The Kasese Cobalt Project
A cobalt recovery plant has been built for Kasese Cobalt Company
Limited in south-western Uganda. The plant will process10 t/h of
a pyrite stockpile containing 1,4% cobalt, to produce 1 000 t/yr of cobalt over the next 11 years.
BATEMAN provided the design, engineering, and construction management.
This included the process design package for cobalt electrowinning as
well as the detailed design and construction of the process plant and
utilities, infrastructure and tailings dams. The process involves bacterial
leaching of the pyrite, neutralisation with limestone to remove acid
and iron, removal of copper and nickel as saleable hydroxides, and the
purification and recovery of cobalt by solvent extraction and electrowinning.
The plant is unique and, so far as is known, is the first to employ
bacterial leaching coupled with solvent extraction and electrowinning
of cobalt.
The activities of two other technology consultants engaged on the project
were also coordinated. The hydropower station was supplied by another
contractor
ENVIRONMENTAL IMPACT
This project will have a beneficial impact upon the environment
in the area. The stockpile is to be treated originates from the old
Kilembe Copper Mine and is situated in the foothills of the Rwenzori
Mountains adjacent to the Queen Elizabeth National Park, some 12km from
the mine. Acidic run-off from the stockpile over the years has caused
widespread damage to the surrounding area. The residue from the new
plant will be safely contained in specially designed dams and on completion
of operations all traces of the plant will be removed and the entire
site grassed over.
REMOTE LOCATION
An office was set up in Kampala to facilitate communications and cope
with the logistics of supplying this remote site. Materials had to be
shipped via Mombasa, which was particularly congested as a result abnormal
foods, and sent by road through Kenya and Uganda, a distance of some
1600km over indifferent roads, also affected by the heavy rains. Goods
could also be flown in via Entebbe, a distance by road of 500km from
site. Clearing goods through customs became a challenge.
DIFFICULT WORKING CONDITIONS
Several dangers lay hidden in the surrounding countryside. Foremost
was Malaria, with the strictest observance of preventative and prophylactic
measures being necessary. Rebel activity was a constant threat with
consequent curfews and proclamations of restricted areas.
EXEMPLARY SAFETY RECORD
Safety was of prime importance and despite the difficult working conditions
exemplary safety record was achieved. After 3million working hours,
the disabling injury frequency rate (DIFR) was 0,33 per million man-hours,
with only one minor disabling injury occurring during the whole project.
PLANT STATISTICS
| Steel (mainly fabricated on site) |
|
| Stainless steel tanks / platework |
346 tonne |
| Carbon steel tanks/platework |
199 tonne |
| Structural steel etc |
645 tonne |
| Concrete poured |
5 250 m³ |
| Excavations for tailings dams |
695 000 m³ |
| Piping Raw water line |
13,7 km |
| Waste water return line |
7 km |
| Cooling coils (stainless steel, fabricated
in RSA) |
30 km |
| Plant (carbon & stainless steel,
HPDE, etc.) |
29,3 km |
| Valves |
1 846 |
| Freight shipped to Kasese |
13 500 freight tonne;
390 containers |
PROJECT
STATISTICS
| Client |
Kasese Cobalt Company
Limited |
| Location |
South-western Uganda |
| Contract Type |
Fast-track reimbursable |
| Duration |
August 1997 to June
1999 |
| Total project cost |
US$120M (about 60 %
BATEMAN) |
| Total project man hours |
3 million |
| DIFR (Disabling injury frequency
rate) |
0,33 per 106hours |
| Disabling injuries |
1 |
More information may be obtained from Tony Cau, BATEMAN General manager,
Base Metals on +61-7-3320-333 or email basemetals@batemanengineering.com.
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