Santa Fe Calvada Mine. Final Closure of a Heap Leach Facility Case Study in Design and Construction of E-cells
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1 Santa Fe Calvada Mine Final Closure of a Heap Leach Facility Case Study in Design and Construction of E-cells
2 Site Location Location with Surrounding Topography
3 Overall Site Layout
4 Google Earth View
5 History Mining started in 1998 and continued through Leaching and processing continued into Waste rock dumps reclaimed 1991 through Leach pads reclaimed 1997 through Leach pads re-graded to 3 to 1 8 inches of growth media applied Ore has enough clay to act as a store and release cover. Santa Fe Pad 1 45 acres, 7.3 Mtons crushed ore stacked to a height of 100 feet. Pad 2 39 acres 3.8 Mtons crushed ore staked to a height of 80 feet. Pad 3 30 acres, 2.8 Mtons run of mine ore stacked to a height of 90 feet. Pad 1 and 2 shared ponds, Pad 3 had separate ponds, All 3 pads tied together at closure Calvada Pad 4, 30 acres, 3.8 Mtons crushed ore stacked to a height of 110 feet Run of mine ore taken to Santa Fe Pad 2 All Solution processed at Santa Fe Process Plant
6 Pad 1 Pad 2 Santa Fe Pad 1 and Pad 2 vegetation to compare with native vegetation in foreground
7 Pad 1 Pad 3 Santa Fe Pad 1 and Pad 3 reclaimed condition
8 Pad 3 Pad 1 Santa Fe Pad 1 and Pad 3
9 Calvada Pad 4
10 Santa Fe Pad 1 Southwest corner observation cut
11 Calvada pond level typically stayed at this level
12 Santa Fe at about max inventory
13 Santa Fe west pond slope with protective rip rap
14 Climate
15 Drain Down Rates
16 Santa Fe TDS
17 Santa Fe Sulfate
18 Santa Fe ph
19 Santa Fe Cyanide
20 Santa Fe Nitrates
21 Calvada Fe TDS
22 Calvada Fe Sulfate
23 Calvada Fe ph
24 Calvada Cyanide
25 Calvada Fe Nitrates
26 Design Criteria Passive system with minimal maintenance Minimize expression of surface water Robust for longevity Contain the 500 year storm event Minimize disturbance of reclaimed facilities Minimize new disturbance Systems Considered Infiltration Galleries - Eliminated due to poor water quality, cyanide kicks and possible quick transport to ground water. Zero discharge added to design criteria. ET Cells - Eliminated due to poor water quality limiting plant growth Open E-cells - Eliminated due to exposed liner having short life and always having a free water surface. Open E-cell with partial soil fill Selected
27 Design Partially filled one pond at each side and double lined the resulting shallow basin with 80-mil primary over 60-mil secondary liner with geo-net in between. Leak detection sump and observation port. Liner covered with select backfill 2 feet of 4 inch minus material with a 6 inch layer of select rock fill. Placed distribution pipes 6 inches below the surface. Simple distribution box with no dosing siphon. Dosing siphons are mechanical and may fail over time especially with low flow rates and periods of no flow. Distribution box placed inside the liner area to provide secondary containment. Distribution box has single outlet to distribution header and overflow. Distribution box has loose fitting lid for additional overflow protection. Included inclined standpipes with insitu level troll to monitor solution elevation. Protected the Santa Fe E-cell with riprap.
28 Santa Fe Plan
29 Santa Fe Cross Section
30 Distribution Box
31 Santa Fe Monthly Water Balance
32 Calvada Monthly Water Balance
33 Santa Fe Annual Water Balance Calvada Annual Water Balance
34 Santa Fe pond backfill to form E-cell base
35 Santa Fe E-cell liner subgrade
36 Santa Fe Secondary liner installed
37 Santa Fe LCRS sump under construction
38 Santa Fe lower 2 feet of fill in place
39 Santa Fe Distribution box in place
40 Calvada Distribution box completed
41 Santa Fe Finished E-cell
42 Santa Fe E-cell completed with rip-rap upstream
43 Calvada E-cell finished
44 Conclusions The E-cells appear to be working as intended with no free water surface observed in first year (October 2016 through present.). A passive system can work for normal conditions. A free water surface can be expected with large events. Fencing is required to keep wildlife and people out of cells. Remove anything that may be removed causing damage such as Carbon or transformers.
45 Santa Fe Pond 2 sampling damage
46 Santa Fe Pond 2 pond damage by samplers assumed to be looking for carbon
47 Santa Fe transformers opened by copper thieves
48 QUESTIONS?
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