Clough

Luke Opray

In this feature with Metals and Mining Review, Luke Opray, Senior Engineering Manager at Clough, shares his insights and experiences from his projects, highlighting the importance of bespoke water management solutions and the implications of both over-engineering and under-preparation.

Are there any particular topics you have in mind that you would like to share or draw special focus on? 

In the diversity of the mining industry, effective water management is vital, not just for operational efficiency but for environmental management. My experience across sectors like Coal Seam Gas (CSG), coal, and copper mining has underscored an important realization – Water management strategies must be meticulously tailored to specific site conditions and mining processes. 

What do you think are the Challenges prevalent in the industry?

In many instances, the mining industry has adopted water management standards from the broader water industry. While standards are essential for ensuring safety and efficiency, the application of standards more stringent than those used generally in the water industry can lead to complex, over-engineered systems. These often result in significant cost overruns, as they may not align perfectly with the mining operations and environmental conditions onsite.

For example, in the Oil and Gas industry, water produced as a by product of gas production can be substantial. If the water management infrastructure is designed using Oil and Gas standards rather than those used for a more conventional water treatment facility, the result can be an unnecessarily expensive and complex system increasing construction and operational costs.

Conversely, the mining sector sometimes resorts to overly simplistic and rudimentary solutions to water management. These "agricultural solutions" often require considerable operational input, leading to increased labor and maintenance costs. In scenarios where water is viewed merely as a by-product or nuisance, insufficient attention to water management can lead to serious operational disruptions.

In the coal industry, for instance, neglecting robust water management practices can result in environmental and regulatory issues, especially when dealing with mine runoff and sediment control. The lack of proper systems can exacerbate the impact of water on mining operations, particularly in adverse weather conditions.

How important do you think is considering weather and Extreme Events?

The increase in extreme weather events, from severe droughts to heavy rainfall, adds another layer of complexity to mine water management. The 2011 floods in Queensland's Surat Basin illustrate this point. Significant rainfall severely impacted both CSG and coal extraction operations, halting production and necessitating extensive remedial work on water management and mining infrastructure. Notably, ponds designed with effective surface water diversion controls experienced considerably less damage compared to those without, underscoring the necessity of anticipating a full range of environmental scenarios in infrastructure design.

One of the most effective strategies I have encountered is the application of Front End Loading (FEL) in the planning and design stages of water management systems. FEL is an element of infrastructure delivery undertaken during initial design phases which enhances the robustness of project execution, minimising risks and potential cost overruns during construction and operational phases.

For a copper mining operation in Chile, a comprehensive FEL approach enabled the successful design and implementation of an 800mm diameter, 100km pipeline paired with a desalination plant. This project was particularly successful because it was underpinned by an extensive dataset that included water demands, site topography, geotechnical conditions, and over 12 months of water quality sampling to capture seasonal fluctuations. This experience and its lessons learned are particularly relevant when looking at projects to be undertaken in Australia over the coming years such as the Northern Water Supply which will provide desalinated water to multiple mining operations across South Australia.

“While standards are essential for ensuring safety and efficiency, the application of standards more stringent than those used generally in the water industry can lead to complex, over-engineered systems.”

Could you share your experiences and insights gained throughout your journey in the insurance industry?

Effective mine water management is not merely about managing water volumes and water quality, it's about understanding and integrating a large variety of factors, from climatic conditions to geological data, into a cohesive management strategy that aligns with both operational needs and environmental responsibilities. Although FEL and similar approaches require upfront investment, they provide long-term benefits in mitigating risks and reducing "whole of life" costs. As we continue to face global challenges in water scarcity and management, the mining industry must adapt and evolve, ensuring that water management is as efficient and site-specific as possible. Through careful planning, innovative thinking, and a commitment to sustainable practices, we can achieve a balance that benefits both our industries and the ecosystems in which they operate.