Long Harbour Processing Plant Overview - Vale.com
Transcript of Long Harbour Processing Plant Overview - Vale.com
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Long Harbour Processing Plant Overview
September 11, 2018
Vale Plating RoundsTM Global Kick-Off: Launch & Learn
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1. Risk Management Share
2. Visitor Safety Orientation
3. Plant Site Overview
4. Performance Highlights
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Risk Management
Share
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Managing fatigue in the workplace
What is fatigue?
• Fatigue is a reversible physical or mental state of exhaustion which reduces a person’s ability to perform their work safely and efficiently.
What causes fatigue?
• Lack of opportunity to sleep
• Medical conditions and medications
• Failure to take advantage of sleep opportunities
• Failing to receive proper rest and sleep
• Working long hours, multiple jobs or home projects without adequate opportunity for rest and recuperation
• Intense, sustained mental exertion or physical effort.
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Managing fatigue in the workplace
Spot the warning signs
Physical Signs
• Being unstable while standing
• Losing focus easily
• Struggling to keep eyes open
• Yawning frequently
• Rubbing of eyes
• Head jerking or gentle swaying
• Nodding off
• Compromised hand-eye coordination
Mental / Emotional Signs
• Increased risk-taking behaviour
• Reduced short term memory function
• Unable to concentrate
• Negative mood
• Unable to solve problems
• Lack of communication
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Visitor Safety
Orientation
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Personal Protective Equipment Requirements
Personal Protective Equipment (PPE) must be worn at all times onsite, unless in a PPE free area, or in a vehicle. Offices and trailers are common PPE free areas.
Where PPE is required, the following types are permitted for general visitor use:
• Class E CSA hardhat.
• CSA approved safety glasses.
• Single or double hearing protection in Production Area buildings, as dictated by
signage.
• A high visibility safety vest, jacket or coveralls. This clothing must have an orange,
lime, yellow or red bright coloured background with continuous striping that
crosses in the back.
• CSA Grade 1 footwear (green triangle) and electrical shock resistance (Y letter
“omega”) with minimum 6: in height.
• Clothing must provide full arm and leg coverage.
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Personal Protective Equipment Requirements
In addition to PPE, there are site rules that all personnel, including visitors, must be aware of, and follow:
• Before entering a Production Area building long hair must be confined within hardhat.
• Visitors are exempt from being clean shaven, but are also restricted from accessing any areas where a respirator is required.
• All jewelry must be removed before entering a Production Area building. It can be carried in pocket.
• Smoking is only permitted in designated smoking area.
• Cell phones are not permitted to be used in the Production Area.
• Visitors must advise their host if they have been involved in an incident where they have been injured or potentially injured.
• Visitors must not cross coloured barrier chains in Production Area building without the knowledge of the host or designate for the area. Colored chains represent barriers to communicate hazards for a work area. Typically chains are yellow for caution and red for danger.
• Visitors are not permitted to be unsupervised in Production Area buildings and must remain in contact with host.
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Emergency Response Protocols
If an emergency where building occupants must muster, visitors must do the following:
• Stay with your host and muster at nearest Emergency Assembly Area (EAA #21).
• If a visitor is involved in an incident or an emergency that requires emergency
response, your host will contact emergency response by phone at 752-3111 or
ERT on Radio Channel #1 to declare the emergency.
• When a building alarm sounds, visitors must follow their host to the nearest
Emergency Assembly Area (EAA) for the respective location/building and wait
further instructions. Your host is responsible to guide you safely in the event of an
emergency. Please follow their direction closely to ensure your safety.
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Shelter in Place Alarm
• If a release of H2S occurs outside, or an uncontrollable release in the H2S
unloading area that is vented outside reaches an alarm condition, a Shelter in Place
alarm is initiated by a request to the control room. The Shelter-in-Place alarms will
differ from the evacuation alarms.
• Like an evacuation everyone reports to a common assemble area. To differentiate
between an evacuation the common assemble area will be called Shelter-in-Place
assembly area (SAA).
• Visitors will be escorted to the designated SAA by their host.
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Designated Walkways
• Visitors are required to stay on
designated walkways where present.
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Security Protocols
• Visitors are expected to uphold site
rules and security protocols on site.
• Vehicle inspections are common,
random and subject to all
personnel, including visitors.
• Visitors are required to check into
security and receive a visitor pass,
and return pass when exiting site.
• Visitors are not permitted to take
pictures – there will be an
opportunity to have your photo
taken during the tour.
• Security cameras are active.
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Plant overview and
development history
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Location and Personnel Statistics
• Long Harbour Processing Plant (LHPP) is located approximately 120 km from the
City of St. John’s. A bus service to/from St. John’s is available for employees.
• Workforce of 530 permanent Vale employees, of which 315 are Process Plant
Technicians (PPTs) working 24/7.
• Contractor numbers are approximately 250, comprised mostly of the outsourced
maintenance and site services personnel.
• Staff employees work 4 days x 10 hours a week.
• Non-unionized workforce utilize a High-Performance Work System (HPWS) model.
Technicians are trained to operate multiple areas of the plant and perform day-to-
day administrative tasks, reduce supervision workload.
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Research and Development
A multi-phased US$200 million R&D program was conducted to extend the application of
hydrometallurgical technology to process Voisey’s Bay nickel concentrate.
Commercial PlantMini-pilot Plant Demonstration Plant
Laboratory Testing and Process
Modeling
1997 – 2002 2003-2004 2005-2008 2006-2016
Studies, Design, Engineering, and Construction
Bench Scale 1/10,000 1/100 1/1
Long Harbour, NewfoundlandMississauga, Ontario Argentia, NewfoundlandMississauga, Ontario
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Long Harbour Site Pre 2009
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Long Harbour Site –May 2010
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Long Harbour Site 2018
Plant Site ~ 17 sq.km
• Distance between Lower Tier (Port) and the Upper Tier: 1 km
• Distance from Upper Tier to the Residue Storage Site: 4 km
• Treated Effluent pipeline discharge into ocean: 5 km on the ocean floor
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Long Harbour Operations Port Site
• The MV Umiak 1 ships ~30,000 tonnes of concentrate, 8 – 10 times per year.
• Concentrate Storage Shed can hold up to 80,000 tonnes.
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Long Harbour Operations Processing Plant
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Site infrastructure and Water Management
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LHPP Process Flowsheet
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World Class Nickel Tankhouse
• 272 Nickel Plating Cells
• Two Automatic Harvesting Cranes plus two Cell Maintenance Cranes
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Long Harbour Processing Plant Products
Vale Electrolytic Cobalt Rounds
>99.9 wt.% Cobalt
250 kg drums – 4/pallet
Long Harbour M-Rounds
ASTM B39 >99.80 wt.% Nickel
2000 kg bags
Long Harbour Plating Rounds
>99.9 wt.% Nickel
10 kg bags – 5/box
Vale Copper Cathode
99.999 wt.% Copper Grade A
Bundled Cathode ~1500 kg
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Performance
Highlights
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Overall Metal Recoveries meet Demo Plant
Targets after the first year of full plant operations
0%
20%
40%
60%
80%
100%
Jan-17 Mar-17 Jun-17 Sep-17 Dec-17 Mar-18 May-18
Ni Co Cu
• Design nickel,
cobalt and copper
recoveries were
95.0%, 93.3% and
73.6% respectively
• YTD-2018:
95.8% nickel,
94.4% cobalt
76.9% copper
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Production Quality and Impurity Controls
continue to improve through 2017 & 2018
99.80
99.85
99.90
99.95
100.00
1-M
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1-J
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2-S
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3-D
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6-M
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6-J
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Nickel Purity (%)
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Product Quality meets LME Specifications
• Nickel round purity continues to meet London Metal Exchange (LME)
specifications and attracts a premium over the market price.
• Copper Cathodes are also meeting LME specifications and is sold as “Grade A”.
• Initial plating tests with USA customers in 2017 have been successful.
• Cadmium, copper and iron are the elements of focus for improving Cobalt Round
Purity.
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Summary
• Long Harbour has been a benchmark ramp up in the world of nickel hydrometallurgy.
• Poised to become the world’s state-of-the-art electrolytic nickel and cobalt producer.
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