OPERATIONAL PHILOSOPHY & LOCATION OF DUST MITIGATION SYSTEMS -TRANSNET PORT TERMINALS, SALDANHA TERMINAL

Transcription

1 OPERATIONAL PHILOSOPHY & LOCATION OF DUST MITIGATION SYSTEMS -TRANSNET PORT TERMINALS, SALDANHA TERMINAL Prepared by: Debby-Jo Ford Sherq Officer

2 TABLE OF CONTENTS 1. INTRODUCTION 2. PURPOSE 3. TERMINOLOGY & ABBREVIATIONS 4. EXISTING DUST MITIGATION SYSTEMS AND OPERATIONAL PHILOSOPHY 4.1 Tippler Dust Extraction Plants 4.2 Emergency Wetting Sprayers in front of Tipplers 4.3 Chemical Spray/Dosing Systems 4.4 Transfer Chute Spray Systems Enclosed Material Transfer Wetting Sprayers Atomising (Fogging) Sprays Head and Discharge 4.5 Stockpile Water Canons/ Sprinklers 4.6 Stacker/Reclaimer Suppression Systems Stacker/Reclaimer Transfer Chutes Stacking Spray System Reclaiming Spray System 4.7 Online Moisture Monitoring & Control 4.8 Conveyor Dust Covers 4.9 Belt Cleaning Scrapers Belt turn-over Atomising Sprays 4.10 Emergency Wetting Sprayers on CV114 & CV Housekeeping Road Treatment Spillage Handling 5. LOCATION OF EXISTING DUST MITIGATION SYSTEMS 5.1 Tippler 1 & CV & CV Transfer Chutes & Chemical Sprays 5.3 CV & CV Transfer Chutes 5.4 CV110, 117, 118, 119 & CV210, 217, 218, 219 Moving Head Chutes 5.5 Stockyard Conveyor Feed Chutes - CV111, 140, 112, 116, Stockpile Stockyard 5.7 Stacker / Reclaimer SR1, SR2 & SR3 5.8 Stacker / Reclaimer SR4 5.9 Stockyard Conveyor Moving Head Chutes (MHC) 5.10 Existing/Old Sampling Building 5.11 Moisture Control Sprayers System 5.12 New Sampling Building 5.13 Point J/Emergency sprayers Transfer Point from CV114 & 214 to CV115 & Stacker at CV305 Head Chute to Mittal Steel FIGURES: Figure 5-1 TPT-SLD Site Plot Plan TP1 & TP2 Figure 5-2 TPT-SLD Site Plot Plan Transfer Chute & Chemical Sprays Figure 5-3 TPT-SLD Site Plot Plan CV & CV Transfer Chutes Figure 5-4 TPT-SLD Site Plot Plan Moving Head Chutes Figure 5-5 TPT-SLD Site Plot Plan Stockyard Conveyor Feed Chutes Figure 5-6 TPT-SLD Site Plot Plan Stockpile Stockyard Figure 5-7 TPT-SLD Site Plot Plan Stacker/Reclaimers 1, 2 & 3 Figure 5-8 TPT-SLD Site Plot Plan - Stacker/Reclaimer 4 Figure 5-9 TPT-SLD Site Plot Plan Stockyard Conveyor Moving Head Chutes

3 Figure 5-10 Figure 5-11 Figure 5-12 Figure 5-13 Figure 5-14 TPT-SLD Site Plot Plan Existing/Old Sampling Building TPT-SLD Site Plot Plan Moisture Control Sprayers Network TPT-SLD Site Plot Plan New Sampling Building TPT-SLD Site Plot Plan Point J/ Emergency sprayers TPT-SLD Site Plot Plan Feed Chute on Mittal steel CV TABLES: Table 5-1 Existing Mitigation Systems TP1 & TP2 Table 5-2 Existing Mitigation Systems Transfer Chute & Chemical Sprays Table 5-3 Existing Mitigation Systems CV & CV Transfer Chutes Table 5-4 Existing Mitigation Systems Moving Head Chutes Table 5-5 Existing Mitigation Systems Stockyard Conveyor Feed Chutes Table 5-6 Existing Mitigation Systems Stockpile Stockyard Table 5-7 Existing Mitigation Systems Stacker/Reclaimers 1, 2 & 3 Table 5-8 Existing Mitigation Systems Stacker/Reclaimer 4 Table 5-9 Existing Mitigation Systems Stockyard Conveyor Moving Head Chutes Table 5-10 Existing Mitigation Systems Existing/Old Sampling Building Table 5-11 Existing Mitigation Systems Moisture Control Sprayers Network Table 5-12 Existing Mitigation Systems New Sampling Building Table 5-13 Existing Mitigation System- Point J/ Emergency sprayers Table 5-14 Existing Mitigation System- Feed Chute on Mittal steel CV 6. REFERENCES 7. TPT-SLD Site Plot Plan with Dust Mitigation Measures

4 1. INTRODUCTION Transnet Port Terminal, Saldanha Terminal (TPT-SLD) was issued with a Record of Decision (Environmental Authorisation) by the Department of Environmental Affairs and Tourism (DEAT) in 2002 for the initial increase from 26 Million Tons Per Annum (MTPA) to 38MTPA (Phase 1A). Again in 2006, DEAT issued a Record of Decision for the further expansion of the ports capacity from 38MTPA to 47MTPA (Phase 1 B).Dust issues were highlighted as a major concern for local communities in the Public Participation Processes of the Environmental Impact Assessments (EIA) conducted for the initial expansions. The recommendations from public, specialists and Environmental Assessment Practitioners relating to the management of dust to reduce the negative impact on the surrounding landowners ultimately formed the basis for the conditions stipulated in the Environmental Authorisation. In addition to the Environmental Authorisation, the Air Quality Permits issued to TPT- SLD for the handling of iron ore also specifies specific conditions to which the operations must comply. At TPT-SLD the finer grades of iron ore typically arrive in the rail wagons with a significant amount of intrinsic moisture and thus do not require additional water application. A reason for the finer ore having better moisture retention is due the increased surface area afforded by the smaller ore grains. In contrast to the finer ore grades the lumpier ore grades do require water addition for dust suppression. Various dust mitigation systems and measures have been implemented to manage dust at TPT-SLD as part of the Phase 1A and 1B expansions. Although the dust measurements in the surrounding areas of the port have not shown an increase in dust fallout, it is important to take note that more complaints and claims from residence are being filed against TPT-SLD for dust fall out. There is thus a need to determine the functionality and effectiveness of existing dust mitigation systems and adherence to the operational philosophies.

5 2. PURPOSE The intent of this document is to serve as a guideline for determining the functionality, effectiveness and adherence to the operational philosophies of the existing dust mitigation systems in decreasing the dust generated by TPT-SLD operations. TPT-SLD will have a stronger case to defend themselves against any future claims for dust fallout or at least experience a decrease in the frequency of the complaints and claims, if seen to properly mitigate the dust generated. 3. TERMINOLOGY & ABBREVIATIONS 3.1 TERMINOLOGY Dust Mitigation System A system of hardware that is permanently installed at, or near to the source of the dust, in order to suppress or reduce the concentration of dust that is emitted into the atmosphere. Proactive in terms of addressing the source of dust or spillage. Housekeeping A protocol that is set into action in order to contain the dust or spillage that results from the utilisation of that area. Reactive action, in terms of addressing the results as opposed to the source. Carry back A term utilised to describe the material that remains on the return side of the conveyor belt after the majority of the material has been transferred into the desired chute. The carry back material is generally as a result of adhesion between the conveyor and part of the transferred material. Spillage Material that is not contained by the conveying system but is cast from the belt and deposited on the floor, where it remains and becomes a source of dust. 3.2 ABBREVIATIONS TPT-SLD: CCR: CV: MHC: LF: PLC: PID: Transnet Port Terminal, Saldanha Terminal Central Control Room Conveyor Moving Head Chute Low Frequency Programmable Logic Controller (Controls the plant automatically) Refers to a controller, Proportional, Integral, Derivative

6 4. EXISTING MITIGATION SYSTEMS & OPERATIONAL PHILOSOPHY The different types of dust suppression systems installed to suppress dust at TPT-SLD are detailed and depicted below along with their operational philosophies Tippler Dust Extraction Plants Ore is offloaded at two tipplers. Each Tippler is equipped with an automatic dust extraction system, to extract the dust generated during the tipping of wagons and offloading of ore. The dust is extracted through filters and residual emissions are released through the dust extraction stacks, which are equipped with dust particle monitoring systems. The extracted dust is swept from the filters to the silo by means of airflow and removed in dust bags or by the vacuum truck to the mixed-grade stockpile. *Picture of Tippler & Dust Extraction Plant 4.2. Emergency Wetting Sprayers in front of Tipplers If the Tippler Dust Extraction System is non-functional, all wagons containing lumpy ore must be wet by means of the Emergency Wetting Sprayers, located in front of the Tipplers, prior to tipping. The Emergency Wetting Sprays are manually activated by the Tippler Operator. *Picture of Emergency Wetting Sprays in front of Tipplers

7 4.3. Chemical Sprayers/Dosing Systems Two Chemical Dosing Plants were installed at both Tipplers. One Chemical Dosing Plant is situated in the Tippler 1 area and sprays in the CV109 Head Chute; the other Chemical Dosing Plant is situated in the Tipplers 2 area and sprays in CV209 Head Chute. These dosing systems utilise three wetting sprays to add a mixture of water and surfactant to the ore. The surfactant sourced from Samchem, is a dust suppression agent that is formulated from hydrocarbons and stabilising agents and is designed to allow easy penetration of water through bulk material as well as to improve the wetting properties of the water. The dosing system is automated according to the ore type, which is inputted by the Tippler Operator, and the Chemical Dosing Plants activate according to the type of ore being unloaded at the Tipplers. The amount of water and surfactant added is controlled according to the tonnage of ore on the conveyor belt in order to keep the ratio constant. The tonnage is calculated according to the ore level which is detected by an ultrasonic sensor. Another Chemical Dosing Plant is operated by Kumba at the Old Sampling Building. This plant adds water and surfactant to the ore on CV113 and CV213 and is manually controlled by Kumba. There is no control or feedback on the operation of this plant to the TPT-SLD system. *Picture of Chemical Dosing Plant and Wetting Sprayers at Tipplers & Old Sampling Building

8 4.4 Transfer Chute Spray Systems The dust generated at the transfer chutes is suppressed through the utilisation of three systems Enclosed Material Transfer The transfer chute is designed such that the material is completely enclosed by plate work while being transferred from one conveyor to the other. This plate work not only contains the dust but also ensures that minimal to no spillage occurs. All the transfer chutes at TPT-SLD are designed as enclosed chutes. *Picture of Enclosed Material Transfer Chute Wetting Sprayers The function of the wetting sprays is to inject water into the ore to increase the moisture content thereof on the conveyor belts when required. There are 3 wetting nozzles per transfer point. The wetting sprays are always in manual mode and are activated by the CCR Operator when additional ore moisture is required. Should a spray be activated when the conveyor belt is not running, the system will automatically deactivate the spray after 2 minutes. This ensures that a wetting spray is not left on while a conveyor belt is stationary which would result in a pool of water on the belt. The wetting sprays are to be managed by analyzing the moisture of the transferred ore via online moisture analyzers which will provide input to the control valves as when to add and when not to add water. The moisture analyzers are discussed in Section 4.7. *Picture of Wetting Sprays

9 4.4.3 Atomising (Fogging) Sprays Head and Discharge The primary function of the atomising sprays is to seal or render each transfer chute closed so that none of the dust created in the ore transfer from one conveyor to another escapes the chute. This is accomplished by providing a fine mist of water particles at the entrance and exit of each conveyor transfer chute. The water particles bond to the suspended dust particles and increase their mass. This forces the particles to settle. The atomising sprays are not intended to add moisture to the ore as they are not designed like the wetting sprays which penetrate the ore body on the conveyors; and the moisture that does in fact impact the ore body quickly evaporates some distance along the conveyor. The atomising sprays should always be in automatic mode, thus they will activate when the conveyor belt starts and spray regardless of the ore type and whether there is ore on the belt or not. The atomisers are to be operational regardless of the weather. *Picture of Atomising Sprays 4.5 Stockpile Water Canons/ Sprinklers The water cannon system is mainly used to wet the stockpile skin layer (surface 300mm) which then acts as a wind barrier to prevent dust from being blown off the surface of the stockpiles. The water cannons are manually operated by CCR in the early morning when the wind is at its calmest and preference is given to stockpiles that are to be reclaimed during the day. Several sprinklers must be operated simultaneously to wet the relevant stockpile area. Specific stockpile sprinklers in the direct vicinity of the Stacker-Reclaimer are used before and during reclaiming from lump ore stockpiles. *Picture of Stockpile Water Canons

10 4.6 Stacker/Reclaimer Suppression Systems All suppression systems on the Stacker/Reclaimers are controlled by the Machine Operator and it is at Operator discretion or by instruction that the systems are activated or not Stacker/Reclaimer Transfer Chutes The transfer chutes on the Stacker/Reclaimers are the similar to the transfer chutes around the port. The tripper chute, the boom feed chute and the centre chute generate dust when material is transferred through them. These chutes are designed to enclose the material that is transferred and utilise atomising sprays to suppress any generated dust. The atomising sprays have the same operating philosophy as previously mentioned Stacking Spray System The stacking of iron ore onto the stockpile is essentially an open transfer of material; hence any dust generated in this process, immediately escapes into the atmosphere. The suppression system applied here is a wetting spray bar that increases the moisture content of the ore before leaving the boom conveyor. The wetting sprays have the same operating philosophy as previously mentioned Reclaiming Spray System The systems installed to suppress the dust generated through the reclamation process are the bucket wheel atomising sprays and a water spray system. The bucket wheel atomising sprays function the same as the transfer chute atomising sprays, by creating a mist to suppress any dust particles already suspended in the air, whilst the water spray system ensures that the ore has sufficient moisture content. *Picture of Reclaiming Spray System

11 4.7. Online Moisture Monitoring & Control The moisture content of the ore has a direct bearing on the amount of dust generated during the handling thereof. The moisture content of fine ores is generally high, in the order of 3.5%. Fine Ores retain their moisture better than the lumpy ores and are observed to generate less dust at the points of handling. Lumpy ores have lower moisture contents and thus tend to generate more dust during handling. It is therefore important to keep the moisture content of the ores a high as possible as this will minimise the amount of dust generated during the handling. The maximum allowable moisture content of the ore is set out in contracts with the iron ore Purchasers, and Kumba is charged penalties if the moisture content exceeds this value. The limit currently set for the maximum moisture content of lumpy ores is 1.2%. The aim of this Online Moisture Monitoring and Control System is to keep the moisture content of the ore as high as possible without exceeding the maximum allowable moisture content. The moisture content of the ore is measured by two LF Microwave Moisture Analysers mounted on CV114 and CV214. The wetting sprayers on the shipside conveyor transfer points i.e.: CV116/113, CV116/213, CV112/113, CV112/213, CV111/113 and CV111/213; the wetting sprayers at the tail end of the direct loading conveyor CV140; and the two Moisture/ Flow Control Wetting Sprayers on CV113 and CV213 are considered as the Moisture Control Sprayers System and are controlled by the Online Moisture Analysers. Water will be added to the ore if the moisture analyser readings fall below 0.8% and stopped when it reaches 1.2%. The system consists of two streams, CV113 Moisture Control and CV213 Moisture Control. The moisture measurement for each of the controllers is selected automatically depending on the conveyor route to be used; i.e. if CV113 is feeding onto CV214, Moisture Analyser CV214 is used for moisture control. Water addition via Moisture/ Flow Control Wetting Sprayers is controlled on conveyors CV-113 and CV-213 depending on route selection to either CV-114 or CV-214 or both. When the moisture value readings of the ore, received from the Moisture Analysers, is below set point (too low), the Moisture/ Flow Control Valve opening will be increased to add more water to the ore. When the moisture value readings is above set point (too high), the Moisture/ Flow Control Valve opening will be decreased to add less water to the ore. By changing the size of the valve opening, the correct moisture value can be achieved. If changes to the Moisture/ Flow Control Valve opening cannot achieve the correct moisture value, the following will take place: Moisture Value too low If the ore is exceptionally dry and the Moisture/ Flow Control Valve has been fully open and the moisture value is still too low, the PLC will open one of the wetting valves associated with the conveyor feeding onto CV113/213 to increase the ore moisture content. The Moisture/ Flow Control Valve opening will be set to 50% and PID control will resume. If the moisture remains too low, another Wetting valve will be opened. This scenario will be repeated for the maximum of 4 wetting valves. Moisture Value too high If the ore is too wet and the Moisture/ Flow Control Valve has been fully closed and the moisture value is still too high, the PLC will close one of the opened wetting valves to limit the amount of moisture added. The Moisture/ Flow Control Valve opening will be set to 50% and PID control will resume. If the moisture remains too high, another Wetting valve will be closed. This scenario will be repeated till all Wetting valves are closed.

12 *Picture of Moisture analyzers mounted on conveyors CV-114 and CV Conveyor Dust Covers Each conveyor, with the exception of CV305, is covered with dust covers where practical. The purpose of the dust covers is to limit the amount of dust picked up off the conveyors by cross winds; to allow for better moisture management by keeping the ore sheltered from the rain and protected against ore moisture evaporation in the sun. *Picture of Conveyor Dust Covers

13 4.9. Belt Cleaning Belt cleaning is installed to address the source of the dust generation from the return side of the conveyor belts. Two systems are utilised to address different sides to the carry back material that remains on the return side of the conveyor Scrapers The scrapers are installed to eliminate, as far as reasonably possible the material on the return side of the conveyor belt. The scrapers are addressed from an operational maintenance point of view. The maintenance philosophy for scrapers is that an outside contractor is appointed to perform the required maintenance and report back to the port on a weekly basis detailing their actions. Belt scrapers are critical and require specific skills to be maintained properly. *Picture of Scrapers Belt turn-over Atomising Sprays Atomising sprays are installed at the belt turn-over points on CV114 and CV214 to clean the dirty under-side of the belt in order to ensure any carry back material is not kicked off as dust when the belt is turned back over. Belt turn-over sprays are always in automatic mode and will turn on when the conveyor belt starts. The sprays wet the underside of the belt regardless of whether ore is being transferred on the conveyor or not and are to be operational regardless of the weather. These sprays will not add any moisture to the ore as they are only used to clean the conveyor belt. *Picture of Belt Wetting Sprays/ Turn-over Spray

14 4.10. Emergency Wetting Sprayers on CV114 & 214 Under normal circumstances no water can be added to the ore after the New Sampling Plant with the exception of the Emergency Wetting Sprayers at the head end of CV114 and CV214. The Emergency Sprayers are employed when CV114 and CV214 have stopped under load (tripped) and the ore dries out while on the conveyors, resulting in excessive dust at the Shiploaders when the conveyors are restarted. The Emergency Wetting Sprayer will add moisture for approximately 10 minutes on belt restart. The moisture content added by these sprayers are recorded by calibrated Flow meters which return the recorded information to the New Sampling Plant for noting on export log Housekeeping Housekeeping is inclusive of all measures to maintain the tidiness of TPT-SLD. The Port has an assigned team, the Operations crew, which are tasked with collecting all spilled ore and removing it to the Mixed-grade stockpile Road Treatment In dry conditions, vehicles moving over the roads result in a concentrated and highly visible clouds of dust. In wet conditions, vehicles cause mud to be splashed onto the undercarriage; this mud is then transported out of the port where it dries and becomes another potential dust source. In both cases, the root of the situation is a fine powder ore on the surface of the roads which is agitated when vehicles move over the roads. The above issues are addressed through the utilisation of three systems. Sweeper truck A sweeper truck is utilised to lift the dust from the surface of the road. The operation of the truck is controlled by the Operations manager and should be in operation on a daily basis. *Picture of Sweeper truck Water truck A water truck is utilised to wet the surface of the road to suppress the dust generated by vehicular movement. Rota foam, a dust suppressant, is applied to all roads surface on a weekly basis by means of the water truck. The operation of the truck is controlled by the Environmental Manager and should be in operation on a daily basis.

15 *Picture of Water truck Wash bays The Wash bay at the Procurement Offices is used to clean operational vehicles and the Wash bay at the Main Gate is used to clean all dirty vehicles before they exist the port, in order to prevent the spread of ore mud by vehicles outside of the port boundaries. The operation of the Wash Bay is controlled by the Operations Manager and should be in operation on a daily basis. *Picture of Wash bay at Main Gate Spillage Handling Spillage is a significant contributor to the dust that is generated from TPT-SLD and ensuring the tidiness of the site is a key aspect in dust reduction. The philosophy around handling spillage is twofold. The source of the spillage needs to be eliminated as far as reasonably possible, and the ore that is spilled needs to be timeously collected and removed through the utilisation of the following systems. Vacuum truck Ore is often kicked off the belts by return idlers, bend pulleys and scrapers. This is then collected and piled in a location by the Operations crew such that it can be removed. These piles, when exposed to dry weather and high wind velocities are a potential dust generation point. The function of the vacuum truck is to collect the fine spillage from hard to access areas, remove it and then dump it at the Mixed-grade stockpile. The vacuum truck does not collect course ores as it causes excessive wear in the vacuum truck s components. The vacuum truck is to operate, along with Operations crew, every day in order to reduce the time that spillage stands and is exposed, thus reducing the dust generated from the spillage.

16 The vacuum truck can also plug into vacuum pipes installed at the Tipplers and the Shiploaders in order to clean these areas. Volvo front-end loader & tipper truck The front-end loader and tipper truck are utilised to collect major volumes of spillages that occur at TPT-SLD. The Volvo and tipper truck are to operate every day, in order to reduce the time major spillages stand and are exposed to the atmosphere, thus reducing the dust generating potential of the spillage. Bobcat The function of the Bobcat is to collect spillages that are in areas where the Volvo front-end loader can t access. They then pile the spillage such that it can be removed by the Volvo front-end loader. The Bobcats are to operate daily in order to remove any spillage and minimise their potential for dust generation. Operations Crew The Operations crew utilise spades to collect and pile spillages around the chutes and conveyors so that it can be removed by the larger equipment. They are assigned to collect the ore that is in positions were the trucks and loaders cannot reach and pile it such that it can be removed. They are to operate in normal working hours every day in order to make the spilled ore available for removal. IF ALL MITIGATION MEASURES AND BACKUP OPTIONS ARE EXHAUSTED, OPERATIONS WILL BE HALTED UNTIL CORRECTED.

17 5. LOCATION OF EXISTING MITIGATION SYSTEMS ON SALDANHA TERMINAL PLOT PLAN

18 5.1 Tippler 1 & 2 Location on plot: Legend: Existing Mitigation Systems: Figure 5-1 TPT-SLD Site Plot Plan TP1 & TP2 Dust Source In front of Tipplers Tippler 1 Tippler 2 Mitigation Hardware 3 Emergency Wetting Sprayers Dust Extraction Plant Dust Extraction Plant Table 5-1- TP1 & TP2

19 5.2 CV & CV Transfer Chutes & Chemical Sprays Location on plot: Legend: Figure 5-2 TPT-SLD Site Plot Plan Transfer Chute & Chemical Sprays Existing Mitigation Systems: Dust Source Mitigation Hardware CV Transfer Chute 3 Chemical Dosing Sprays (CS) 6 Head Chute Atomising Nozzles (A) 6 Discharge Chute Atomising Nozzles (A) (W) CV Transfer Chute 3 Chemical Dosing Sprays (CS) 6 Head Chute Atomising Nozzles (A) 6 Discharge Chute Atomising Nozzles (A) (W) Table 5-2 Existing Mitigation Systems Transfer Chute & Chemical Sprays

20 5.3 CV & CV Transfer Chutes Location on plot: Legend: Figure 5-3 TPT-SLD Site Plot Plan CV & CV Transfer Chute Existing Mitigation Systems: Dust Source CV Transfer Chute Mitigation Hardware 6 Discharge Chute Atomising Nozzles CV Transfer Chute 6 Discharge Chute Atomising Nozzles Table 5-3 Existing Mitigation Systems CV110/305 & CV210/305 Transfer Chute

21 5.4 CV110, 117, 118, 119 & CV210, 217, 218, 219 Moving Head Chutes Location on plot: Legend: Figure 5-4 TPT-SLD Site Plot Plan Moving Head Chutes Existing Mitigation Systems: Dust Source CV110 CV117 CV118 CV119 CV210 CV217 CV218 CV219 Mitigation Hardware Moving Head Chutes 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 6 Head Chute Atomising Nozzles Table 5-4 Existing Mitigation Systems Moving Head Chutes

22 5.5 Stockyard Conveyor Feed Chutes- CV111, 140, 112, 116, 120 Location on plot: Legend: Existing Mitigation Systems: Figure 5-5 TPT-SLD Site Plot Plan Stockyard Conveyor Feed Chutes Dust Source CV CV CV CV CV CV CV CV Mitigation Hardware CV111 & 140 Feed Chute Discharge

23 CV CV CV CV CV CV CV CV CV CV CV112 Feed Chute Discharge CV116 Feed Chute Discharge CV120 Feed Chute Discharge Table 5-5 Existing Mitigation Systems Stockyard Conveyor Feed Chute

24 5.6 Stockpile Stockyard Location on plot: Legend: Figure 5-6 TPT-SLD Site Plot Plan Stockpile Stockyard Existing Mitigation Systems: Dust Source Stockpile Water Cannons Mitigation Hardware Sprinkler every 50m (WC) Table 5-6 Existing Mitigation Systems Stockpile Stockyard

25 5.7 Stacker / Reclaimer SR1, SR2 & SR3 Location on plot: Legend: Existing Mitigation Systems: Dust Source Centre Chute Bucket Wheel Stockpile Water Cannons Tripper Chute Boom Feed Chute Boom Figure 5-7 TPT-SLD Site Plot Plan Stacker/Reclaimers 1, 2 & 3 Mitigation Hardware SR1, 2 & 3 - When Reclaiming, the following chutes are utilised 2 Head Chute Atomising Nozzles (same Nozzles as utilised for stacking) 6 Discharge Chute Atomising Nozzles 6 Reclamation Nozzles (Operator controlled) Sprinkler every 50m SR1, 2 & 3 - When Stacking, the following chutes are utilised 4 Head Chute Atomising Nozzles No Discharge Chute Atomisers 4 Head Chute Atomising Nozzles 2 Discharge Chute Atomising Nozzles 6 Atomising Nozzles Table 5-7 Existing Mitigation Systems Stacker/Reclaimers 1, 2 & 3

26 5.8 Stacker / Reclaimer -SR4 Location on plot: Legend: Figure 5-8 TPT-SLD Site Plot Plan Stacker/Reclaimer 4 Existing Mitigation Systems: Dust Source Mitigation Hardware When Reclaiming, the following chutes are utilised Centre Chute Bucket Wheel Stockpile Water Cannons Tripper Chute Boom Feed Chute Boom 3 Head Chute Atomising Nozzles (Operator controlled) 6 Discharge Chute Atomising Nozzles (Operator controlled) 6 Reclamation Nozzles (Operator controlled) Water Cannon every 50m When Stacking, the following chutes are utilised 4 Head Chute Atomising Nozzles No Discharge Chute Atomisers 4 Head Chute Atomising Nozzles 3 Discharge Chute Atomising Nozzles (Operator controlled) 1 Wetting spray (Operator controlled) 1 Extended arm wetting spray (Operator controlled) Table 5-8 Existing Mitigation Systems Stacker/Reclaimer 4

27 5.9 Stockyard Conveyor Moving Head Chutes (MHC) Location on plot: Legend: Figure 5-9 TPT-SLD Site Plot Plan Stockyard Conveyor Moving Head Chutes Existing Mitigation Systems: Dust Source CV /213 MHC Mitigation Hardware CV111-CV113/213 Moving Head Chute (MHC) 6 Head Chute Atomising Nozzles CV Discharge CV Discharge CV /213 MHC 6 Discharge Chute Atomising Nozzles 6 Discharge Chute Atomising Nozzles CV140-CV113/213 Moving Head Chute (MHC) 6 Head Chute Atomising Nozzles CV Discharge 6 Discharge Chute Atomising Nozzles CV Discharge 6 Discharge Chute Atomising Nozzles

28 CV /213 MHC CV112-CV113/213 Moving Head Chute (MHC) 6 Head Chute Atomising Nozzles CV Discharge CV Discharge CV /213 MHC 6 Discharge Chute Atomising Nozzles 6 Discharge Chute Atomising Nozzles CV116-CV113/213 Moving Head Chute (MHC) 6 Head Chute Atomising Nozzles CV Discharge 6 Discharge Chute Atomising Nozzles CV Discharge CV /223 MHC CV Discharge CV Discharge 6 Discharge Chute Atomising Nozzles CV120-CV123/223 Moving Head Chute (MHC) 6 Head Chute Atomising Nozzles 6 Discharge Chute Atomising Nozzles 6 Discharge Chute Atomising Nozzles Table 5-9 Existing Mitigation Systems Stockyard Conveyor Moving Head Chutes

29 5.10 Existing/Old Sampling Building Location on plot: Legend: Existing Mitigation Systems: Dust Source CV Transfer Chute CV Transfer Chute CV Transfer Chute Figure 5-10 TPT-SLD Site Plot Plan Existing/Old Sampling Building Mitigation Hardware 8 Discharge Chute Atomising Nozzles 2 Head Chute Atomising Nozzles 8 Discharge Chute Atomising Nozzles 2 Head Chute Atomising Nozzles (Same nozzles utilised for 113 HCA) 3 Wetting Spray 8 Discharge Chute Atomising Nozzles 2 Head Chute Atomising Nozzles CV Transfer Chute 3 Wetting Spray Nozzles 8 Discharge Chute Atomising Nozzles 2 Head Chute Atomising Nozzles (Same as above mentioned 213 HCA) CV113 3 Kumba Chemical Dosing Nozzles per conveyor CV213 3 Kumba Chemical Dosing Nozzles per conveyor Table 5-10 Existing Mitigation Systems Existing/Old Sampling Building

30 5.11 Moisture Control Sprayer System Location on plot: Legend: Figure 5-11 TPT-Existing Mitigation Systems- Moisture Control Sprayer Network Dust Source CV114 CV214 Mitigation Hardware Moisture Control Sprayers LF Microwave Moisture Analysers LF Microwave Moisture Analysers CV Discharge (Same as mentioned in 5.9) CV Discharge (Same as mentioned in 5.9) CV Discharge (Same as mentioned in 5.9) CV Discharge (Same as mentioned in 5.9) CV Discharge (Same as mentioned in 5.9) CV Discharge (Same as mentioned in 5.9) CV Discharge (Same as mentioned in 5.5) CV113 Moisture/ Flow Control Wetting Sprayers CV213 Moisture/ Flow Control Wetting Sprayers Table 5-11: Existing Mitigation System- Moisture Control Sprayer Network

31 5.12 New Sampling Building Location on plot: Legend: Figure 5-12 TPT-SLD Site Plot Plan New Sampling Building Existing Mitigation Systems: CV114 CV214 Dust Source Mitigation hardware 3 Return Belt Wetting Sprays Nozzles Nozzles 8 Discharge Chute Atomising Nozzles 6 Head Chute Atomising Nozzles 3 Return Belt Wetting Sprays Nozzles Nozzles 8 Discharge Chute Atomising Nozzles 6 Head Chute Atomising Nozzles Table 5-12 Existing Mitigation Systems New Sampling Building

32 5.13 Point J/ Emergency sprayers Transfer Point from CV114 & 214 to CV115 & 215 Location on plot: Legend: Figure 5-13: TPT-SLD Site Plot Plan Point J/Emergency sprayers Existing Mitigation Systems: Dust Source CV Transfer Chute CV Transfer Chute CV314 Head Chute CV Transfer Chute CV Transfer Chute CV Transfer Chute CV114 Head Chute Mitigation Hardware Nozzles 6 Discharge Chute Atomising Nozzles 6 Discharge Chute Atomising Nozzles 4 Head Chute Atomising Nozzles 8 Head Chute Atomising Nozzles Enclosed Discharge 6 Discharge Chute Atomising Nozzles 6 Discharge Chute Atomising Nozzles 10 Head Chute Atomising Nozzles Table 5-13: Existing Mitigation Systems Point J/Emergency sprayers

33 5.14 Stacker at CV305 Head Chute to Mittal Steel Location on plot: Existing Mitigation Systems: Figure 5-14 TPT-SLD Site Plot Plan Feed Chute on Mittal steel CV Dust Source Feed Chute on Mittal steel CV Mitigation Hardware Dust Extraction system operated by Mitttal Table 5-14: Existing Mitigation System- Feed Chute on Mittal steel CV

34 6. REFERENCES PDNA & SRK Consulting, March 2006, Phase 1B Expansion of Sishen-Saldanha Iron Ore Export Channel, Saldanha Bay, Western Cape, Final Environmental Scoping Report HMGJV, Augustus 2009, Transnet Capital Projects Oreline Port Dust Mitigation Measures, Discussion Document: BTS Dust Audit SRK Consulting, 2010, BTS Operational Environmental Management Program: Air Quality Permit Amendment