) W4 Dump End of Pit Lake (EPL) North Mine Center Pond (NMCP) Year CT 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 2039 2040 2041 2042 2043 2044 2045 2046 7.0 7.7 5.0 6.7 6.0 7.1 7.3 7.6 8.6 6.5 - SCT Cyclone O/F 11.7 12.6 0.5 15.5 0.5 12.8 1.5 10.2 1.5 8.3 1.4 6.8 1.4 7.4 1.4 8.2 8.2 13.3 - MFT Water CT SCT MFT 13.4 15.4 25.6 34.1 30.6 22.9 15.3 11.2 - 25.0 40.2 26.0 24.0 24.0 20.0 12.0 10.0 5.0 5.0 2.0 - 2.5 15.5 15.5 13.8 13.5 13.0 12.9 15.3 22.4 22.1 - 2.4 8.7 23.8 24.8 25.6 24.8 24.6 24.7 19.9 33.1 24.9 - 0.6 6.3 14.5 29.8 64.7 96.7 85.0 65.0 45.0 30.0 32.0 20.0 - *Centrifuge Cake 2.2 1.8 1.3 0.9 3.0 3.0 8.1 6.8 6.8 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 - Water *Centrifuge Cake 18.8 33.0 39.4 5.0 55.3 5.0 65.7 5.0 59.4 5.0 35.0 5.0 30.0 5.0 20.0 15.0 12.0 5.0 - Coke 5.6 5.8 5.9 6.0 4.9 4.1 4.1 5.1 5.6 5.7 5.7 5.6 5.8 5.7 5.6 5.6 5.7 5.6 5.9 6.6 5.1 5.2 5.3 5.2 5.3 4.1 2.8 2.7 Cyclone O/F 1.4 1.4 1.4 1.4 - MFT 41.5 78.3 111.7 145.3 150.4 150.0 140.0 130.0 110.0 100.0 90.0 80.0 70.0 60.0 52.0 44.0 36.0 20.0 10.0 - *Centrifug e Cake 0.5 1.0 1.5 2.0 - Water MFT Water 45.6 40.4 50.9 65.2 84.5 100.0 90.0 80.0 80.0 70.0 60.0 50.0 40.0 30.0 20.0 15.0 5.0 5.0 5.0 - 9.1 35.6 42.3 58.6 64.9 71.0 77.2 83.4 89.6 93.6 97.5 101.5 118.7 129.9 141.1 144.2 154.4 154.4 154.4 154.4 154.4 154.4 154.4 29.3 58.5 105.3 85.6 80.6 67.7 64.2 52.1 48.1 48.3 39.1 27.0 20.0 20.0 25.0 20.0 23.4 23.4 23.4 23.4 23.4 36.4 50.4 3 Note: all numbers are in million m and represent Incremental deposit volumes from 2008 onward (MFT and water are net volumes) * North Mine North Pond (NMNP) is called End of Pit Lake (EPL) * Centrifuge cake volumes are reported at 65% solids by weight Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 28 of 39 4.2 North-South Dyke and East-West Dyke 1 The North Mine in-pit tailings dykes are to be constructed using overburden material. The construction of the North-South Dyke began in 2007 and is scheduled for completion in 2012. The North-South Dyke is an intermediate dyke partitioning the NMSP to allow for earlier tailings disposal in the North Mine South Pond – West (NMSPW), while protecting mine equipment and facilities operating at pit bottom. Figure 4.1 & Figure 4.2 show the current asbuilts for the North-South Dyke and East West Dyke 1 respectively (refer to the 2010 status map in Figure 3.2 for an overview of the entire North-South Dyke footprint configuration relative to other features). Typical design cross sections for the North-South Dyke and the East-West Dyke 1 are illustrated in Figures 4.3 and Figure 4.4 respectively. The construction schedule for the North Mine in-pit dykes is shown in Table 4.5 below. Table 4.5 Structure Construction Schedule Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2023 4.3 E/W Dyke 1 E/W Dyke 2 N/S Dyke Volume Elevation Volume Elevation Volume Elevation MBCM masl. MBCM masl. MBCM masl. 3.2 274-292 17.7 250-286 6.0 292 26.4 250-294 37.5 255-330 47.7 295-330 16.6 320-330 7.1 330 36.1 255 45.9 270 50.4 288 34.8 310 0.9 310 - East-West Dyke 2 The East-West Dyke 2 will be constructed within the North Mine to create the NMCP (to the south) and the EPL (to the north). Table 4.5 shows the annual volume placement and average top elevation(s) of the in-pit structures. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 29 of 39 Figure 4.1 North South Dyke Asbuilt (year end 2009) NS Dyke 269.4m 277m NMSP-W 281m 286m 276.2m 6320 000 Figure 4.2 4550 00 291.5m *Asbuilt as of January 1, 2010 North-South Dyke Typical Design Cross Section Core (7H:1V Overall Slope) O/B Berm Syncrude Canada Ltd. Interior Shell 286m Crest 292m Main Shell 286m Crest 2010 Directive 074 Submission: Mildred Lake All Weather Core (12H:1V Overall Slope) Page 30 of 39 Figure 4.3 East-West Dyke 1 Asbuilt (year end 2009) 6320 EW Dyke1 000 00 248.5m 4550 272.6m Figure 4.4 283.5m *Asbuilt as of January 1, 2010 East-West Dyke 1 Typical Design Cross Section 304m 314m 2m Core South 325m All Weather Core 314m 2m Core North Interior Shell (Kc-clays) Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake 294m 284m 274m Main Shell (Kcw/IB) Page 31 of 39 264m 254m 5 Site Wide Material Balance A projected site wide material balance is provided in Tables 5.1 to 5.3. The modeled values are provided in three parts: Sand Management (> 44µ Solids Fraction), Fines Management (< 44µ Solids Fraction and Mildred Lake Free (i.e. Recycle) Water Management. Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 32 of 39 Table 5.1 Site Wide Material Balance - Sand Management Sand Management (> 44µ Solids Fraction) Year Recovered Bitumen (per ID 2001-7 ) Net Feed Sand Sand in feed (dry Rejects Mt) MBBl 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 71.9 73.3 75.1 71.2 72.4 65.8 64.7 64.9 66.9 68.7 73.3 72.9 33.2 - Mildred Lake 78.8 82.8 82.7 83.7 81.7 79.3 78.5 77.8 80.6 81.6 83.4 82.4 36.8 - Aurora North 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.4 Sand in Slurry Streams Pri. Extract Sand Sec. Extract Sand Froth Treat. Sand (dry Mt) (dry Mt) (dry Mt) (dry Mt) 3.7 3.8 3.8 3.9 3.9 3.8 3.7 3.7 3.7 3.6 3.6 3.6 1.6 - 69.9 73.5 73.6 74.2 72.2 70.2 69.7 69.0 71.8 72.8 74.6 73.7 33.2 - 2.7 2.8 2.8 2.9 2.9 2.8 2.7 2.7 2.7 2.7 2.7 2.7 1.2 - 3.1 3.2 3.2 3.3 3.3 3.2 3.1 3.1 3.1 3.1 3.1 3.1 1.4 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.4 Cycloned & Straight Coarse Tails Sand NonSand to Cycloned CT Sand Cyclones (dry Mt) (dry Mt) 60.5 63.2 63.6 44.5 43.3 42.1 41.8 41.4 43.1 43.7 44.8 44.2 33.2 - 9.4 10.3 10.0 29.7 28.9 28.1 27.9 27.6 28.7 29.1 29.9 29.5 - Sand to Deposits SCT Cell SCT Cyclone CT (U/F) Sand to Beach O/F Feedstock new MFT (dry Mt) (dry Mt) (dry Mt) 10.7 5.2 2.5 1.0 - 48.9 57.1 60.1 42.8 42.6 41.4 41.2 40.7 42.4 43.0 44.1 43.5 32.7 - 0.6 0.7 0.6 1.9 1.9 1.8 1.8 1.8 1.8 1.9 1.9 1.9 - Other Information Froth Tails Float / Middlings Sand in MFT to CT CT % Sand to Deposit CT process (dry Mt) (dry Mt) (dry Mt) (dry Mt) (dry Mt) (dry Mt) (%) 8.8 9.7 9.3 27.7 27.0 26.2 26.1 25.8 26.9 27.2 27.9 27.5 - 1.1 1.1 1.1 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.8 0.6 - 3.0 3.2 3.1 3.3 3.3 3.1 3.0 3.0 3.0 3.0 3.0 3.0 1.3 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.6 0.4 2.6 2.8 2.7 2.8 2.8 2.7 2.6 2.6 2.6 2.6 2.6 2.6 1.2 - 0.1 0.2 0.2 0.4 0.4 0.4 0.4 0.4 0.4 0.4 0.5 0.5 - 8.9 9.8 9.5 28.2 27.4 26.6 26.5 26.1 27.3 27.7 28.4 28.0 - 13.4% 14.0% 13.5% 40.0% 40.0% 40.0% 40.0% 40.0% 40.0% 40.0% 40.0% 40.0% - Net Sand Feed Balance: [Sand in Feed] - [Rejects] = [Primary Extraction Sand] + [Secondary Extraction Sand] + [Froth Treatment Sand] Complete Sand Balance: [Primary Extraction Sand] + [Secondary Extraction Sand] + [Froth Treatment Sand] = [Cell] + [Beach] + [Cyclone O/F] + [Cyclone U/F (CT Feedstock)] + [Sand to new MFT] + [Froth Tails] + [Float / Middlings Tails] Construction Sand Balance: [Primary Extraction Sand] = [Non-Cycloned Sand] + [Sand to CT Cyclones] Sand in CT Deposit Balance: [CT Deposit Sand] = [Cyclone Feedstock Sand (U/F) to CT] + [Sand in MFT to CT] % Sand to CT Process = [Sand to CT Cyclones] ÷ [Primary Extraction Sand] (which is *approximately* the cyclone overflow + the cyclone underflow feedstock) Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 33 of 39 Table 5.2 Site Wide Material Balance - Fines Management Fines Management (< 44µ Solids Fraction) Year Recovered Bitumen (per ID 2001-7) Fines in Net Feed New Fines in Feed (dry Rejects Mt) Fines MBBl bit Mildred Lake 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 Fines in Suspension 71.9 73.3 75.1 71.2 72.4 65.8 64.7 64.9 66.9 68.7 73.3 72.9 33.2 - 24.8 25.3 24.0 28.1 29.8 28.4 25.3 26.0 22.9 21.7 19.1 20.2 8.5 - Aurora North 1.5 1.5 1.5 1.7 1.7 1.6 1.7 1.6 1.7 1.6 1.6 1.6 1.5 1.5 1.5 1.6 1.5 1.6 1.5 1.5 1.6 1.7 1.6 1.6 1.6 1.5 1.6 1.1 Total Site MFT (dry Mt) % solids by wt. 0.9 1.0 0.9 1.0 1.0 0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.4 - 48.3% 48.6% 48.9% 49.2% 49.5% 49.7% 50.0% 50.3% 50.6% 50.9% 51.2% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.3% 51.2% 51.2% 51.2% 51.2% Site MFT Inventory (Start) New TFT Fines (dry Mt) (dry Mt) 268.6 279.5 289.2 298.3 307.7 313.5 318.4 320.9 324.0 324.4 323.7 320.9 320.4 317.7 313.7 309.7 305.9 301.9 298.0 294.0 290.0 286.2 282.4 278.5 274.6 270.7 266.8 262.9 12.1 12.3 11.6 15.6 16.7 16.0 14.0 14.4 12.5 11.8 10.2 10.9 4.0 1.4 1.4 1.6 1.4 1.5 1.4 1.4 1.5 1.6 1.5 1.5 1.5 1.4 1.5 1.1 Fines in MFT to CT Fines to Deposits Fines O/F; CT consumed Site MFT Cell/ CT (U/F) CT SFR Flotation; Centrifuged Deposit Inventory Beach Feedsto in Ratio 'cake' fines Froth Fines ck Fines Centrifuge (End) Fines Cake (dry Mt) (dry Mt) 1.3 1.4 1.4 3.8 3.4 3.4 3.7 3.6 4.2 4.5 5.0 4.7 - 1.1 1.1 2.3 7.6 7.7 7.8 7.8 7.9 8.0 8.1 6.7 6.7 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 (dry Mt) (dry Mt) (dry Mt) 279.5 289.2 298.3 307.7 313.5 318.4 320.9 324.0 324.4 323.7 320.9 320.4 317.7 313.7 309.7 305.9 301.9 298.0 294.0 290.0 286.2 282.4 278.5 274.6 270.7 266.8 262.9 258.6 11.8 12.0 11.6 9.1 9.4 9.1 8.3 8.4 7.8 7.4 6.7 7.0 5.4 - 0.9 1.0 0.9 3.2 3.4 3.3 2.9 3.0 2.6 2.5 2.1 2.3 - (dry Mt) (dry Mt) (dry Mt) 0.5 0.6 0.6 0.9 0.9 0.8 0.8 0.8 0.8 0.7 0.7 0.7 0.2 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 1.1 1.1 2.3 7.6 7.7 7.8 7.8 7.9 8.0 8.1 6.7 6.7 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 5.4 2.2 2.5 2.4 7.0 6.8 6.6 6.6 6.5 6.8 6.9 7.1 7.0 - 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 4.0 Fines in Suspension (MFT) Balance: [Site MFT Inv. (Start)] + [New TFT Fines] - [Fines in MFT to CT Process] - [Fines concumed in centrifugation] = [Net Site MFT Inventory (Ending)] New Fines Balance: [New Fines in Feed] - [Reject Fines] = [New TFT Fines] + [Cell/Beach Fines] + [Cyclone U/F Fines to CT] + [Cyc. O/F; Froth; & middlings Fines] Fines in CT Deposit Balance: [CT Deposit Fines] = [Fines in MFT to CT] + [Cyclone U/F Fines to CT] Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 34 of 39 Table 5.3 Site Wide Material Balance - Water Management Mildred Lake Free (i.e. Year 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027 2028 2029 2030 2031 2032 2033 2034 2035 2036 2037 2038 Recovered Recycle) Water Management Bitumen Free Water Net (per ID Inventory New Free Free Water 2001-7) (start) Water Inventory (end) 3 3 3 (Mm ) (Mm ) (Mm ) MBBl bit 71.9 73.3 75.1 71.2 72.4 65.8 64.7 64.9 66.9 68.7 73.3 72.9 33.2 - Syncrude Canada Ltd. 87.6 83.8 102.4 114.8 128.2 138.8 154.5 160.4 155.3 174.4 167.0 163.0 164.6 186.2 226.1 242.2 280.9 262.9 249.5 228.2 216.2 195.5 182.9 174.3 161.3 140.4 129.5 130.6 (3.8) 18.6 12.3 13.5 10.6 15.7 5.9 (5.1) 19.1 (7.5) (4.0) 1.7 21.6 39.9 16.1 38.7 (17.9) (13.4) (21.3) (12.0) (20.7) (12.6) (8.6) (13.0) (20.9) (10.9) 1.1 1.0 83.8 102.4 114.8 128.2 138.8 154.5 160.4 155.3 174.4 167.0 163.0 164.6 186.2 226.1 242.2 280.9 262.9 249.5 228.2 216.2 195.5 182.9 174.3 161.3 140.4 129.5 130.6 131.6 2010 Directive 074 Submission: Mildred Lake Page 35 of 39 6 Water Chemistry Syncrude maintains a network of surface water sampling points and groundwater monitoring wells to identify any impact that the tailings facilities, sulphur storage, special waste interim storage, proposed Flue gas de-sulphurization (FGD) landfill and sewage treatment areas may have on groundwater quality. Monitoring is focused on the geologic units with the greatest potential for contaminant transport. The groundwatermonitoring network has been divided into eight separate areas based on geology and potential contaminant sources. Data gathered on surface water samples from both potential sources and receptor areas are considered as the results pertain to each area. Trend of key parameters over time and the relative concentrations of major ions are routinely examined. Elevated chloride concentrations and/or naphthenic acids are useful tracers of process water. A summary of the monitoring program in place in the vicinity of tailings facilities is provided below. For further details regarding groundwater monitoring at the Mildred Lake site, refer to the “2009 Groundwater Monitoring Report – Syncrude Mildred Lake Site”, submitted to AENV on March 15, 2010. 6.1 Mildred Lake Settling Basin MLSB covers an area of approximately 30 square kilometers. Significant natural topographic changes occur to the east of the MLSB. The geology east of MLSB varies significantly from the toe of the tailings structure to the Athabasca River. At the top of the escarpment near the MLSB, glacio-fluvial sands and gravels range in thickness from zero to fifteen meters. This fluvial deposit is generally underlain by glacial till which can be over fifteen meters thick. The surficial Pleistocene sand and gravel deposit has the greatest potential for contaminant transport east of the MLSB. This deposit forms a generally continuous unconfined aquifer from the east side of the MLSB to the east side of T-Pit. The aquifer is vertically bound by the underlying till, oil sand or limestone aquitard. Contaminant migration is expected to be limited through the underlying units, due to their low hydraulic conductivity. The groundwater monitoring network east of the MLSB consists of eighty-one monitoring wells (in 2009, there were 77 active wells). In general, the groundwater flow direction is to the east, from the MLSB to the Athabasca River escarpment. At the base of the first significant drop in the escarpment (T-Pit area), groundwater flow changes toward the south. A pumping remediation strategy east of the Mildred Lake East Toe Berm (MLETB) was initiated in 2003 to stop the progression of a groundwater plume. The objective of the six pumps and a sump is to intercept and retard the migration of contaminant within the source zone. The pumping strategy has been successful in intercepting and retaining the plume within the source zone. 6.2 Southwest Sand Storage Facility The geologic sequence below the SWSS typically consists of muskeg, glacio-lacustrine clay, till, Clearwater Formation clays, and McMurray Formation oilsand. North of the SWSS, a buried glacio-fluvial channel is incised into the Clearwater Formation and underlies the till. The glacio-lacustrine clay deposit present in most areas has a low hydraulic conductivity (10-8 to 10-10 m/s). This minimizes the risk of process water influencing groundwater quality around the SWSS. The buried Pleistocene G-Pit Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 36 of 39 channel north of the SWSS is the most significant hydrogeologic feature in this area, having a hydraulic conductivity in the range of 10-4 to 10-5 m/s. Overall groundwater flow around SWSS is toward the northeast, following the topography. Locally around the SWSS, there may be flow outward from the tailings structure and will be intercepted by the toe ditch. The concentrations in the groundwater wells installed upstream and downstream of the groundwater flow direction at SWSS are in line with historic trends. 6.3 In-Pit Tailings Facilities SWIP, WIP and EIP continue to be used for tailings disposal. The geology of the Base Mine typically consists of Devonian limestone underlying the McMurray Formation. The Clearwater Formation conformably overlies the Upper McMurray. Near the centre of the WIP, the Beaver Creek channel cuts through the Clearwater Formation into the Upper McMurray. West of the Beaver Creek channel, the Clearwater Formation increases in thickness to approximately twenty meters at the west end of the WIP. Anywhere from one to five meters of glacio-lacustrine clay and till overlies the Clearwater clays. The BML wells of the in-pit groundwater monitoring are restricted to deep flow paths (44 to 81 meters) through the Lower McMurray Formation water sand and Devonian Waterways Formation (limestone). Five wells were drilled in 2003 to monitor groundwater quality in surficial sand aquifer in-between the highway and Mildred Lake Reservoir (MLR). Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Page 37 of 39 Appendix 1 Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Appendix Concordance Table: Directive 074 Appendix E – Mildred Lake Project Section Introduction 1 2 Description Cross-Reference (Section) Submission document Beginning in 2009, an annual tailings management plan for the next calendar year must be submitted by September 30 each year. The plan must include annual projections for the first Sections 3.1, 3.2, 3.3, 4.0, ten years, followed by five-year intervals to the end and 5.0 of the scheme. This plan must include: a description of the tailings management plan and any deviations from the approved tailings plan for the entire mine scheme; a process flow diagram for the scheme’s tailings operations; Sections 2.1, 2.3, and 3.2 Figures 1.1 and 1.2 a mineable oil sands reserves table for the life of the mine scheme that includes: mine total waste, overburden, and interburden, and Table 3.2 ore quantity, bitumen grade, fines, sand, and water (as a weight per cent of the ore), and recovered barrels of bitumen; a production forecast table for the life of the mine scheme by time period, including Table 3.1 3 4 mined total waste, Table 3.2 mined ore, bitumen grade, and recovered barrels of bitumen, and Table 3.1 total tailings production by type; Table 3.3 a table of waste material (overburden and interburden) classified by: 5 geologic formation (Holocene, Pleistocene, Waste material provided as Clearwater, McMurray, etc.) with associated high/med/low spec, volume and weight, Table 4.1 type and per cent of material suitable for Section 4.0 and tailings impoundment construction, and Table 4.1 the amount projected for use in tailings impoundment construction; Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Section 4.0 and Tables 4.1 and 4.2 Appendix Section Description Cross-Reference (Section) a table that schedules the source and destination of waste material by mass and volume, classifying material type by structure, the material types—overburden, interburden, crusher rejects (or oversize), and tailings—used for structures, 6 7 8 9 10 11 12 13 14 15 16 17 Volume available: Table 4.1 Volume to structures: Table 4.2 Tailings: Tables 3.3 Mine Waste: Section 4.0 and Tables 4.1 Tailings: Tables 4.3 and 4.4 Mine Waste: Table 4.2 Sections 4.1, 4.2, and 4.3 destination area, including DDAs, external and in-pit waste disposal areas, external and in-pit tailings impoundment structures, and external and in-pit tailings areas; a starting baseline for all structures, including the present elevation of each waste material type within each structure; a construction schedule, volume, and projected life Tables 4.3, 4.4, and 4.5 span for each tailings impoundment structure; an illustration of fluid tailings impoundment and DDA Figure 2.1 capacity versus the associated storage requirements; destination and description of each tailings type by structure, including mass, volume, and components (water, fines, sand, and bitumen, as a per cent of the ore); a site-wide tabulation and illustration of fluid tailings inventory; site-wide sand, fines, and water balance; Tailings Types: Table 3.3 Tailings by Structure: Tables 4.3 and 4.4 Figure 2.3 and Table 3.3 Tables 5.1, 5.2, and 5.3 mine scheme development maps by reporting period, and a text description of the major development activities as illustrated on each map; a summary of tailings water chemistry, seepage water chemistry, and seepage water rates into the groundwater from reports of groundwater and tailings monitoring programs provided to AENV; a description of the process for remediation or rehandling of segregated fines within the DDAs within one year of segregation; planning assumptions and criteria used to support the tailings management plan, such as fines distribution in the ore body, tailings stream-specific gravities, tailings consolidation curves, tailings deposition angles, and tailings impoundment design and construction criteria; and any other information that the ERCB requires. Section 3.3 including Figures 3.2 to 3.8 Syncrude Canada Ltd. 2010 Directive 074 Submission: Mildred Lake Section 6 DDA Strategy: Section 2.2 Table 2.1, Sections 3.2, and 4.0 Appendix
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