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CASE REPORT A Case Study of The Deep-Sea Tailings Outfall in The Tropical South Pacific
CASE REPORT A Case Study of The Deep-Sea Tailings Outfall in The Tropical South Pacific
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CASE REPORT A case study of the deep-sea tailings outfall in the tropical
south Pacific
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Albert Tsz Yeung Leung, Aurelien Hospital, Chris Young, Daniel Potts, James
Stronach & Allister Thompson
To cite this article: Albert Tsz Yeung Leung, Aurelien Hospital, Chris Young, Daniel Potts,
James Stronach & Allister Thompson (2020): A case study of the deep-sea tailings outfall
in the tropical south Pacific, Journal of Applied Water Engineering and Research, DOI:
10.1080/23249676.2020.1761899
CASE REPORT
A case study of the deep-sea tailings outfall in the tropical south Pacific
Albert Tsz Yeung Leunga∗ , Aurelien Hospitala , Chris Younga , Daniel Pottsa , James Stronacha and Allister Thompsonb
a Water and Marine Engineering Department, Tetra Tech Inc., Vancouver, Canada; b Van-Dive Marine Consultants Ltd, Vancouver,
Canada
(Received 7 June 2018; accepted 9 April 2020 )
Deep-Sea Tailings Placement (DSTP) systems have been used at several mines to discharge diluted mine tailings at great
depths. DSTP often provides considerable environmental and engineering benefits compared to traditional on-land tailings
storage. The key element in the viability of a DSTP system is the ability to discharge mine tailings at sufficient depths and
at such a location that a density current is formed that carries the tailings along the seabed to the abyssal ocean, and such
that adequate dilution can be achieved and environmental impacts minimized. Depending on the composition of the slurry,
sub-sea plumes might also form from the density current at different levels of neutral buoyancy, further diluting the effluent.
The engineering, environmental and construction aspects of the deep-sea outfall system are illustrated through a case study
of the DSTP outfall system on Woodlark Island in Papua New Guinea, located in the tropical south Pacific.
Keywords: DSTP; engineering; numerical modelling; density current; tailings management; dilution
therefore functional failure of the tailings pond, or in areas Description of the framework
where excessive rainfall could trigger landslides. A DSTP system usually consists of the following com-
Submarine tailings disposal (STD) is the alternative ponents: Figure 1 shows a sketch of a typical DSTP
method to on-land disposal: shallow/mid-depth and deep- system.
sea This disposal method has an advantage of presenting
a ‘walk-away’ and ‘cheaper’ solution: the cost of oper-
ating a STD of the Placer Dome mine in Calancan Bay • A mix/de-aeration tank at the shore, in which slurry
in Philippines was claimed to be less than half of the from the plant is mixed with seawater before being
cost associated with a tailing-pond system (Zandee 1985). discharged to the sea. In addition to providing initial
The STD method would save Kitsault mine, located in dilution, the mix/de-aeration tank allows the slurry
the Province of British Columbia, Canada, where it was to be de-aerated before it enters the outfall pipe to
given a permit for STD, 25 million dollars every year avoid unwanted buoyancy due to air entrapment, to
as opposed to the cost associated with an on-land sys- ensure efficient conveyance of the slurry in the pipe,
tem (Mining Watch). US Department of Interior estimated and to eliminate the possibility of air bubbles exit-
an average of 17% reduction in capital cost with a STD ing the outfall pipe and carrying contaminants to the
system. surface;
Various mine operations that have released mine tail- • A feed pipe carrying slurry from the plant, discharg-
ings at shallow or mid depths include the Marcopper Mine ing into the mix/de-aeration tank;
and Atlas Mine in Philippines, the Island Copper Mine • A seawater intake pipe leading into the mix tank,
in Canada, Minahasa Raya Mine in Indonesia. However, either pumped or gravity-driven (by the head differ-
detrimental effects of shallow-depth disposal to the envi- ence between the operating level in the tank and sea
ronment were well documented for some of these mines, level, considering the relative densities of tailings
such as the Marcopper Mine owned by Placer Dome in slurry and seawater); and
Philippines (Coumans 2006). • A tailing discharge pipe from the mix/de-aeration
The other submarine tailings disposal method is Deep- tank, transporting the tailings/seawater mixture to
sea Tailings Placement (DSTP), the main focus of this the outfall terminus at depth.
article. DSTP involves discharging mine tailings to the
abyssal ocean where pollutants are unlikely to surface, The efficiency of a deep-sea tailings system depends
biological activities are scant and any change in ambient on its ability to create a density current. As shown in
condition is slow and more predictable than that of near- the bottom panel of Figure 2, slurry (tailings solids and
surface; this method takes advantage of diluting the tailings liquid) discharged at depths usually greater than 150 m
with large amount of deep ocean water acts as an acid and below the mixed layer, will, upon exiting the outfall pipe,
chemical buffer that renders the discharged tailings largely form a density current that travels along the seabed to the
benign. If done properly, DSTP is considered more envi- deeper parts of the ocean floor, i.e. depths greater than
ronmentally sustainable and subject to significantly lower 1,000 m. As the density current descends, it casts off dis-
risk and uncertainty. However, if done carelessly, such as solved material and fine sediment to the overlying water
selecting an overly shallow discharge depth, or choosing a column as this material finds its neutral buoyancy, usu-
less than optimal submarine valley such that a density cur- ally at depths greater than 400 m. This material generally
rent could not be properly formed and maintained to carry stays at that depth and spreads horizontally under the action
the discharged tailings downward, or under-designing the of the ocean currents, unless the discharge location is in
pipe ballast requirement, etc., could all lead to the same an area of strong upwelling or downwelling. Sediment
level of, if not greater, environmental disaster that would ultimately settles out from the density current and the sub-
take years or decades to recover from, not to mention sea plumes. Since these processes occur at great depths,
the financial suffering the stakeholders and relevant parties the interaction with the upper mixed layer, and, hence,
must bear. surfacing of the discharged material, both important envi-
For these reasons, a properly-designed DSTP system ronmental considerations, are non-existent. Similarly, the
has gained significant popularity in recent years worldwide discharged material does not enter the photic zone, the
(e.g. Misima, Lihir, Woodlark, Ramu and Simberi mines in region where sunlight penetrates and primary production
Papua New Guinea, Black Angel Mine in Greenland and from photosynthesis occurs, because the slurry constituents
Batu Hijau Mine in Indonesia, etc.). Many more have been could interfere with biological activity.
proposed to use the DSTP system for tailings discharge. The determination and optimization of an efficient
Comprehensive studies into the environmental impact deep-sea tailings system is usually a two-component pro-
and feasibility of utilizing a DSTP system were conducted cess: both engineering and environmental aspects must be
for mines in Goro, Ramu, Moa, Simberi and Woodlark. considered.
Journal of Applied Water Engineering and Research 3
Figure 2. Outfall discharge not forming (Top) / Forming (Bottom) a density current.
4 A. T. Y. Leung et al.
Slurry characteristics
A DSTP system can operate only within a specific range of
parameters, including solids concentration. Systems with
solids concentrations that are too high may present risks in
terms of deposition both inside the outfall pipe and after
leaving it. The slurry flow velocity in the outfall pipe has
to be large enough to maintain the solids in suspension
while scouring of the pipe wall due to wear and tear from
the solids in the liquid is to be avoided. The flow at the
outfall exit is also critical in the design: if solids deposi-
Figure 3. Mix tank and outfall pipe installation at Simberi tion occurs in the receiving environment in the immediate
Island. vicinity of the exit from the pipe, the depositional area
may grow to include the pipe itself, causing some form
of failure. In these situations, the usual mode of failure
is that the pipe can transport slurry even though there is
Engineering aspects of the system
a deposit built up just outside its terminus, but as soon
Mix/De-aeration tank design as the system is shut down, for repairs or maintenance
The mix/de-aeration tank is constructed on the shore say, the deposited material falls back into the pipe, mak-
(Figure 3), and usually placed in a dry moat to allow ing it very hard to start the system up again. Systems with
access for inspection and maintenance. The slurry feed and solids concentration that is too low may develop an unsta-
seawater intake lines deliver flow to the mix tank where ble density current in the receiving environment, due to the
the two input streams are mixed. The mixed stream then small density difference between the slurry and the ambi-
exits the tank through the outfall line. Inside the tank, a ent water, resulting in the formation of sub-surface plumes
submerged, circular weir is installed to eliminate short- near the outlet. These sub-surface plumes will result in a
circuiting in the tank. An important role for the mix-tank, failure of the system in terms of a negative environmental
in addition to providing a vessel for seawater and efflu- impact.
ent to mix, is to allow entrained air bubbles to escape. The Slurry feed to a typical DSTP system would have its
semi-circular weir within the mix tank forces the flow to solids content ranging between 5% and 40% by weight.
rise in the tank, promoting the liberation of any entrained Dilution by seawater, which was fed into the mix/de-
air to the atmosphere. The diameter of the mix/de-aeration aeration tank by gravity, will typical achieve an initial
tank is established with consideration of the liberation of dilution ranging between 1 and 8. However, the operat-
air bubbles that may be entrained within the slurry. This ing concentration range of the system is very dependent on
consideration requires that the downward velocity of the the following factors: seabed slope, particle size, solid con-
slurry within the tank shall be less than the rise velocity of centration and pipe diameter. Typically, seabed slope and
entrained air bubbles within the slurry. particle size are fixed, and only pipe size and solids concen-
The mix tank can be fabricated in concrete or steel with tration can be varied to optimize the system. For example,
appropriate protection against corrosion. Other material a greater seabed slope will allow a shift of the operating
options include stainless steel or carbon steel with/without range of solids concentration towards higher values since
a brick or ceramic tile liner. The concrete option is con- higher solids concentrations may tend to deposit less when
sidered to be the most economical solution, while also the slope becomes greater. On the other hand, low solids
offering excellent durability, strength, corrosion resistance, concentrations may tend to form sub-surface plumes close
and resistance/stability in terms of seismic loading. Con- to the outfall terminus due to the steep slope which causes
crete walls also provide structural support for the access a strong entrainment of the overlying waters. This quali-
platforms/walkways and steel grating on top of the tank, tative description is also true for flatter slope: high solids
and simplifies connection of the intake/outfall pipelines concentrations would lead to deposition, hence should be
via cast-in-place (stainless steel and 28% chrome allow avoided in favour of low solids concentrations. Ultimately,
steel) nozzles through the tank walls. Furthermore, there the operating range for the system will need be carefully
is a large number of available contactors to choose from determined, based the parameters described. In some cases,
who could construct the concrete tank. the location of the outfall may need to be changed from the
The mix tank design has to take into consideration both initial candidate location, in order to discharge into a region
the steady state mode for different inflow rates and the with acceptable seabed slope.
Journal of Applied Water Engineering and Research 5
one pipe diameter; this consideration reduces the risk from a lay barge. The sinking process is usually monitored
of localized high scouring velocities underneath the by an ROV, and by monitoring the flow of water into the
pipeline and helps ensure the pipe remains supported pipe versus touch-down point.
above the seabed in loose/soft granular soils; Generally, for this type of sinking, past experience has
• The maximum spacing is selected for a minimum shown that a tug boat must provide a tension of at least 12.5
25% air offset (i.e. the pipeline could be up to 25% tonnes. Also a safety factor of two should be considered.
full of air by volume along its entire alignment), Thus a tug boat that provides a tension of about 25 tonnes
and would remain on the seabed (not buoyant) in should be considered. Figure 4 illustrates the typical DSTP
seawater; pipe installation, showing the launch of the pipeline.
• The maximum spacing is selected to accommodate
pipe handling on land such that the bending stress
experienced by the pipe with one unsupported block Environmental characterization
suspended between two adjacent supported ballast Tailings fate modelling
blocks is within tolerable design limits for HDPE
In order to address the overall fate of the tailings, a den-
(e.g. maximum design stress of 8 MPa as per Aus-
sity current model coupled with the sub-sea plume model
tralia and New Zealand Standard – AS/NZS 4131),
is required. The first phase is a two dimensional near-field
and
density current model to simulate the behaviour of the tail-
• The maximum spacing is selected such that if the
ings as they leave the pipe and form a density current.
seabed were to slough away beneath three of the
This model uses a relatively fine grid, commensurate with
ballast blocks, then the bending stress experienced
the diameter of the pipe. The subsequent behaviour fol-
by the pipe suspended between two other ballast
lows two pathways. The heavier fractions of the solids stay
blocks while carrying the weight of the unsupported
within the density current and are carried further offshore,
ballast blocks is within tolerable design limits for
along the bottom, where they settle. This phase is mod-
HDPE (e.g. maximum design stress of 8 MPa as
elled by a far-field density current model using a larger
per Australia and New Zealand Standard – AS/NZS
grid spacing, commensurate with the dimensions of the
4131).
receiving basin. The lighter fractions will leave the den-
sity current as passive sub-surface plumes, at depths where
the density of the fluid comprising the density current is
Installation and pipe sinking approximately equal to the density of the ambient water.
The HDPE outfall pipe is generally installed using S bend As the lighter fractions strip off, the material left behind in
sinking. The pipe is fitted with ballast blocks and blind the density current is in fact the heavier fraction, whose
flanges at both ends, and towed into its approximate align- greater density relative to the ambient density provides
ment. The inshore end is attached to the mixtank. During additional forcing to carry the density current onward to
sinking, water will be pumped into the landward end of the greater depths. The density current thus acts as an exten-
floating pipe, causing that part of the pipe to sink. A tug sion of the outfall pipe, carrying material deeper, but with
will maintain tension on the weighted pipe, and gradually some losses to subsurface plumes along the way. The
more water will be introduced, accompanied by controlled stripped off portion the tailings will form sub-sea plumes
release of air at the floating seaward end, and the contact as they are lifted off from the bottom near the level of neu-
point of the pipe on the bottom will move seaward: the tral buoyancy. The fate of these plumes require a sub-sea
pipe will be sinking. During this process, the configuration plume model to determine the behaviour as they drift away
of the pipe is an elongated S shape: hence the term S-bend from the bottom and into the open sea.
sinking. If the pipe must be raised during sinking, then air
will be introduced, preferably from the seaward end, and
water drained from the landward end. It would be possible Density current model
to inject air from the landward end, but at the expense of The tailings fate numerical model, also called the den-
considerable turbulent flow and disruption in the pipe. sity current model, is a two-dimensional reduced-gravity
During S-bend sinking, the part of the pipe that is sus- model of the density current created by the tailings dis-
pended in the water column is supported to a large extent charge. That is, it considers the two-layer flow consisting
by the buoyancy of the air in the seaward part of the pipe. of the density current flowing under the receiving water as
At some point, the amount of air-filled pipe is insufficient if the density current were a one layer flow, but with the
to support the pipe, and the pipe must then be lowered to acceleration of gravity in the equations of motion modified
the sea-bed under control of the tug, but with some assis- according to:
tance from the air in the pipe. For the purposes of this
discussion, this phase is referred to as J-bend lowering, D − h ρ − ρambient
greduced = g · · (4)
although this term is also typically used to refer to sinking D ρambient
Journal of Applied Water Engineering and Research 7
where D is the total water depth, h is the thickness of the of mass into each cell, velocity components, and concen-
density current, ρ ambient is the ambient seawater density and trations of dissolved scalars and sediment. The net result
ρ is the density of the density current, including both the is that the density current readily flows in the downstream
effects of entrained ambient seawater and the solids load. direction, but also spreads laterally, the expected behaviour
Commonly, the layer thickness of density current is much for a density current discharging down a slope, and similar
less than the overall water depth, and the above equations to the configuration of a turbulent wall jet (Rajaratnam and
reduces to: Pani 1974).
ρ − ρambient The model hydrodynamics include:
greduced = g · (5)
ρambient
• Advective terms; Coriolis term; bottom friction;
The model is a time-stepping model, and uses a spa-
interfacial friction, expressed as a fixed fraction of
tial grid of uniformly spaced cells. The simulation starts
bottom friction; turbulent kinetic energy associated
with a bare seabed, and with all cells devoid of the denser
with the confined pipe flow;
tailing-bearing fluid. As tailings are discharged, more and
• Entrainment of ambient fluid based on a fit to the
more computational cells are turned on as the density cur-
Ellison and Turner (1959) observations:
rent distribution builds in a down-slope direction with time.
Ultimately, a quasi-steady state is reached, with the solids E = E0 · e−k·Ri (6)
either being carried out of the model domain, settling to
the seabed within the model domain, or being carried off in where E 0 and k are adjustable constants and Ri is the
subsurface plumes. local Richardson number;
In order to simulate the frontal advance of the density • Depletion, which removes material from the top of
current, an algorithm similar to the algorithm for flood- the density current when it is unstable, based on a
ing and drying tidal banks in shallow water is used. At Richardson Number criteria;
each timestep (i.e. the simulated period is broken down • Horizontal eddy viscosity, and drag by ambient cur-
in smaller intervals with limited changes from one time rents.
interval to the next – these intervals are called timesteps),
each active cell is first examined to see if it should be de- As the density current exits the pipe, the central core
activated because the density current has retreated from maintains a high velocity, but the flow along the two outer
that particular cell. boundaries, to either side of the main core, is slower, and
Next, de-activated cells are examined to see if they generally, small levees form along these lateral bound-
should be re activated, because the thickness of the density aries. However, their height is limited, because once they
current in an adjacent cell is sufficient to flood into that are tall enough to exceed a critical slope, they collapse
cell. The simulation then proceeds to evaluate the fluxes into the main core of the flow, where the high turbulence
8 A. T. Y. Leung et al.
Table 1. Comparison of modelled and observed lift-off distance for the density current with data from
Hurzeler et al. (1996).
qo (m3 /s) 3.9 × 10−3 5.9 × 10-3 3.6 × 10-3 4.2 × 10-3 4.3 × 10-3
ρ 0 (kg/m3 ) 1011.6 1002.1 1005.2 1003.7 1003.3
ρ i (kg/m3 ) 1001.9 998.6 998.6 999.8 998.3
ρ a (kg/m3 ) 1004.5 999.9 1000.2 1001.1 999.5
Lobs (m) 14.5 14.3 9.8 7.7 14.5
Lmod (m) 14.5 12.0 11.0 6.8 11.2
L Difference (%) 0 − 19 + 11 − 12 − 22
Figure 6. Comparison of (a) Field-observed (Source: Hay 1982) and (b) Modelled (Source: Stronach et al. 2000) Change in Bathymetry
in Rupert Island resulting from the tailings discharge from the Island Copper Mine in BC, Canada.
for the tailings outfall from the Island Copper Mine in Sub-surface plume model
BC, Canada. Both the field-observed (Figure 6a) and mod- As the density current propagates down-slope, a con-
elled (Figure 6b) change in bathymetry illustrated a distinct siderable amount of dissolved and fine suspended mate-
and similar meandering channel depositional pattern as the rial is transported from the density current into the
density current migrated into the deeper waters. water column by the generation of subsurface plumes.
10 A. T. Y. Leung et al.
A three-dimensional circulation model, H3D (details Gulf of Mexico (Rego et al. 2010). H3D is typically driven
described in the next section), is used to track the fate by the following forcing mechanisms:
of the liquid and solid fractions of the tailings once they
have separated from the density current, thus complet- • Tidal and non-tidal water level fluctuations, such
ing the tailings fate modelling. On oceanic scales of this as storm surges, at the open boundaries, based on
size, ocean conditions are often characterized by eddies observed, hindcasted or predicted water levels.
which propagate through the region with time scales of • Wind stress acting at the water surface: winds are
several days, in addition to slower-varying quasi-mean determined by data from one or more meteorological
states. These eddies are a form of turbulence, on ocean- stations. Wind forcing causes surface currents and
basin scales, and hence are not predictable. As an example, return current in enclosed water bodies; water level
currents at Lihir Island, Papua New Guinea, where stud- differences; and enhanced vertical mixing.
ies were conducted into the consequences of an increase in • Propagating air pressure systems, acting as an
flow, provided an interesting challenge to numerical sim- inverted barometer.
ulation. The most significant feature of the current field • River and land drainage inflows: these bring mass
at Lihir was the large ratio of the rms speed to the mean and momentum into the water body, as well as
speed, and the persistence of this characteristic throughout contaminants. Water exits this way as well.
the water column. Observed current metre data did not pro- • Turbulence modelling is important in determin-
vide sufficient coverage that it could be used exclusively to ing the correct distribution of velocity and scalars
provide three-dimensional currents over the entire area the such as contaminants. The diffusion coefficients for
subsurface plumes would utilize. Thus, a standard dynamic momentum and scalars at each computational cell
circulation model was used to provide the velocity field for are dependent on the level of turbulence at that point.
the subsurface plumes. This same circulation model was H3D uses a shear-dependent turbulence formula-
used to provide the velocity field for the far-field density tion in the horizontal, and a shear and stratification
current model. By adjusting an impressed mean current and dependent formulation in the vertical. These param-
mean sea surface slope, the resulting modelled current had eterizations have been shown to work well when
similar mean and rms values to the observed values. Impor- simulating flows and scalar distribution in a variety
tantly, the model calibrated very well against observed of waterways.
seabed deposits of tailings, with a much wider area of cov-
erage than earlier thought based on the application of a The model operates in a time-stepping mode over the
simpler modelling system by others. period of simulation. Thus, a one-month simulation for
example, might be broken down into a number of small
timesteps, possibly of size one to five minutes, depend-
ing on grid size. During each time step, values of velocity,
Three-dimensional circulation model: H3D temperature and contaminant concentration are updated in
H3D is a three-dimensional time-stepping numerical each cell.
model which computes the three components of velocity H3D was used at two different steps in determining
(u,v,w) on a regular grid in three dimensions (x,y,z), as well the fate of the discharged tailings. First a simulation was
as scalar fields such as salinity, temperature and contami- conducted to provide bottom current values to the density
nant concentrations. The model uses the Arakawa C-grid current model. Then the density current model simulated
(Arakawa and Lamb 1977) in space, and uses a two level the fate of the tailings through deposition and release into
semi-implicit scheme in the time domain. the overlying water column forming and sustaining sub-sea
H3D is an implementation of the numerical model plumes. The fate of these sub-sea plumes are then modelled
developed by Backhaus (1983, 1985) which has had by H3D.
numerous applications to the European continental shelf,
(Duwe et al. 1983; Backhaus and Meir-Reimer 1983),
Arctic waters (Kampf and Backhaus 1999; Backhaus and Environmental guidelines
Kampf 1999) and deep estuarine waters, (Stronach et al. Meeting receiving water criteria is achieved in two
1993). Locally, H3D has been used to model the tempera- ways:
ture structure of Okanagan Lake (Stronach et al. 2002), the
transport of scalar contaminants in Okanagan Lake, (Wang (1) By virtue of the seawater dilutions in the mix-
and Stronach 2005), sediment movement and scour / depo- tank on shore, reducing levels of contaminants
sition in the Fraser River, circulation and wave propagation considerably, but usually not totally in compliance
in Seymour and Capilano dams, and salinity movement in with water quality standards;
the lower Fraser River. H3D forms the basis of the model (2) Negotiating a mixing zone, similar to municipal
developed by Saucier and co-workers for the Gulf of St. regulations in Canada, within which water qual-
Lawrence (Saucier et al. 2003), and has been applied to the ity guidelines can be exceeded. The radius of the
Journal of Applied Water Engineering and Research 11
Table 2. Physical properties of the proposed tailings at the discharge depth must be in accord with the following
woodlark mine. criteria:
Woodlark
(1) At a minimum depth of 120 m where the maximum
Tailings Solids Production Rate 305 depth of the euphotic zone is 80 m or less,
(Tonnes per hour) (2) Where the euphotic zone is deeper than 80 m the
Slurry Solids Content 51–58% by weight discharge should be below the maximum observed
29–35% by volume
Specific Gravity of Slurry 1.49–1.59 depths of the surface mixed layer or the euphotic
Specific Gravity of Solids 2.65 zone, whichever is deepest, + 50% of that length,
Specific Gravity of Liquid 1.025 (3) Formation of plumes of tailings in the water col-
umn must be minimized. In the event of density
changes in the water column occurring the length
mixing zone is often quite large, up to 3,000 m at of the pipe should enable the discharge of tail-
Lihir, for instance, but this area of exceedance must ings to occur below low-density weakly stratified
remain below a specified water depth, such that the surface waters as detailed in the site specific hydro-
effluent does not come into contact with the bio- graphic measurements.
logical activity occurring in the top 150 m or so of
the water column. Such a mixing zone is typically The CTD data collected between 2010 and 2018 has
negotiated between the mine and the appropriate been analysed by Coffey Environments and Tetra tech
government agencies, assisted by the mine’s envi- Canada Inc. in order to determine the seasonal fluctua-
ronmental consultants who often have to conduct tions in, and the maximum depths of, both the surface
extensive pioneering baseline studies; and by itera- mixed layer and the euphotic zone. Based on the den-
tions on the outfall design, to arrive at a design that sity profiles (Figure 9) derived from available CTD data,
causes the tailings to quickly move to deep water, the maximum measured euphotic zone depth is in excess
and to dilute to the greatest extent possible. of 80 m and the maximum measured surface mixed layer
depth (153 m) exceeds the maximum measured euphotic
zone depth (106 m). Therefore, the DSTP outfall terminus
A case study of the deep-sea outfall system: woodlark must be located at a minimum depth of 230 m (50% greater
mine than 153 m).
Woodlark Mining Ltd. (WML), owned by Geopacific
Resources Ltd., was considering a DSTP system as the
tailing management strategy for a proposed gold mine Wind and wave climate
(Woodlark Island Goldmine Project, hereafter referred to The offshore wind and wave climate of Woodlark Island
as the Project) on Woodlark Island (also referred to as was determined based on modelled winds produced by
Muyua Island) in Milne Bay Province, Papua New Guinea. WAVEWATCH III for period between 2005 and 2012
Lycopodium Minerals Pty Ltd. retained Tetra Tech Canada due to lack of long-term observed wind record for the
Inc. to develop a feasibility design of the DSTP system project site. Figure 10 is the wind rose for the offshore
capable of managing 2.4 Mtpa of tailings, which was pro- wind. Statistical extreme value analysis for the wind was
posed to be located about 10 km north east of the mine site, then undertaken using the peak-over-threshold method
near Wamunon Bay. Table 2 details the physical properties (Goda 1988) based on the modelled wind data. While
of the proposed tailings. the strongest winds are from the southeast direction, the
project location is largely sheltered by land in that direc-
tion; on the other hand, winds from the north-northeast
Location and Bathymetry direction, due largely to the presence of the land, would
The study area is located on the north-eastern shore of likely lead to the strongest wave climate at the site. Table 3
Woodlark Island, at approximately 9.07°S and 152.83°E. details the offshore wind conditions with 200-year return
Woodlark Island is part of the Milne Bay Province in Papua period.
New Guinea, located in the Solomon Sea, approximately To determine the nearshore wave climate along the
160 km east of Papua New Guinea’s main island, as shown proposed pipe route, SWAN was utilized. A compound,
in Figure 7. Figure 8 illustrates the offshore bathymetry at or nested, configuration was created for SWAN. First, a
the project site. coarse grid with 30-m cell size was implemented over
a domain extending to about 18 km from shore. Second,
a fine grid with 5-m cell size was implemented over a
Mixed layer and CTD data much smaller domain within Wamunon Bay, extending to
Draft General Guidelines for DSTP in Papua New Guinea about 350 m from shore in order to provide finer resolution
(SAMS 2010) include the provision that the DSTP pipeline of the wave transformation in the nearshore environment
12 A. T. Y. Leung et al.
Figure 9. Density profile of the water column at the project site derived from CTD measurements.
Figure 10. Wind rose of the offshore wind near the project location.
Table 3. 200-year return period design offshore wind and Figures 11–13 show simulated wave heights and direc-
wave conditions based on modelled results from WAVEWATCH tion from SWAN, for the 200-year design storms from
III.
east, north-northeast, and southeast respectively, as sum-
Signficant marized in Table 4. Vectors in the figures show the domi-
Wind Wind wave Wave nant wave directions. The contoured colours represent the
direction speed height period variation in significant wave height for the given storm
Southeast 16.2 m/s 4.6 m 10.8 sec event. It should be noted that the offshore wave heights
East 15.9 m/s 4.5 m 10.6 sec in these figures are in accord with the 200-year wave
North-Northeast 15.5 m/s 4.3 m 10.4 sec heights calculated by WAVEWATCH III and shown in
Table 3. Depth contours are provided for reference in
the coarse grid domain. Visual comparison of the SWAN
wave heights, wave periods, bottom orbital velocities, as model results confirms that the proposed outfall location
well as assessment of wave shoaling and wave break- is partly sheltered from southeast storms (Figure 13) and
ing location/depths are dependent on the local bathymetry. that the largest local waves and bottom orbital velocities
14 A. T. Y. Leung et al.
Figure 11. Modelled wave conditions with 200-year design storm from the East.
Figure 12. Modelled wave conditions with 200-year design storm from the North-Northeast.
are associated with a storm from the north-northeast 35.7 m, and the corresponding maximum bottom orbital
(Figure 12). velocity is 0.3 m/s. Where the pipeline comes out of the
The wave conditions near shore govern the design sea bottom at around 7 m water depth, the maximum
for trench and riprap protection of the pipes. The vari- significant wave height is 3.2 m with a corresponding max-
ation in depth, wave height, wave period, and bottom imum near bed velocity of 1.1 m/s. Note that the largest
orbital velocity along the pipe route for a design 200- maximum near bed velocity (1.7 m/s) occurs in 2.9 m
year return period storm event from the north-northeast depth where the pipeline will be protected within the
is shown in Figure 14. Note that the maximum signifi- trench by backfill as well as by scour protection (armour
cant wave height (3.4 m) occurs where the water depth is layer).
Journal of Applied Water Engineering and Research 15
Figure 13. Modelled wave conditions with 200-year design storm from the Southeast.
Table 4. 200-year return period design nearshore wave The mix/de-aeration tank is surrounded by soil, except
conditions from SWAN. for on its north side where an access and protection cham-
Wind direction Signficant wave height Wave period ber (about 4 m × 7 m cross section), and about 5.8 m deep
is provided to facilitate access to the nozzles (pipe interface
Southeast 1.0 m 11.1 sec with tank) and isolation valves during regular inspection
East 2.5 m 10.5 sec and maintenance procedures. The walls of this access
North-Northeast 3.4 m 10.3 sec
chamber are 500 mm thick reinforced concrete, supported
by internal struts, anchors, or tie-backs as required. Expe-
rience on similar systems has shown that the seal at this
Currents interface point where the nozzles pass through the walls
The maximum speed observed at a depth of 200 m at of the mix/de-aeration tank may deteriorate over time (i.e.
this point was 0.55 m/s, with an average speed of approx- potential source of leaking, or potential weak point), and
imately 0.10 m/s. These currents represent open ocean thus it is highly recommended that easy access to this point
conditions, whereas the proposed route is sheltered by a is facilitated in design. The intake pipeline and the out-
bay. Therefore, a design current speed of 0.67 m/s, based fall pipeline each have one knife gate valve situated within
on the measured ADCP current data, was judged to be this access chamber, which may be used to isolate the
adequately conservative. Thus a current speed of 0.67 m/s mix/de-aeration tank from the rest of each marine pipeline.
was used for assessing the potential lateral (along-pipe and The tank walls are comprised of 500 mm thick rein-
across pipe) currents along the pipeline during design of forced marine concrete. The mix/de-aeration tank rests on
the ballast blocks. top of a 700 mm thick reinforced concrete slab. A 5.4 m
thick jet grout plug is installed below the mix/de-aeration
tank (below the concrete slab) in order to provide adequate
Engineering – Mix/De-aeration tank weight (downward force) to offset the upward buoyancy
The circular mix/de-aeration tank inside diameter is 8 m forces that will exist due to the displaced groundwater
and the tank walls are 7 m tall. Given that the system below/around the mix/de-aeration tank and also to provide
operates passively, during normal steady-state operating a groundwater cutoff below the structure.
conditions, the operating fluid level in the tank is below The tailings slurry feed pipe and seawater intake pipe
sea level; hence the bottom of the mix/de-aeration tank discharge into a semi-isolated inner mixing chamber (25%
is situated 4.5 m below LLW in order to ensure the oper- of entire mix tank plan view area) that is separated from
ating level in the tank during steady-state operation and the rest of the mix/de-aeration tank by a continuous 3-
during transients remains safely above the top of the outfall segment arching 2 m tall baffle wall (Figure 15). This
pipeline (to prevent vortex formation or air ingestion). baffle wall is designed to encourage efficient mixing of the
16 A. T. Y. Leung et al.
Figure 14. Wave conditions and bottom orbital velocity along the proposed pipe route.
inflowing streams of tailings slurry and seawater, prevent of the pipe located about 0.5 m from the bottom of the
short-circuiting of the tank (i.e. increase the length of the tank.
flow path between the inlet and the outlet of the tank), and
also direct the inflowing tailings/seawater mixture upward
towards the fluid surface level to facilitate detrainment of Engineering – pipe route
any air that may be in the tailings slurry. The inside walls The selected outfall pipe route is based on the mix/de-
of the inner mixing chamber (tank walls and baffle walls) aeration tank location, an assessment of the available
where flows are expected to be most turbulent are lined bathymetric data in the nearshore (shallow water) and
with a ceramic liner, given its superior wear and corrosion offshore (deep water) environments, and the above-noted
resistance. criteria. The selected route is approximately 1,000 m in
The seawater intake pipeline (1,000 mm outside diame- the horizontal plane, and 1,038 m in actual length. The
ter (OD), 814.9 mm inside diameter (ID), HDPE, standard proposed discharge point is 230 m below LLW. Figure 16
diameter ratio (SDR) 11) is connected to the tank via a shows the proposed pipe route overlaid on a contour map
815 mm ID stainless steel nozzle and terminates inside the coloured by the bottom slope in the vicinity of the pipeline
tank with a flap valve in order to prevent any backflow with black lines outlining the depth contours. Figure 17
within the intake pipeline. The bottom of the inside of the illustrates the profile and slope along the proposed pipe
seawater intake pipeline is located about 0.5 m above the route.
bottom of the tank in order to ensure that the intake pipeline
is not at risk of being blocked should any deposition of
tailings solids occur within the tank. Engineering – selection of outfall and seawater intake
The DSTP outfall pipeline (800 mm OD, 651 mm ID, pipes
HDPE, SDR 11) passes through the tank wall, via a 28% Hydraulic analysis and pipe structural analysis were under-
chrome alloy 651 mm ID steel nozzle, with the bottom taken with different combinations of tidal conditions (high
Journal of Applied Water Engineering and Research 17
tide and low tide) and operation process parameters such as Engineering – pipe protection with riprap and trench
solid throughput, solid concentration and process flow rate Depending on the pipe and the existing bed profile, the
to determine the most suitable dimensions for the outfall outfall and seawater intake pipes will either be buried in
and seawater intake pipes, which are detailed in Table 5. an armoured trench or be protected by riprap in order to
18 A. T. Y. Leung et al.
Figure 17. Profile view of and slope along the proposed pipe route.
Table 5. Outfall and seawater intake characteristics for the Table 6. Detail of sizes and distribution of rocks in riprap.
woodlark DSTP systems.
Pipe section Pipe section Pipe section
Outfall pipe Seawater intake 0–42 m 42–122 m 122–142 m
Type PE100, SDR 11 PE100, SDR11, Armour Layer D15 275 mm 1,000 mm 590 mm
HDPE HDPE Armour Layer D50 300 mm 1,100 mm 650 mm
Outside Diameter 800 mm 1,000 mm Armour Layer D85 320 mm 1,200 mm 700 mm
Inside Diameter 651 mm 814.9 m 1st Filter Layer D15 125 mm 465 mm 235 mm
Minimum Wall 72.5 mm 90.3 mm 1st Filter Layer D50 140 mm 510 mm 300 mm
Thickness 1st Filter Layer D85 150 mm 550 mm 330 mm
2nd Filter Layer D15 – 175 mm –
2nd Filter Layer D50 – 190 mm –
2nd Filter Layer D85 – 200 mm –
Table 7. Concrete block ballast requirement for outfall pipe. outfall terminus. At 100 m downstream the terminus, flux-
averaged dilutions of 473:1 are achieved. Finally, at 120 m
Number of
Chainage Nominal ballast Mass of downstream from the outfall terminus, at the downstream
along ballast block blocks in ballast block boundary of the fine-grid model, flux-averaged dilutions of
pipeline spacing section in air 639:1 are observed. Vectors are shown on these figures,
enabling one to observe the pathway of the density cur-
0 - 140 m 6.5 m 23 1,701 kg
140–290 m 5.2 m 29 1,701 kg rent as it moves downslope away from the outfall pipeline
290–1,002 m 6.0 m 119 1,701 kg discharge location. The thickness of the density current
(Figure 21) reaches an average of 0.47 m height at 10 m
downstream of the outfall terminus and up to 2.90 m height
Table 8. Concrete block ballast requirement for seawater intake when reaching the northeast boundary of the model domain
pipe. about 120 m downstream from the terminus.
Number of The depositional footprint within the near field domain
Chainage Nominal ballast Mass of is shown in Figure 22. The velocity of the density cur-
along ballast block blocks in ballast block rent exiting the pipeline is about 3.0 m/s. The central core
pipeline spacing section in air of the density current maintains a relatively high veloc-
ity as it exits the pipe. In comparison, the flow along the
0–140 m 5.0 m 31 1,914 kg
140–296 m 4.2 m 38 1,914 kg two outer boundaries, to either side of the main core of
the density current, is relatively slower. This results in the
formation of small transient levees along the lateral bound-
Table 9. Density current dilution at various distances from aries of the density current’s predominant pathline. The
outfall. height of the levees are limited, and hence they levees are
transient, because once they are tall enough to exceed a
Distance from Flux-averaged Plume centre-line
outfall dilution dilution critical slope, they then collapse into the main core of the
flow where the high turbulence and velocity carry the col-
10 m 22 19 lapsed sediment away from the pipe. The levee growth and
20 m 42 36 failure cycle is simulated in the model – levees grow until
30 m 149 122
40 m 473 355 the slope exceeds the angle of repose, at which point they
50 m 639 473 then collapse and begin to grow again. The angle of repose
is considerably less than the angle of repose in stationary
water due to the velocity of the flow.
which the stabilizing force is provided by the overburden Since the required dilution has been achieved in the
from trenched material and/or riprap. near-field, far-field density current model and sub-sea
plume model were required.
Figure 20. Modelled dilution of the nearfield density current. Figure 21. Modelled thickness of the nearfield density current.
Journal of Applied Water Engineering and Research 21
NF. He has also worked on several other underwater out- tors. North Sea Dynamics. Heidelberg: Springer-Verlag; p.
fall designs, developing and exercising numerical tools 63–84.
to assess pipe strength during installation and sinking. Coumans C. 2006. Summary of findings from environmental
studies of Calancan bay related to surface disposal dump-
He holds a Master’s Degree in hydrotechnical engineer- ing of mine tailings into the bay from the Tapian Pit of the
ing, and has experience in a variety of oceanographic and Marcopper Mine. MiningWatch Canada.
hydraulic engineering projects and 3-D modelling. He has Duwe KC, Hewer RR, Backhaus JO. 1983. Results of a semi-
developed numerical tools and models for underwater pipe implicit two-step method for the simulation of markedly
installation, breakwater moorings, project prioritization, non-linear flow in coastal seas. Cont Shelf Res. 2:255–274.
Ellison TH, Turner JS. 1959. Turbulent entrainment in stratified
wastewater chemistry and more. flow. J Fluid Mech. 6:423–448.
Dr. Stronach is a Principal Technical Specialist and Goda Y. 1988. On the methodology of selecting design wave
height. Proc. 21st International Conference on Coastal Engi-
Senior Physical Oceanographer with EBA, A Tetra Tech neering; 1988; Torremolinos, Spain: 899-913.
Company in Vancouver, BC. He has over 34 years of Hay AE. 1982. The effects of submarine channels on mine tailings
experience in physical oceanography and marine engi- disposal in Rupert inlet, BC. Mar Tailings Disposal. 5:139–
neering, including the design and implementation of field 182.
programmes, data processing, software development and Hurzeler BE, Imberger J, Ivey GN. 1996. Dynamics of turbidity
current with reversing buoyancy. J. Hydr. Engrg. 122:230–
numerical modelling of three-dimensional hydrodynamics 236.
and related transport of waste water, tailings, pollutants Jain SC, Kennedy JF. 1984. Near-field model study of mine-
and sediments in complex waterways. Dr. Stronach has tailings discharged into a fjord. Institute of Hydraulic
also designed large marine outfalls, developed a compre- Research, University of Iowa, USA.
hensive sediment transport model for rivers, lakes and Kampf J, Backhaus JO. 1999. Ice-ocean interactiofns dur-
ing shallow convection under conditions of steady winds:
marine environments, and has recently developed a com- three-dimensional numerical studies. Deep-Sea Res Pt II.
prehensive oil spill model that was used for environmental 46:1335–1355.
assessments and permit applications for the three major Rajaratnam R, Pani BS. 1974. Three-dimensional turbulent wall
hydrocarbon transportation projects on the west coast of jets. Journal of the hydraulics division. Am Soc Civil Eng.
Canada. 100:69–83.
Rego JL, Meselhe E, Stronach J, Habib E. 2010. Numerical
Mr. Thompson is a marine construction specialist with modelling of the Mississippi-Atchafalaya rivers’ sediment
over 30 years of experience in land and marine pipeline transport and fate: considerations for diversion scenarios. J
Coastal Res. 26:212–229.
construction and related underwater technology. VMC Ltd. SAMS 2010. Final report: independent evaluation of deep-sea
has introduced many innovative solutions to pipeline prob- mine tailings placement in PNG.
lems. Mr. Thompson is the inventor and holder of the US Sarpkaya T, Issacson M. 1981. Mechanics of Wave Forces on Off-
Patent 6,357,966 for his Ballasting Method and Appara- shore Structures. New York, NY: Van Nostrand Reinhold
tus for the Installation of Synthetic Underwater Pipelines. Co.
Saucier FJ, Roy F, Gilbert D, Pellerin P, Ritchie H. 2003. The
Prior to forming VMC, Mr. Thompson worked as a Diver formation of water masses and sea ice in the Gulf of St.
and Marine Construction Manager for several Canadian Lawrence. J Geophys Res. 108(C8):3269–3289.
diving and construction companies. Mr. Thompson has Stronach JA, Backhaus JO, Murty TS. 1993. An update on
been involved with various subsea tailings and pipeline the numerical simulation of oceanographic processes in the
projects worldwide. waters between Vancouver Island and the mainland: the G8
model. Oceanogr Mar Biol. 31:1–86.
Stronach JA, Gardiner SRM, Zhang Y, Schriek WS. 2000. Sub-
marine mine tailing fate. Can. J Chem. Eng. 78:770–779.
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