1 ecosystems and quarry rehabilitation: csi experience csi forum 2009

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Ecosystems and quarry rehabilitation:CSI experience

CSI Forum 2009

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‘Local Impacts on Land and Communities’• Key work area identified in CSI Agenda for Action (2009)• Remit of Task Force 5, includes Biodiversity Working

Group• Basic principles:

– Cement companies become part of local community when exploitation begins

– Companies must maintain ‘license to operate’

‘CSI members are committed to ‘a business model that respects, appreciates and cares for both local landscapes and the people who live in them’

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• Stakeholder engagement: Communication Guidebook for Cement Plant Managers (2002)

• Local impacts: development of ESIA (2005)

• Biodiversity: development of 2 KPIs on biodiversity (2008)

CSI TF5: work to date

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Environmental and Social Impact Assessment (ESIA) (2005)• CSI tool for:

– Understanding and managing impacts of a site– Developing effective options for dealing with impacts

• For new limestone quarries• For cement plant sites: almost impossible to plan ahead for

rehabilitation, due to land use changes. Therefore plant site plans need to be developed near closure date

• Note: companies to look at sites on case-by-case basis

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Outline• Roles and responsibilities• Scoping phase / Greenfield site assessment (stakeholder mapping,

land use, social structure and population, public health, biodiversity and ecosystems, cultural heritage and landscapes, alternatives)

• Construction phase (environmental and social impacts, health and safety)

• Operations phase (environmental and social impacts, occupational health and safety, monitoring and reporting)

• Site closure (community involvement, future site use, rehabilitation, employment, social structure, post-closure monitoring)

Environmental and Social Impact Assessment (ESIA) (2005)

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ESIA recommendations• Rehabilitation plans are most effective when:

• based on scientific analysis and stakeholder engagement

• drawn up as early as possible in site development process

• in conjunction with relevant local stakeholders• reviewed periodically

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Key Performance Indicators• Reporting for 2006:

• Biodiversity KPI updated 2009 (divided into 2): KPI 1: Number of active quarries within, containing or adjacent to areas designated for their high biodiversity value (as defined by GRI EN11)

KPI 2: % of sites with high biodiversity value (according to KPI 1) where biodiversity management plans are actively implemented

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Performance over time

• CSI members adopting KPI over time

• Reporting shows improvements over time

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Key Performance Indicators

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CSI quarry rehabilitation case studies

• 21 case studies

• Reviewed by external experts

• Published online

• Links made with UEPG,

UNEP, CEMBUREAU

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Case studies: available online

CSI website (www.wbcsdcement.org):

Quarry rehabilitation

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Case studies: available online

WBCSD website (www.wbcsd.org)

Quarry rehabilitation

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Votorantim ExperiencesQuarry Rehabilitation

Planning Ahead

September 1, 2009

Ronaldo Dos Santos - VCNA

Joe Horton - VCNA

Note: some photos shown on this presentation have the only objective to illustrate the concepts developed.

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As previously mentioned quarry rehabilitation plans are most effective for sustainability when developed as early as possible.

For existing quarries this presents many constraints and challenges to the planning of this reclamation/rehabilitation and can lead to extreme operational costs, capital expenditures and process issues. However, with early planning quarry rehabilitation can not only lead to improved biodiversity and community welfare but can also provide operational and cost savings both in the near term and future when incorporated into a global Mine Plan.

This is most evident in a Greenfield quarry. The following outlines one Case Study of such a Greenfield and the advantages of Planning Ahead.

OVERVIEW

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Houston American Cement

BACKGROUND• Houston American Cement

(HAC) is a Joint-Venture Company managed by Votornatim Cimentos North American (VCNA) a part of Votorantim Cimentos.

• HAC is a Greenfeild Project located in the State of Georgia in the United States. Currently HAC has not begun mining but has obtained its necessary licenses for Construction of the Plant.

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BACKGROUND• Mining activities for this Project were governed by the State of Georgia. Georgia

regulations, which requires mines to have a Reclemation Plan and Financial Assurances for the Reclemation Plan.

• VCNA approached the Reclamation Plan with a plan of progressive reclamation. This include the input of all stakeholders and focused on the following key objectives:– Meeting and exceeding Regulatory Requirements– Positive and supportive relationship with local community for mining activies– Minimizing environmental risks– Minimizing operational costs, capital costs, and operational issues for the quarry

• This process lead to the creation of the HAC progressive reclamation plan (PRP), a result of the combination of the HAC Operational Mine Plan and the proposed reclamation strategies which also aligned with defined site licensing requirements.

• This presentation shows the main operational activities for the PRP as outlined below and the benefits each brings to both Sustainabiity and Operations:

• Backfilling• Grading and slope stability• Drainage and water management• Revegetation associated with the HAC PRP.

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SITE CHARACTERISTICS• A key feature of the HAC site as well as a major constraint in

the development of the PRP is the occurrence of a large amount of overburden as compared to the relatively thin layer of limestone resulting in a high stripping ratio (averaging 1.7 across the entire mine).

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SITE CHARACTERISTICS• Although this overburden (twiggs clay) is suitable to be

used as a filling material, superficial water management and re-handing issues are important factors of the PRP and its effectiviness.

•Approximately seventy years of proven limestone reserves have been quantified on nearly 1,940 acres associated with the mining operations.

• The Mining Operations is scheduled to produce the following in the first 10 years: - 1,200,000 t of limestone- 60,000 t of clay - 900,000 t of overburden to be disposed according the PRP.

• Walker Pond Stream, the primary stream that bisects the site, and its tributaries and related wetland are to be relocated as mining and reclamation activities progress.

HAC Site : Pit A & Pit BHAC Site : Pit A & Pit B

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BACKFILLING ACTIVITY• Using a method of backfilling known as Castback Backfilling,

which allows reclamation to remain concurrent with active mining. This practice of mining and backfilling is both economical and environmentally compatible. The overburden is handled only once during the stripping and reclamation process. This results in an economical method of mining.

• Backfilled material will be used to contour the previous phase of mined area per the PRP concurrently with the current active phase of mining or stripping area. – This results in an a minimal incremental cost for the reclemation

and the benefits of having reclaimed areas immediately. – Wherever possible, soils should be moved directly from areas

being stripped to areas being restored, negating the necessitate for double handling.

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BACKFILLING ACTIVITY• The PRP was developed in phases in order to accomodate

progressive stripping ratios; minimize material re-handling as well as faciliatate activities associated with the relocation of the superficial streams.

Mining Sequencing : 0 - 10 years PlanMining Sequencing : 0 - 10 years Plan

HAC Progressive Reclamation Plan – Phasing HAC Progressive Reclamation Plan – Phasing Overview Overview

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BACKFILLING ACTIVITY• A continuous re-habilitation process was also established, as

excess overburden from the development of the future mine areas shall be utilized according to the PSP into the previously mined areas.

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GRADING AND SLOPE STABILITY• Final slopes and surface contours will approximate native

gradients and will blend with adjacent topography to minimize impacts to existing land use characteristics. Main aspects of this process are overall landcaping, erosion control and soil infiltration characteristics. HAC Final Grading – Master Plan HAC Final Grading – Master Plan

HAC proposed channels - Profile DesignHAC proposed channels - Profile Design

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GRADING AND SLOPE STABILITY• Mine operations will utilize dozers, excavators and graders for

these activities. An important feature of the PRP is the coordination with the previous backfilling operation and ongoing active stipping area in order to minimize input as well as to provide proper workable material to areas being actively reclaimed.

HAC Engineering Guidance - Sloping Design HAC Engineering Guidance - Sloping Design

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DRAINAGE AND WATER MANAGEMENT• Surface water flow will be re-established in the backfilled

phases via the countering with the grading and sloping.

• Ephemeral channels to be impacted by the mining activity will be temporarily directed around active mining stages and recreated in the backfill phases to re-establish pre-mining habitats.

• Channel design for both temporary and permanent diversions were desinged to enhence the final reclamation phase to reduce the cost of reclemation.

• This approach assists in reducing ongoing operational costs for water management by minimizing the active area of water management and the volumes of water handled.

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• The routes of the proposed channels in the PSP were based on hydrologic, environmental, safety and logistic considerations. The stability of the stream and potential flooding are two additional factors evaulated in design of channel routes.

• Development of the mine areas included additional aspects of water management in order enhence operational conditions as well as enhance the reclamation effort.

DRAINAGE AND WATER MANAGEMENT

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Log structures such as log vanes and root wads add Log structures such as log vanes and root wads add woody debris to the stream, enhancing habitat and woody debris to the stream, enhancing habitat and having as main goals:having as main goals:Maintenance of a stable width-to-depth ratio;Maintenance of a stable width-to-depth ratio;Reductions in near-bank velocity;Reductions in near-bank velocity;Reductions in erosion potential and sediment Reductions in erosion potential and sediment deposition;deposition;Improvements in fish habitat;Improvements in fish habitat;Visual compatibility with natural channels of the Visual compatibility with natural channels of the region;region;

• The PSP approached surface water with a plan for sequentially relocating the streams and channels as equivalently as possible to the original locations as the active mine progresses.

• With this approach, the disruption to the streams is minimized while also relocating the streams and channels to reclaimed areas near their original location.

Quarry would generate excess overburden that would Quarry would generate excess overburden that would be used to reclaim the mine site to ridges and streams be used to reclaim the mine site to ridges and streams that would adequately convey surface water across that would adequately convey surface water across the site.the site.

DRAINAGE AND WATER MANAGEMENT

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REVEGETATION• Progressive reclamation reduces the need for topsoil

storage, but this may still be required for part of a site.

• Revegetation procedures will begin following contouring and topsoiling of the disturbed areas. Revegetation enhances site stabilization and erosion control while restoring natural habitat in a more timely manner. This process has also a direct impact on minimizing mine requirements associated with dewatering and dust control activities.

• Ascetic benefits for community are also improved.

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REVEGETATION

Importance of the proper revegetation Importance of the proper revegetation and grade design specially along the water and grade design specially along the water streams.streams.

• Permanent vegetation will be installed as soon as the mining and stockpiling activities cease in an area. Temporary ditches will be grassed with temporary and permanent grassing.

• Topsoil will be directly on leveled area. The seeding process will use broadcast seeder and hydro-seeding when feasible. Several tree establishment techniques will be also implemented, especially within slope areas and floodplains.

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OTHER COST• Each completed phase of mining that is reclaimed

via these methods adds the advantage of experince for enhanced knowledge for reclemation of future phases. This allows for optimization of these methods for further reduced cost in future reclamation.

• Additional cost savings occur in the following areas:– Implementation cost (shared resources with the mine

operations: equipments, trained personnel, supervision, power, communications, staff support, etc.)

– Active Mine Auxiliary cost (dewatering, dust control, erosion control, etc.)

• This also reduces outstanding cost associated with future liabilitis such as Finacial Assurances required for reclemation.

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OVERALL COST EVALUATION“True magnitude of reclamation and closure cost liabilities are often initially unknown…externally and internally”. So, good practices in planning, cost management and its proper record can bring financial incentives.

Regulatory Regulatory ““Financial AssurancesFinancial Assurances”” can be can be beneficial beneficial

Source: Boxill, Lois, AMEC “Reclamation and Closure Cost Planning and Estimation and the Mining Life Cycle”

Source: MINISTRY OF ENERGY AND MINES Mining and Minerals Division, British Columbia - Canada “MINE RECLAMATION COSTING AND SPREADSHEET” 2006

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Votorantim Experiences:Decomissioning Plans

for Itaú de Minasand Rio Branco

September 1, 2009

Patrícia Monteiro Montenegro

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Itaú de Minas

Adm. areaOpen quarry Industrial Area

Local scale

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Rio Branco do SulCava de argila ativa

Labels

Sterile deposits

Plants

Adm. instalations

Active clay quarry

Inactive clay quarry

Active limestone quarry

Rented limestone quarry

Inactive limestone quarry

Poligonal DNPM

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Methodology Roadmap

SELECTION OF CONCEPTUAL SCENARIOSFOR DECOMISSIONING

PROPOSAL OF ALTERNATIVES / SCENARIOS

FOR POST-CLOSURE USE

Participation/Interaction: VCB Corp. Production Plants

Filters / Guidelines C.S.I

Votorantim Guidelines + +

Guidelines Business Plan

Threats/ Opportunities Processes

Environmental Aptitudes/Restrictions Legislation/ Land Use

Local Vocation

Community ExpectationsGOLDER METHODOLOGY

EnterpriseDiagnosis/Prognosis

Environmental/ Social Survey and Assessment

X

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Concepts and Guidelines

• Local/Regional Perspectives and Vocations;

• Applicable National and International Legislation;

• National and International Experiences;

• Technical-Scientific Literature about decomissioning from the most recent forums and seminars;

• Guidelines and Protocols from Environmental and Social-Economical Multilateral agencies;

• Especial Focus on CSI Guidelines;

• Gain of financial trust through actions of Social-Environmental responsibility linked to the decomissioning;

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Example of Alternatives• AAA

Open quarry

Forest units

Adm. area

Industrial area

Small Hydro Power

Public water supply center

Multiple uses for leisure

and tourismFish culture

Public supply center +

Multiple uses for leisure and

tourism

Recovery of natural

ecosystem

Keep agro-forest usage

Diverse farming usage

Real estate incorporation

Real estate incorporation + agro-forest

use

Real estate incorporation + diverse farming

including country tourism

Center for small furniture or

manufacturing businesses

Cultural stationKeep/adjust

existing structure

Complete demolition of

structure

Management of cement production

with imported clinker from anther

plant

Wood warehouse

Small industrial district for furniture or

manufacture

Wood warehouse + small industrial

district for furniture or

manufacture

Commercial production

of electricity (biomass)

Recovery of natural ecosystem (total deactivation of

structures)

Supply energy to the complex

Supply energy to the National Grid System

Complete Deactivation

Alternative 1 Alternative 2 Alternative 3 Alternative 4 Alternative 5 Alternative 6

Operational Areas and Proposed Alternatives

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Alternatives Assessment

Physical and biotic environment• Geotechnical and hydrological integrity of the containment• Potential Impacts to the aquatic, terrestrial, atmospheric

environments

Each alternative for each operational area is assessed according to the different types and degrees of intervention predicted, considering the restrictions and potentials of the following aspects:

Social-economical aspects• Economical scenarios of the region• Political and Institutional Contexts • Impacts on the social-territorial restructure • Levels of social perception and support

Viability of execution• Complexity of monitoring, cost and duration of plan• Population access and exposition• Reuse of existing infra-structure • Risk of failure

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Proposal of scenarios

According to the previous assessment, some of the alternatives are chosen and combined into four different scenarios:

1) Sustainable use of water resources and promotion of cultural and socio-economic activities

2) Industrial adjustment to the local social-economic vocations (partial decommissioning)

3) Social-economic and cultural diversification aligned to the local vocations

4) Total rehabilitation of impacted areas and strict adjustments for tourism, leisure and culture

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Sustainable use of water resources and promotion of cultural and socio-economic activities

• Specific studies for: determination of the water level after closure, water quality of the future lake and storage capacity of the quarry.

• Enclosure of the quarry• Demolition of the structures surrounding the quarry• Re-vegetation of the area surrounding the quarry• Monitoring

Operational or Interest Areas

Pretended Future Use

Decomissioning Actions

• Re-vegetation of the piles

• Adequate buildings.• Re-vegetation of courtyard areas (pet coke, wood).• Monitoring.

• Disassembly of equipments and demolition of structures (70% clinker and cement, 100% aggregates).

• Re-vegetation of degraded areas.• Monitoring.• Disassembly of crushing and grinding equipments.

None

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Scenarios for Itaú de Minas

Open quarry

Forest units

Adm. area

Industrial area

Small Hydro Power

Public water supply center


Cultural station

Small industrial district for furniture or

manufacture


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Industrial adjustment to the local social-economic vocations (partial decommissioning)

Multiple uses for tourism and leisure

Keep/ Adequate existing structure

None

2





• Specific studies for: determination of the water level after closure, water quality of the future lake and storage capacity of the quarry

• Geotechnical studies for slope stability and enclosure of quarry; Demolition of the structures surrounding the quarry

• Re-vegetation of the area surrounding the quarry• Monitoring

• Re-vegetation of the piles area

Open quarry

Forest units

Adm. area

Industrial area

Small Hydro Power



Management of cement production with imported clinker from anther plant



• Re-vegetation of courtyard areas (pet coke, wood).

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Social-economic and cultural diversification aligned to the local vocations3

Multiple uses for tourism and leisure

None





• Geotechnical studies for slope stability and enclosure of quarry; • Demolition of the structures surrounding the quarry• Re-vegetation of the area surrounding the quarry• Monitoring

• Re-sloping/ re-vegetation of the piles

Open quarry

Forest units

Adm. area

Industrial area

Small Hydro Power



Management of cement production with imported clinker from anther plant




Cultural station


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Total rehabilitation of impacted areas and strict adjustments for tourism, leisure and culture

Incorporation to the natural surrounding

ecosystem

• Re-vegetation of the whole area with native species • Re-sloping/ re-vegetation of the piles

• Construct new transmission lines

4Operational or Interest Areas



Open quarry

Forest units

Adm. area

Industrial area

Small Hydro Power


Cultural station


ecosystem


ecosystem (total deactivation of strictures)

Supply energy to the national grid system




• Demolition of the structures surrounding the quarry• Re-vegetation of the area surrounding the quarry


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Upcoming issues1. How to communicate decomissioning plans with

local communities without raising any rumors?

2. How can the cement industry prepare the local community for active participation on the decomissioning plan?

3. How to conciliate recovery of biodiversity with economical / social impact on the community when choosing options for decomissioning?

4. Is biodiversity impact from emissions becoming a focus for your local policy-makers?

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Upcoming issues• How can the CSI companies evaluate the biodiversity

lost due to mining activity?• What future regulations regarding quarry

decomissioning do you see arising from policy markers?• Is your company aware of any new technologies or

methods for reclamation?• Is there opportunities to work with or learn from other

mining industries?• What future issues around ecosystems do you see?• Is there any recommendations from your country

concerning the life time of the mine?

1 ecosystems and quarry rehabilitation: csi experience csi forum 2009

Documents

quarry rehabilitation

time slide

date slide

implemented slide

cembureau slide

case basis slide

biodiversity kpi

social impacts