ppc riebeeck mine and cement factory - Aurecon AME ...

PPC RIEBEECK MINE AND CEMENT FACTORY:
STORMWATER MANAGEMENT PLAN REPORT
September 2011
Prepared by
Gerswain Manuel
Justin Dell
Pretoria Portland Cement Company
Limited
PPC Building
Barlow Park Extension
180 Katherine Street
Sandton
2146
Tel: (011) 386-9122
Fax : (011) 386-9117
www.ppccement.co.za

PPC Riebeeck West: Amendment to the Environmental Management Plan Report Page i
PROJECT DETAILS
TITLE PPC Riebeeck Mine and Cement Factory Stormwater
Management Plan 2011
AUTHORS Justin Dell , Gerswain Manuel
CLIENT Pretoria Portland Cement Company Limited
REPORT STATUS Draft
SUBMISSION DATE September 2011
..........................................
JUSTIN DELL
EMPR Environmental Practitioner
This report is to be referred to in bibliographies as:
2011. PPC Riebeeck Mine and Cement Factory Stormwater Management Plan 2011.

PPC Riebeeck West: Amendment to the Environmental Management Plan Report Page ii
CONTENTS
Project details ........................................................................................................................... i
Contents .................................................................................................................................. ii
1 Introduction ............................................................................................................................ 1
1.1 BACKGROUND .............................................................................................................. 2
Table 1.1 Summary of Water Uses to be licensed ................................................................... 2
1.2 Methodology and report structure.................................................................................... 3
1.3 Information of the applicant ............................................................................................. 4
1.4 Site location .................................................................................................................... 5
1.5 overview of mining operations ......................................................................................... 9
1.6 Production process description ..................................................................................... 21
1.7 Packing and logistics ..................................................................................................... 28
1.8 Quality assurance ......................................................................................................... 31
1.9 Engineering ................................................................................................................... 31
1.10 LEGAL REQUIREMENTS ............................................................................................. 39
2 APPROACH TO THE SWMP DEVELOPMENT .................................................................... 44
2.1 OBJECTIVES OF THE PROJECT ................................................................................ 44
3 CATCHMENT AREA ............................................................................................................. 51
3.1 SENSITIVITY OF THE WATER RESOURCE ............................................................... 51
3.2 Surface and Groundwater ............................................................................................. 53
3.3 DETERMINING MINE RISK .......................................................................................... 61
4 water balance ....................................................................................................................... 64
5 GN704 AND OTHER REQUIREMENTS ................................................................................ 67
5.1 integrated water use license requirements .................................................................... 67
6 WATER CONSERVATION PROGRAMMES ......................................................................... 69
6.1 water conservation measures implimented ................................................................... 70
7 monitoring ............................................................................................................................ 71
7.1 Water monitoring ........................................................................................................... 71
7.2 Surface water monitoring programme: .......................................................................... 71
7.3 Environmental monitoring requirements ........................................................................ 75
8 Knowledge Gaps.................................................................................................................. 78
9 Environmental Management Programme........................................................................... 79
9.1 Management plan – mining department ........................................................................ 80
9.2 Management plan –production department ................................................................... 89
9.3 Management plan - packing and logistics ...................................................................... 92
9.4 Management plan - quality assurance ........................................................................... 93
9.5 Management plan - engineering .................................................................................... 95
9.6 Management plan – administration ............................................................................... 99
9.7 Management plan - risK management ........................................................................ 100
9.8 Management plan - environmental management ........................................................ 101
9.9 Management plan - potential emergencies .................................................................. 110
10 REFERENCES .................................................................................................................... 116
11 Annexures .......................................................................................................................... 118
ANNEXURES:

PPC Riebeeck West: Storm water Management Plan Page ii
Annexure A: Integrated Water Use license
Annexure B: Waste Disposal Site permit
Annexure C: Current Alien Vegetation Removal Plan
FIGURES:
Figure 1-1: Locality of PPC Riebeeck in relation to the surrounding roads.................................. 6
Figure 1-2: Plan showing the mining environment area associated surrounding landuse with
PPC Riebeeck ..................................................................................................................... 7
Figure 1-3: Indication of the PPC Riebeeck surface holdings ..................................................... 8
Figure 1-4: Process flow and organisation structure at Riebeeck ............................................... 8
Figure 1-5: Site layout .............................................................................................................. 11
Figure 1-6: Plant layout of PPC Riebeeck................................................................................. 12
Figure 1-7: Flow chart of the mining process ............................................................................ 13
Figure 1-8: The current overburden dump ................................................................................ 15
Figure 1-9: Location of the various overburden dumps ............................................................. 16
Figure 1-10: Visual indication of the future overburden dumps ................................................. 16
Figure 1-11: Visual indication of the future overburden dumps ................................................. 17
Figure 1-12: Existing Crusher setup ......................................................................................... 18
Figure 1-13: Production Process .............................................................................................. 22
Figure 1-14: Two rotary kilns currently being used on site ........................................................ 25
Figure 1-15: Flow chart of the activities implemented by the Packaging and Logistics
Department ....................................................................................................................... 28
Figure 1-16: Quarrying and Crushing ....................................................................................... 32
Figure 1-17: Raw Material Storage ........................................................................................... 33
Figure 1-18: Clinker Production ................................................................................................ 34
Figure 1-19: Burning ................................................................................................................. 35
Figure 1-20: Cement Milling and Transport............................................................................... 37
Figure 1-21: Cement Packing, Loading and Dispatch ............................................................... 38
Figure 2-1: Hierarchy of decision making.................................................................................. 44
Figure 3-1: Indication of the location of the various streams associated with PPC Riebeeck .... 54
Figure 3-2: Geological cross-section of the Kasteelberg between Riebeek-Wes and Riebeek
Kasteel .............................................................................................................................. 57
Figure 3-3: Indication of the location of boreholes in and around PPC Riebeeck ...................... 58
Figure 3-4: Indication of groundwater flow at PPC Riebeeck. ................................................... 59
Figure 3-5: Quaternary Catchments. ........................................................................................ 61
Figure 3-6: Quaternary Catchments. ........................................................................................ 63
Figure 4-1: Current water balance of the operation. .................................................................. 64
Figure 7-1: Surface water sampling points................................................................................ 72
TABLES:
Table 1-1: Summary of Water uses to be licensed. .................................................................... 2
Table 1-2: Raw Material Consumption. ..................................................................................... 23

PPC Riebeeck West: Storm water Management Plan Page iii
Table 3-1: Management Measures in the Short Term .................. Error! Bookmark not defined.
Table 3-2: Management Measures in the Long Term .................. Error! Bookmark not defined.
Table 3-3: Sensitivity of water resources. ................................................................................. 52
Table 3-4: Summary of ecological status of each stream. ......................................................... 54
Table 3-5: Summary of groundwater quality. ............................................................................ 60
Table 3-6: Indication of anticipated impact of the deepening of the quarry................................ 61
Table 3-7: Mine/Industrial Risk ................................................................................................. 61
Table 4-1: Summary of Water Uses to be licensed ................................................................... 65
Table 7-1: Indication of the location and frequency of sampling ................................................ 73
Table 7-2: Schedule of analytes ............................................................................................... 73
ABBREVIATIONS:
DEAT Department of Environmental Affairs and Tourism
DMR Department of Minerals and Resources
DWA Department of Water Affairs
EIA Environmental Impact Assessment
EMPR Environmental Management Programme Report
FDG Furnace Dust Granules
ISO 14001 International Organisation for Standardisation: Environmental
Management Systems
MPRDA Mineral and Petroleum Development Act
NEMA National Environmental Management Act
PPC Pretoria Cement Company Limited

PPC Riebeeck West: Storm water Management Plan Page 1
1 INTRODUCTION
The Pretoria Portland Cement Company Limited (PPC) Riebeeck Limestone Quarry and
associated cement manufacturing plant (Riebeeck) has been in operation since 1956. The
mine and plant are located on the Farm 1222 & Farm 1176 (previously known as Vlakkerug No.
503, Delectus 509 and Ongegund 508). The mine falls within the local Swartland Municipality
and the West Coast District Municipality in the Western Cape.
The mining environmental area to which this document covers also includes a section of the
adjacent Farm Middelpos 969, of which future overburden dumping will take place on.
The current limestone and shale mining operations are authorised through mining license
ML 42 / 2002 and the current sand and clay mining operations are authorised through mining
license ML 43 / 2002 granted in terms of the now repealed Minerals Act (No. 50 of 1991).
The conversion of the existing Mining Licences to a Mining Right in terms of the transitional
arrangements of the Mineral and Petroleum Resources Development Act, Act 28 of 2002
(MPRDA) has been submitted to the Department of Minerals and Resources (DMR). The
reference number for the conversion of both applications is WC 266 CMR.
Pretoria Portland Cement Company Limited (PPC) Riebeeck has applied for an Integrated
Water Use Licence Application (IWULA) for the water use related to its mining operations
(limestone quarry) and cement plant.
The IWULA process includes collation of all the necessary information required by Department
of Water Affairs and Forestry (DWAF) for the identified Section 21 water uses and motivation
for exemption from certain requirements of Government Notice 704 (GN704) (Government
Gazette 20118, 4 June 1999).
PPC Riebeeck is committed to implementing best practice in terms of Government Notice 704
and DWAF‟s recently developed Best Practice Guidelines (BPG) for Water Resource
Protection in the South African Mining Industry which adheres to DWAF‟s water management
hierarchy for all aspects of water and waste management:
minimise use and avoid spillage;
reuse and recycle wherever possible;
treat water for reuse or discharge;
discharge (as a last resort), in compliance with DWAF limits.
This management hierarchy is of particular importance in the Berg water management area,
which is a stressed water management area requiring more efficient and beneficial use of water
(DWAF, 2004).
This IWWMP takes into account the stresses in the water management area due to the demand
of the agricultural sector in terms of the quantity and quality of irrigation water and the needs of
other water use sectors as detailed in the Internal Strategic Perspective for the Berg water
management area (DWAF, 2004).

PPC Riebeeck West: Storm water Management Plan Page 2
Integrated planning, incorporating demand management initiatives to relieve the stress on
current water supply schemes and possibly delay the need for implementing new schemes is of
particular relevance to the Berg water management area.
1.1 BACKGROUND
PPC Riebeeck have a number of existing lawful water uses for their existing site, namely:
Permit Number: B33/2/710/2
Authorising the use for industrial purposes at the Permit Holders premises, a quantity of 602
250 m3 per annum of water made up as follows.
o 146 000 m3 of water removed underground in the mine
o 456 250 m3 of water obtained from the Berg River Government Water scheme
Disposal of water found underground may be disposed of into an unnamed tributary of the
Berg River
Authorises the disposal of 100 400 m3 of purified sewage effluent per annum into an
unnamed tributary of the Berg River (This WWTW has been taken over by the local
municipality)
The following have been identified as water uses requiring a license on the existing site:
TABLE 1.1 SUMMARY OF WATER USES TO BE LICENSED
Activity
Delectus Dam Water storage 21 (g) 100 000
Storage in quarry 21 (g) 240 000
Section of
NWA Volume (m3) Comments
Currently 146 000
m3 removal is
licensed
Remove Pit water/annum N/A Currently 146
000 m3
Existing
diversion
21 (j) 354 916/annum
channel
Movement of the origin of a drainage line
downstream to accommodate the extension of
21 (c) & i N/A
the overburden dump 21(i) N/A Not shown on map
Disposal of general waste 21 (g) N/A
Disposal of overburden 21 (g) N/A
Dust suppression 21 (g) 84124/annum
Discharges
Expansion WWTW effluent 21 (f) 7 305
/month General
Authorisations* Withdrawn
Currently 146 000
m3 discharge is
Pit water 21 (f) 354 916/annum licensed
Discharge of water
from plant runoff and
Existing stormwater 21 (f) 77 550/annum Pit B combined
Delectus Dam 21 (f) To be added

PPC Riebeeck West: Storm water Management Plan Page 3
1.2 METHODOLOGY AND REPORT STRUCTURE
The environmental management programme report has been compiled as follows:
Sec STORMWATER MANAGEMENT PLAN – (excluding the
management and monitoring measures and technical
appendices)
1
2
3
4
5
6
Introduction and background information: Provide background
information of the mining operation such as locality plans.
The description of the receiving environment will be provided
as well as the Legislative background. This description will
make use of information already available from the following
sources:
Intergrated Water Use Application
The approved EMPR and amendments
The approved IWULA
Specialist reports compiled for the mine.
Approach to the Stomwater Management Plan Development
This approach is to make use of information already available
from the following sources:
Recent monitoring feedback reports
The approved IWULA and communication
Specialist reports compiled for the mine.
The objectives and strategies will be discussed in this section
PPC Riebeeck Catchment and the sensitivity of the area
The impact assessment on the receiving environment will be
presented and including the determination of the risk
associated with the PPC Riebeeck Operation..
The PPC Riebeeck Water Balance and associated Water Uses
identified.
The Mine‟s water re-use strategy and opportunities
The GN704 requirements and other. These will include the:
IWULA and waste license
Future overburden dumping requirements
PPC Riebeeck conservation programmes such as
The monthly monitoring and the use of water for dust
suppression.
Applicable Section
or Regulation of
SWMP BPG1
Chapter 2
BPG H3
STORMWATER MANAGEMENT PLAN - (plus management measures and technical
appendices as required per the EIA)

PPC Riebeeck West: Storm water Management Plan Page 4
7
8
9
10
11
12
The proposed mitigation measures, including management and
monitoring will be outlined in Section 7. The management
measures will detail the environmental management
requirements for all the activities described in Section 3. In
addition, there will be;
Detailed management measures to implement in the case
of environmental emergencies
Detailed description of the environmental monitoring which
is required to be implemented by the mine.
Where possible the environmental management measures will
be linked to the current ISO 14001 procedures implemented by
the mine.
Based on the information presented in the SWMP, the known
knowledge gaps will be listed in Section 8 including the
reasoning as to why the information is not available in the
report.
Recommendations and the way forward will be discussed in
section9.
Where possible the environmental management measures will
be linked to the current ISO 14001 procedures implemented by
the mine.
An undertaking to be signed by the applicant will be included in
Section 10.
A reference list of all material referenced or consulted in the
compilation of this report will be listed in Section 11.
The technical reports and supporting information, will be
included as Appendices in Section 12. This will include the
specialist studies referred to in the baseline description.
Regulation 51 (a)
1.3 INFORMATION OF THE APPLICANT
The table below provides information on the Mining Right holder and associated contact details:
Name of Applicant: Pretoria Portland Cement Company Limited – Riebeeck
Registration No. of Applicant: 1892/000667/06
DMR Reference No.
Old order mining license: ML 42 / 2002 and ML 43 / 2002
Mining Right: WC 266 CMR
Contact Person (Riebeeck): Sustainability and Environment Manager
Contact person (Head Office): Group Manager: Sustainability and Environment
Postal Address:
Telephone Number:
P.O. Box 45
Riebeek West, 7306
Riebeeck: 022 461 8000
Head Office: 011 386 9000

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Fax Number:
Commodity:
Riebeeck: 022 461 2388
Head Office: 011 386 9117
Limestone and Shale in ML 42 / 2002
Sand and Clay in ML 43 / 2002
Mining Production rate ± 1.85 million tons of limestone per annum
Life of Mine: ± 100 years
1.4 SITE LOCATION
The mine and cement plant are located on the Farm 1222 & Farm 1224 (previously Vlakkerug
No.503, Delectus 509 and Ongegund 508). The mining environmental area also includes the
adjacent farm Middelpos 969 of which future overburden dumping will take place on. The
closest town located approximately 4km to the south of the mine is Riebeek West.
Situated at the foot of the Kasteelberg mountain range, Riebeek West is situated north-north
east of Cape Town approximately 70km away. The village of Riebeek West is situated 4km
from Riebeek-Kasteel on the R311 in the direction of Moorreesburg (33km away) and is closely
linked with Riebeek-Kasteel. The town of Malmesbury is south west of Riebeek West
approximately 30km away. Riebeek West falls within the West Coast District Municipality and is
managed by the local Swartland Municipality. Malmesbury is the administrative centre for the
Swartland Municipality.
The mining right area encompasses and area of approximately 1 114.8 hectares.
Figure 1.1 below provides a visual indication of the location of the mine of the mine to the
surrounding roads.
Figure 1.2 below provides a visual indication of the extent of the mining environment area
and the surrounding land use.
Figure 1.3 below provides an indication of the land owned by PPC which equates to the
mining environment area.

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Figure 1-1: Locality of PPC Riebeeck in relation to the surrounding roads

PPC Riebeeck West: Storm water Management Plan Page 7
Figure 1-2: Plan showing the mining environment area associated surrounding landuse with PPC Riebeeck

PPC Riebeeck West: Storm water Management Plan Page 8
Figure 1-3: Indication of the PPC Riebeeck surface holdings

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1.5 OVERVIEW OF MINING OPERATIONS
1.5.1 EXISTING FACILITY
The purpose of this section is to provide the reader with a brief description of the activities
taking place at Riebeeck and to ensure that the environmental management measures (in
Section 6) can be assigned to specific activities.
The description of the activities is linked to the organisational flow of the mine. The
organisational flow includes the core processes which are:
Mining
Production
Packaging and logistics (dispatch of product)
In addition to the core processes, PPC Riebeeck have the following supporting processes:
Quality assurance
Risk management (including environmental management)
Engineering
Administration / Stores
Organisational performance.
The description of the activities has been provided in a chronological order which follows the
mining of the limestone, shale, sand and clay through to production and dispatch of the clinker /
cement from the plant, followed by a description of the supporting services to ensure the
smooth operation of the mine. This section describes both the existing operations and the
intended cement expansion project.
The description of the activities is interlinked into the PPC Riebeeck aspect register which was
developed for the implementation of the ISO 14001:2004 environmental management system.
The following figures have been provided to assist in the readers understanding of the
description of the activities that take place on the site:
Figure 1.4 provides a diagrammatic indication of the overall process that takes place on
the site. This diagram is interlinked into the organisational flow at Riebeeck.
Figure 1.5 provides an aerial photograph of the whole of the site.
Figure 1.6 provides an aerial photograph of the current plant area and a brief
description of the function of each building.

PPC Riebeeck West: Storm water Management Plan Page 10
Figure 1.4: Process flow and organisation structure at Riebeeck

PPC Riebeeck West: Storm water Management Plan Page 11
Figure 1.5: Site layout.

PPC Riebeeck West: Storm water Management Plan Page 12
Figure 1.6: Plant layout of PPC Riebeeck

PPC Riebeeck West: Storm water Management Plan Page 13
1.5.2 Mining process description
The mining process is outlined in Figure 1.7 below and described in the following text.
Figure 1-7: Flow chart of the mining process.
Current mining operations include the mining of the Block A and Block B. The short term
intention is to combine Block A and B into one pit which is regarded as the Final Pit. Over time
the Final Pit will be deepened (240m in depth) and extended in diameter towards the current
plant resulting in the Opti Pit. To ensure continued limestone supplies future mining will involve
the opening up and development of the Delectus Pit (in over 30 years).
The mining department can be separated up into the following sub-headings:
1.5.3 Mine and resource planning
The aim of any mining operation should be to ensure optimal utilisation of the mineral
resources. In order to achieve this aim at PPC Riebeeck, mine and resource planning is critical.

PPC Riebeeck West: Storm water Management Plan Page 14
The chemical compositions of the mineral deposits have been established by means of an indepth
prospecting programme. On-going prospecting of future mining areas is continuous
throughout the life of mine in order to improve the understanding of the mineral resource and
therefore improve the final utilization of the resource. Topsoil / overburden removal and storage
forms an integral part of resource planning at Riebeeck.
Every year an annual plan is developed to be implemented by the mine manager. The annual
plan compliments both a phased plan (+/- 5 years) and a long term mine plan, all which are
coordinated with the final closure objectives of the mine. Mine planning is updated as more
information concerning the reserves is established.
Current Mine Planning:
The base of the existing mine pit is currently approximately 120 m deep (i.e. 78 mamsl). The pit
will be expanded eastwards (towards the existing factory) and deepened to approximately 180
m (i.e. 18 mamsl) to form the “final pit”.
Day to day mine planning is achieved through taking a composite of the fines from the drill holes
required to mine the reserve and sampling the composite as per the “drill hole sampling” work
instruction.
This is used by the mining manager to ensure that as chemically consistent a material as
possible is been mined for clinker production and allows for high and low grade material to be
blended, which reduces wastage of mineral resources.
1.5.4 Haul road construction & maintenance
In order to access the mineral reserves, haul roads are required. Under current mining
conditions in the Final and Optimal pit, the limestone reserves are accessed through the
deepening and widening of the current pit, hence no new haul roads are required except for the
extension of the roads within the mining pit.
As and when mining commences from the new Delectus pits and access to the new cement
plant is required, additional haul road construction will be required. The positioning of haul
roads is determined during the mine resource planning meetings. Haul roads are maintained
through appropriate grading as and when required.
1.5.5 Stripping of topsoil and overburden
In order to access the limestone reserve, through the extension of the Final Pit to the Opti Pit,
topsoil and overburden needs to be removed. As and when mining commences on the future
development of the Delectus pit, topsoil and overburden will also need to be removed.
As and when topsoil is available for removal, it is removed separately to the underlying
overburden and is either used immediately in concurrent rehabilitation projects within the mining
area or stored separately for future rehabilitation projects.
Description of Current Planned Overburden Dumping:

PPC Riebeeck West: Storm water Management Plan Page 15
When encountered, the softer phyllite overburden is dug and loaded onto haul trucks by a
hydraulic excavator. The overburden is transported and deposited on pre-determined areas
and developed into overburden dumps. Future overburden encountered during the
development of the Delectus pit will be used to backfill the Optimal Pit. Refer to Figure 1.8 for a
visual indication of a current overburden dump.
Figure 1-8: The current overburden dump.
PPC‟s existing land holdings (Malmesbury 1176 and Vlakkerug 503) are unable to
accommodate the required volumes of overburden dumping in the specified pattern
recommended by the mining specialists. The most appropriate extension to the PPC property
for the purpose of overburden dumping has been identified as the Middelpos 969 property. This
would enable either the extension of the Vlakkerug overburden dump onto Middelpos or the
establishment of a new dump on Middelpos. It is for this reason that the section of the
Middelpos farm is included in the mining environment.
Current overburden dump planning is for 3 dumping areas namely;
The existing Vlakkerug Dump
The Southern Overburden Dump
The extension to the western overburden dump referred to as the “Delectus Berm.
As and when the Delectus pit is developed, the overburden will be backfilled into the void
created by the final pit.
Figure 1.9 below provides a visual indication of the location of the 3 dumping sites.

PPC Riebeeck West: Storm water Management Plan Page 16
Figure 1-9: Location of the various overburden dumps
Figure 1.10 and 1.11 provide a visual indication of the future extent of the planned overburden
dumps.
Figure 1-10: Visual indication of the future overburden dumps

PPC Riebeeck West: Storm water Management Plan Page 17
Figure 1-11: Visual indication of the future overburden dumps
1.5.6 Drilling, blasting and secondary breaking
Drilling: Drill holes are marked out in accordance with short term mine plans in areas stripped
of overburden. PPC Riebeeck has their own drill rig which is fitted with dust containment
equipment to perform the required drilling operations.
Explosives / Blasting: Blasting is conducted in accordance to detailed blasting work
instruction. Blasting in the quarry involves the direct ordering of bulk explosives from the
blasting contractor, transporting the explosives to the working face, the design of the blasting
pattern, the inspection of the hole depths, the charging of the holes, the stemming of the holes,
detonation of the explosives, ensuring that security arrangements are made and put in place
and the making safe of the working area after blasting (inspection and destruction of misfires).
Mining will take place through conventional drilling and blasting methods to an estimated final
depth of 240m. Blasting occurs on average every 2 weeks. Each blast is monitored for air
blast, noise and ground vibration.
Due to the soft nature of the overburden and shale, it can be removed using an excavator.
Below 30m depth the waste rock requires blasting to optimise the side wall slopes and to
expose the deeper limestone resources.
PPC Riebeeck has a licensed explosive magazine which is used to house accessories for the
blasting activities.
Secondary breaking: According to recent blasting studies, nearly all the fragmented rock is
less than 750mm which can then fit within the current primary crusher. The occasional
fragment of rock which is too large to fit into the primary crusher is transported to the primary
crusher area and then broken up through secondary breaking using a pecker, until it is of
suitable size to be crushed.

PPC Riebeeck West: Storm water Management Plan Page 18
1.5.7 Loading & hauling
After the mineral resource has been fragmented through blasting it is loaded, using front end
loaders, onto haul trucks and transported to the primary crusher for processing. Active haul
roads are watered to reduce dust generation during haulage. Alternative means of dust
suppression on haul roads are intermittently being investigated and viable solutions will be
implemented.
Material is loaded from various areas in the quarry to ensure the correct quality of limestone is
crushed and blended for clinker production. The blending is determined through mine planning.
1.5.8 Crushing / primary stockpile
The fragmented rock is processed through the primary crusher and conveyed to the primary
stockpile. Primary crushing involves controlling the tipping of limestone and shale into the
primary gyratory crusher and the operating of the hydraulic rock hammer. A water spray system
is operated when necessary. Material passing through the primary crusher is separated at the
primary stockpile according to material type and grade. There is a dust control system on the
primary stockpile.
As and when varying grades of material from the primary stockpiles is required, it is convey to a
secondary and tertiary crusher to reduce the limestone fraction to -25mm which is then
stockpiled (Refer to Figure 1.12 below). Dust generated during crushing activities is reduced
through the use of water sprays and enclosing the crushers and transfer points.
Figure 1-12: Existing crushing set up.
Secondary
Crusher
Crusher
Various grades of
primary stockpile
Tertiary
Crusher
Primary Crusher
1.5.9 Stockpiling limestone / sand & shale
The crushed limestone material is deposited by a variable height stacker onto one of 2 blending
beds with a capacity of 25 000 tons each. The material is stockpiled in such a way that when
complete it consists of a large number of thin layers of limestone of varying composition.

PPC Riebeeck West: Storm water Management Plan Page 19
The material from the blending beds is reclaimed for clinker production in thin vertical slices
which are transverse to the longitudinal axis of the deposition, and slices tend to contain the
various components in the desired proportions.
The sand and shale mix which is processed through the crushers is stored separately in the
shale shed. When the mine has a surplus of sand / shale mixture, it is been stored adjacent to
the quarry pit (Refer to Figure 1.4).
1.5.10 Screenings
During future mining activities there will be a need to screen out the fines from the mineral
resource. These fines are regarded as screening. Historically the screens were conveyed to a
screening dump (See Figure 1.5). However there in no space available for future screening to
be placed on the existing screening dump. Therefore PPC Riebeeck will need another solution
for the disposal of screening.
One such solution could involve the slurrying of the screenings and pumping the slurry to a
settlement dump created within the existing overburden areas. The water from the settlement
dam would be recycled back to the plant. The settled out screenings would then be covered
with overburden.
1.5.11 Concurrent rehabilitation / conservation
Concurrent rehabilitation includes, backfilling mined out areas (sand mining area), the
rehabilitation of the overburden dumps, protection and upkeep of the Renosterveld and the
removal of alien vegetation.
The main backfilling of mined out areas will involve the intended future backfilling of the
overburden from the Delectus pit area into the Final pit. There is currently backfilling taking
place within the southern section of Block B and in the sand mining area.
Overburden dumps are profiled as per the overburden dump design through dozing, grading
and terracing. Once profiled, they are covered in topsoil and re-vegetated as per the
requirements for future farming. Sub soil and topsoil are analysed to ensure suitability for future
farming requirements. Storm water control and the control of potential erosion are considered
during the design and development of the dumps.
The main invader species of concern at PPC Riebeeck is Rooikrans (Acacia cyclops), Port
Jackson (Acacia saligna), Longleaf wattle (Acacia longifolia), and Mesquite (Prosopis sp.). PPC
Riebeeck has developed and will implement an alien vegetation removal programme.
Within the mining property is an area of Renosterveld vegetation which is of high conservation
importance. In recognition of its conservation value, PPC Riebeeck will implement
management measures to protect and conserve the area. This will be undertaken under the
guidance of a suitably qualified botanist.

PPC Riebeeck West: Storm water Management Plan Page 20
1.5.12 Mining supporting services
In order to successfully implement the mining activities described above, there are a number of
supporting services dedicated to the mining department which are described below.
Fuel depot: Quarry vehicles are re-fuelled on a daily basis at the bunded fuelling station
adjacent to the quarry office and in the quarry by means of a fuel tanker. There are two 33 000
litre fuel tanks within the bunded facility.
Vehicle parking: Quarry vehicles are parked adjacent to the quarry offices when not in use.
Mining administration: Mine administration and training of employees is performed within the
quarry offices.
Workshop / Washbay: There is a dedicated workshop for the servicing of all quarry and plant
vehicles. The workshop also services the drilling equipment, compressors and pumps.
Associated with the workshop is lubricant store, a store for tyres and a store for lead alkaline
batteries. Spray painting of mobile equipment is also performed by the workshop.
There are four 2,000 litre used oil containers adjacent to the workshop to temporarily store old
oil prior to disposal through OILKOL. There is a wash bay with an oil separation system located
close to the workshop to which all storm water is directed.
There are two 9,000 litre underground fuel tanks located adjacent to the workshop which is
used for the workshop requirements and for the refuelling of light vehicles.
Quarry de-watering / Storm water control: The design, construction and maintenance of a
storm water management system around the quarry pit to cope with a 1 in 50 year flood is
ongoing as the quarry pit expands.
Dewatering of the quarry pit takes place in order to ensure the access to the limestone reserves
is not flooded. At present water is pumped from A-Block quarry to farm dam A located north of
the mining area and water is pumped from B-Block quarry into the storm water system
associated with the plant. See the integrated water use license application for details
concerning storm water management associated with the mine.
Waste disposal site: The mining department is responsible for the management of the
approved general waste disposal site in terms of dumping, ensuring the area is maintained and
the concurrent rehabilitation of the site. The waste that is disposed of in the waste disposal site
includes:
Fines from the processing plant / packaging and logistic
Domestic waste
Garden refuse
Slope monitoring: For safety and environmental reasons, regular surveying of pits sidewalls is
done by a qualified surveyor in terms of the legal requirements for open pits. Peizometers are
installed in the sidewall slopes.

PPC Riebeeck West: Storm water Management Plan Page 21
1.5.13 Sand and clay mining
The current sand and clay mining on the southern portion of the farm Ongegund 508 at PPC
Riebeeck is authorised through the approved mining license ML 43 / 2002 and an approved
EMPR. This sand and clay mined is used as a raw material for the clinker manufacturing.
The area is 9 ha piece of land, located to the south west of the existing limestone quarry. The
area forms a shallow valley that has over time accumulated up with siliceous sand. The mining
of sand and clay was phased to enable the stripping of the topsoil, followed by mining of the
sand, followed by mining of the underlying clay (where available), followed by back-filling the
void to the original ground level. The footprint of the operation was kept to a minimum (0.5
hectares) by ensuring the minimum lag time between mining and concurrent rehabilitation. All
mining is undertaken by free dig methods using an excavator and haul trucks.
In the long term the sand mining area will be covered by the southern overburden dump.
1.6 PRODUCTION PROCESS DESCRIPTION
The Production Department is responsible for the storage of the raw material, followed by the
processing of the raw material through 2 kilns to generate clinker. The current permit allocation
for PPC Riebeeck is the generation of a total capacity of 570 000 tons of clinker per annum.
The clinker is milled with additives to create cement which is sold to the market. Refer to
Figure 1.6 for the location of the various buildings associated with the production process.
Figure 1.13 illustrates the production process in a flow diagram.
PPC Riebeeck are in the process of undertaking an environmental impact assessment to
authorise the upgrade of their existing cement plant which would increase production capacity
to 800 000 tons of clinker per annum.

PPC Riebeeck West: Storm water Management Plan Page 22
Figure 1-13: Production process.
1.6.1 Raw material stockpiles
The Packaging and Logistics Department is responsible for the delivery and off-loading of raw
material to the raw material stockpiles. Once at the stockpiles, the responsibility of the material
falls under the Production Department. Table 1.2 provides an indication of the raw material
used in the current cement manufacturing at PPC Riebeeck. The raw material is stored within
respective stockpiles, which is highlighted in Figure 1.6. The table has been sub-divided into
the material required for each aspect of the cement manufacturing process.
Table 1.2: Raw material in cement manufacturing
RAW MATERIAL
Raw meal and Clinker production
Limestone Riebeeck Mine
CURRENT SOURCE TRANSPORT
Conveyor
system
STOCKPILE CAPACITY
AND LOCATION
(APPROXIMATE)
50 000 tons (2 x 25
000 blending beds) 90%
AVERAGE USAGE
FOR CLINKER
PRODUCTION

PPC Riebeeck West: Storm water Management Plan Page 23
RAW MATERIAL
Sand / Shale mix Riebeeck Mine
CURRENT SOURCE TRANSPORT
Conveyor
system
Sweetener Sand Piketberg Road
FDG – (60% iron
oxide)
Saldanha Rail
Coal (for the coal mill) Delmas Colliery
Milled clinker
Clinker
Gypsum
NDM (Limestone
extension)
Additive / grinding
agent. Different
additive for OPC &
Rapo
Clinker – Crane
Store
BPB Boesmanland
– (Natural)
Riebeeck Mine
CBA for OPC
TDA for Rapo
Rail and
Road
Conveyor
system
Rail
Conveyor
system
Road
STOCKPILE CAPACITY
AND LOCATION
(APPROXIMATE)
15 000 tons –
covered stockpile
8 000 tons –
stockpile
8000 tons -
covered stockpile
16 000 – Circular
blending bed
2500 – Crane store
Crane store – 80
000 tons
2 500 tons - Crane
store
1 000 tons – Crane
Store
2 x 20 000 litres
tanks - in bunded
facilities
Cement storage (clinker / blended with extenders such as limestone)
OPC Cement silos Conveyor 3 x 3000 ton silos
Rapo Cement silos system 1 x 3000 ton silo
AVERAGE USAGE
FOR CLINKER
PRODUCTION
7 %
1%
2%
App. 8 000 tons
per month
91%
4.5%
4.5%
1250 ml per ton
for Rapo
250ml per ton
OPC
1.6.2 Raw milling and storage of raw meal
Raw meal required for clinker production is achieved by the proportioning and monitoring the
flow of sand, shale, FDG and limestone conveyed to the raw mill. This is controlled
electronically from the control room. In the raw milling process, the input material is ground to a
fine powder.
PPC Riebeeck has two operating raw mills (ball mills). The mills operate in closed circuit, which
means that the milled product is passed to a separator where the material which is fine enough,
is separated from the coarse particles. The latter are returned to the mill for further grinding
whilst the product (fine material) is transferred to a blending silo as raw meal.
The raw meal from the blending silos is transferred by compressed air to a kiln feed silo from
where it enters the kilns for the production of clinker. The gaseous emission‟s from the Raw
Mills are drawn through Electrostatic Precipitators (ESP) to limit dust emissions. Emissions from
mill stacks are reported monthly.

PPC Riebeeck West: Storm water Management Plan Page 24
1.6.3 Coal milling
Coal is transported by means of a Japanese pipe to a tube ball mill called a coal mill..
Pulverised coal is then passed through a separator and a cyclone. Fines from the cyclone are
fed directly to the kiln. The coal milling process is a closed system.
There are temperature recording controls on the coal mill, to ensure that coal mill explosions do
not occur. For emergency procedures, explosive discs and a system which can flood the mill
with CO2 is maintained.
1.6.4 Clinker production
Riebeeck currently has 2 operating kilns (Refer to Figure 1.14 below):
No.1 kiln – a rotary kiln with an approximate capacity of 750 tons of clinker / day.
No. 2 kiln – a rotary kiln with a one stage preheater capable of producing an
approximate 840 tons of clinker / day.
Raw meal is fed into the Kilns from one end and coal used to generate the heat in the kiln from
the other.
For Kiln No.2 while the material passes through the preheater, the raw meal is dried and partial
calcinations takes place at approximately 900ºC. During calcination, limestone (predominantly
CaCO3) breaks down and releases carbon dioxide (CO2), CaCO3 + heat CaO + CO2. For
Kiln 1 all of the heating process occurs within the kiln.
The heated material is then passed through the coal fired rotating kilns, where various minerals
start to fuse together to form calcium silicate crystals, known as clinker. The coal is burnt
through mono channel burners.

PPC Riebeeck West: Storm water Management Plan Page 25
Coal mills
Planetary
coolers
Figure 1-14: Two rotary kilns currently being used on site.
Kiln 1
Kiln 2
The clinker reaches the end of the kiln and drops into a “planetary cooler” which begins the
cooling process of the clinker. Air heated up from clinker cooling is recycled as combustion air
for the kiln so as to maximise the benefit of the heating process. From the planetary cooling
system the clinker is transported via incline dragchains to the clinker storage area in the crane
store.
Off gases such as sulphur dioxide, nitrogen oxides and particulate matter generated as a result
of the burning process in the kiln are cooled down in the conditioning tower in kiln 2 and with
fresh air for kiln 1 and released through a stack. Monitoring of emissions is undertaken through
online monitors (OPSIS on kiln 2 stack) and by calculating (doing) mass balances. Monitoring
results are used to ensure compliance to permit allocations.
Particulate emissions from the kilns are reduced through the use of electrostatic precipitators.
1.6.5 Cement milling and cement storage
Clinker, gypsum, other extenders (currently NDM limestone) and a grinding media / strength
enhancer are fed into one of 2 finishing mills (cement mills). The finishing mills are ball mills,
consisting of large steel tubes filled with steel balls rotating around their axes. On entering the
mill, the grinding media first crush the clinker particles and then, by attrition, grind them to a fine
powder. Prior to entering the mill, a small quantity of gypsum is added to the clinker. The
purpose of gypsum is to retard the setting of the cement.
PPC Riebeeck currently produces Ordinary Portland Cement (OPC) and Rapo (this may
change based on market demands). The difference in the products is that Rapo uses a

PPC Riebeeck West: Storm water Management Plan Page 26
difference grinding media / strength enhancer and that the Rapo cement is finer through
extended milling.
The cement is transferred to different cement silos. There are 3 x 3000 ton silos allocated for
OPC and 1 x 3,000 ton silo for Rapo. After entering the silos the continued responsibility of the
cement shifts to the Packaging and Logistic Department.
Dust emissions during cement milling are controlled using an ESP for finishing mill 1 and a bag
house for finishing mill 2.
1.6.6 Processing supporting services:
Kiln shutdown / maintenance and start up: Kilns are shut down annually for maintenance
and additional ad hoc shutdowns may be necessary between annual shutdowns. In order to
restart the kilns, diesel is burnt while the ESP‟s are shutdown. Although diesel burns clean,
there is some discharge of dust via the stacks during this process due to incomplete
combustion.
Maintenance is overseen by the Engineering Department.
Fuel tank: The production process has 2 diesel tanks with a capacity of 2,500 litres each which
are required for the initial start up of the kiln flame after a shut down event.
Kiln bricks: During maintenance of the kilns, the lining of the kilns (refractory bricks) may need
to be replaced. There is a store for the new kiln bricks close to the tippler and old kiln bricks are
sold and occasionally disposed of at the waste disposal site.
Electricity usage: Running the mills and the kilns require high electricity usage. Encouraging
efficiency in terms of electrical usage is paramount for the production department. The
production department participate with Eskom in terms of load shedding and where possible
reducing the use of mills during peak times. The Production Department has a diesel generator
which can be used to keep the kilns rotating during times when there are power cuts.
Cooling ponds: Water treated to prevent corrosion and scaling of pipes and equipment is
pumped from the cooling ponds (next to the coal stockpile) to the plant to cool down equipment.
The cooling circuit is a closed circuit and only requires “top-ups” with municipal water.
Crane store: The crane store has a number of separated compartments which are allocated for
the storage of material. The majority of the store is allocated to clinker storage and then also
gypsum, NDM limestone and coal. Material delivered to the crane store is off loaded and
transported to the applicable compartment via an overhead grab crane.

PPC Riebeeck West: Storm water Management Plan Page 27
1.6.7 Plant upgrade project:
With the changes in environmental legislation concerning emissions, PPC will be required to
upgrade / replace equipment at PPC Riebeeck to remain compliant when the new regulations
(and the associated minimum emission standards) come into effect.
The existing plant infrastructure lends itself to a combination of upgrading and replacement of
equipment cost effectively, while maximising the use of the current plant infrastructure and
equipment. Accordingly old equipment would be replaced to ensure process efficiency and
associated compliance with legislated air quality standards. The upgrade would also allow for
optimising energy and raw material use efficiency. PPC subsequently appointed an
environmental consulting company to undertake the requisite authorisation processes required
for the proposed PPC Riebeeck upgrade project. What PPC is proposing:
Upgrade certain sections of the existing PPC Riebeeck cement manufacturing plant with the
view to increase the clinker production capacity from the current 570 Kiloton/annum to 800
Kilotton/annum via:
Replacing the existing two kilns with one new kiln line;
Decommissioning and removing the two existing kilns;
Upgrading the existing raw milling facility to accommodate the increased production rate;
Installing a new coal mill for indirect firing and inert operations;
Upgrading the existing cement milling facility to increase the current capacity to
accommodate the increased production rate;
Converting each mill to a closed circuit operation via the installation of a high efficiency
separator;
Upgrading existing conveying equipment to meet the increased production rates; and the
Installation of emission abatement technology to improve air quality.
No changes are proposed for other on-site operations, however additional on-site storage would
be required for fly ash and slag which will be used in the process as raw materials.

PPC Riebeeck West: Storm water Management Plan Page 28
1.7 PACKING AND LOGISTICS
As and when the OPC and the Rapo cement enter the various cement silos, it becomes the
responsibility of the Packaging and Logistic Department, for the dispatch in either in bulk, bags
or 1.5 ton bags. The department is also responsible for the acceptance of delivery of raw
materials via rail or road. For an indication of the various buildings associated with the
customer services department refer to Figure 1.6. Currently approximately 370,000 tons of
cement is being dispatched from PPC Riebeeck per annum. The cement is transferred from
silos through air slides and screw conveyors.
Figure 1.15 provides an overview of the activities implemented by Packing and Logistics
Department.
Figure 1-15: Flow chart of the activities implemented by the Packaging and Logistics
Department.
On average (subject to market demand) the distribution of cement is as follows:
20% of cement produced is Rapo
o Rapo – 40% distributed in bags, 60% in bulk
80% of cement produced is OPC
o OPC – 10% distributed in bags, 90% in bulk.
Approximately 30% of cement distributed by rail and 70% by road.
Clinker can be transferred to other PPC operations in bulk either by rail or road.

PPC Riebeeck West: Storm water Management Plan Page 29
1.7.1 Bulk loading
Bulk loading refers to the loading of cement in a large tanker and not in bags. Cement is
exported in bulk either via railway trucks or road trucks.
Cement from the cement silos is fed into a 1000 ton bulk silo for OPC and a 1000 ton bulk silo
for Rapo cement. There is a loading point for both road trucks and rail containers from each of
the bulk silos. Loading is controlled by manual measurements, level indicators and by loading
activities taking place on a weigh bridge. This weight is re-confirmed by a weigh bridge at the
sales office.
1.7.2 Clinker loading
If and when required clinker is transported by the overhead crane out of the crane store and
loaded either into railway wagons or road trucks. Once loaded the wagons or trucks are
weighed and if necessary topped up from a small stockpile of clinker adjacent to the tippler.
Clinker is transferred between PPC operations depending on demand and stock.
1.7.3 Packing / palletising plant – loading of bags
The PPC packing plant is SANS 1841 accredited, which aims to guarantee the correct weight
within the bags. This is achieved through daily checks of all scales, ongoing in house
calibration and external calibration of all scales every 12 months. Any bag of a weight of 49.5
kg or less is classified as underweight and destroyed.
Riebeeck has one automated packer which can pack up to 3,200 bags per hour, but normally
runs at 1,800 bags per hour. Cement from the silos is fed into the packer which bags 50kg of
the cement into bags. Either 70gsm 3ply paper bags or polypropylene bag are used. All bag
breakages (which include destroyed underweight bags) are monitored and if excessive break of
a batch of bags is recorded, a different batch will be used. Breakage target is less than 0.6%.
From the packer, the bags of cement are transferred via conveyor belts to a palletiser which
stacks either 40 bags or 20 bags of cement onto one pallet.
PPC Riebeeck also dispatches bags via a 1 or 2 ton “belly sling”. This is where bags on a pallet
are inverted into the belly sling and once in, the pallet is reused.
Pallets of cement and belly slings of cement bags are stored in the warehouse, until being
loaded by forklift onto haulage trucks for final dispatch. The PPC policy is to advise all
transporters to cover the cement loads from the plants with a tarpaulin to protect it from the
elements.
Dust suppression in the packing and palletising plant is achieved through use of a bag filter that
traps cement dust and returns it back to the cement silos for redistribution.
1.7.4 Big bag machine
Some cement is loaded in big bags which can hold 1.5 tons of cement per bag. Big bags are
filled from the extraction system from the main silos to the bulk silos. There is a bag filter to

PPC Riebeeck West: Storm water Management Plan Page 30
control dust at the big bag machine. Big bags are mainly for the distribution by rail to the PPC
George Depot. Occasionally export orders are dispatched in bulk bags.
1.7.5 Raw material deliveries / railway activities
The Packaging and Logistic Department is responsible for the delivery and off-loading of raw
material to their respective stockpiles. FDG, gypsum and coal is delivered by rail (or road if
necessary). All material delivered is weighed at the tippler upon arrival. FDG and the majority
of coal are transferred from the tippler to its designated storage area via a conveyer. After offloading
is completed, the tippler area is cleaned.
Material destined for the crane store is shunted to the area outside the crane store and then
transferred into the crane store using the overhead crane.
Sand is delivered by road and off loaded adjacent to the tippler where it is fed into a sand
hopper and then conveyed to its respective stockpile.
In order to optimise transport requirements, often the rail trucks which deliver raw material are
used for the dispatch of clinker from the operation. After delivery of the raw material at the
tippler, the rail trucks are clean to avoid material contamination with the clinker.
Shunting / tippler: Shunting and tippling exercises can occur any time during normal operating
hours.
Maintenance of rail infrastructure: Rail activities fall under the responsibility of Spoornet.
PPC Riebeeck makes use of a contractor to upkeep the PPC Riebeeck specific rail
infrastructure which is approximately 3km of rail line. These requirements are overseen by the
Engineering Department.
1.7.6 Supporting services
The following supporting activities are associated with Packaging and Logistics Department:
Cleaning / recycling spills: All uncontaminated cement cleaned up, is recycled through the
cement extraction system into the bulk silo. Contaminated cement with other raw materials is
disposed of at the waste disposal site.
Mobile equipment (Forklift,shunter,tractor,tipper truck) maintenance: The vehicles are on a
maintenance plan undertaken by workshop personnel. Fuel for the forklifts is obtained from the
underground tanks adjacent to the workshop.
Calibration of scales: External calibration of scales takes place annually. Internal checks of
weighing scales takes place at the following frequency: Packer – daily, weigh bridges under
bulk silos and at dispatch office – weekly and tippler weigh bridge monthly.
Pallet repair: As and when pallets are damaged they are repaired on site.
SUPPORTING PROCESSES
In order to ensure the smooth operation of the cement manufacturing plant, there is a
requirement for supporting departments. Although the services of the supporting department

PPC Riebeeck West: Storm water Management Plan Page 31
will often be required for all 3 core processes individual departments resume responsibility for
the individual supporting processes.
1.8 QUALITY ASSURANCE
To ensure that the quality of the cement generated by PPC Riebeeck is in specification with
PPC standards, samples are collected, prepared and analysed from predefined areas /
sampling points in the mine and the plant. Samples are forwarded to the quality assurance
laboratory for inspection and testing. Refer to Figure 1.6 for an indication of the location of the
quality assurance laboratory.
The most frequently used chemicals in the analysis process are ethylene gylcol, methanol,
ethanol and general acids. All chemicals are stored in a locked chemical cupboard. The
laboratory, makes use of an X-ray Fluorescent Spectrometer which has a registered radioactive
source and appropriate fume cupboards.
Pellets are created during the sampling process, which are then x-rayed to determine chemical
composition. After sampling pellets are returned to the kilns for reprocessing.
The results are evaluated, documented and distributed. Action is taken in the form of process
readjustments to prevent out-of-specification cement. The PPC Riebeeck cement plant is ISO
9001 certified which is an internationally recognised quality assurance management system.
1.8.1 Material Safety Data Sheets (MSDS)
The Quality Department assumes the responsibility of checking and assessing all chemicals
that are used by Riebeeck. As and when new chemicals are ordered, it is the Quality
Assurance Department that reviews and approves the MSDS. MSDS are then maintained at
the stores where the chemicals are kept prior to distribution to the various departments.
1.9 ENGINEERING
The Engineering Department is responsible to repair, replace and modify machines, and to
make sure the quarry and plant is reliable and running at optimum output. This department is
responsible for the quality of maintenance and repairs and the ordering of spares. For an
indication of the location of the various buildings in which the Engineering Department operates
refer to Figure 1.6.
The Engineering Department is separated into four main sub-departments which coordinate all
the engineering requirements. PPC Riebeeck has an extensive computerised scheduled
maintenance programme which is implemented to reduce the likelihood of breakdowns.
Scheduled maintenance is vital to reduce the risk of any breakdown incident causing
environmental impacts such as oil spills or uncontrolled dust emission events. Maintenance is
essential for ongoing safety of employees.

PPC Riebeeck West: Storm water Management Plan Page 32
The scheduling of maintenance activities is based on risk of equipment failure. All equipment is
monitored to determine the efficiency with which equipment is operating and if lubricants need
to be replenished. An example of such monitoring is the continuous monitoring of the condition
of the refractory brick lining in the kiln required to prevent damage to the kiln. Standard
maintenance activities of the plant include:
Changing oil and other lubricants,
Replacing bearings and parts that may wear,
Replacing filters.
Replacing kiln bricks.
1.9.1 Engineering - Planning
All maintenance is scheduled through detailed planning. The planning department directs all the
maintenance needs of the operation to the sub-sections within the Engineering Department.
The planners within the Engineering Department produce short term schedules for ongoing
maintenance.
Planning is also involved with the scheduling of special maintenance and capital projects for
continual improvements to the plant.
The basic process of how cement is made is highlighted below. The appropriate process exert
figure from Figure 1.4 is provided to link each portion of the production process back to the
overall process diagram.
1.9.2 Raw Materials (including Quarrying and Crushing)
Figure 1.16: Quarrying and Crushing
The plant will receive raw materials by road, rail and belt conveyor from the crushing plant. Raw
materials delivered to the plant are:
The raw materials include:
Limestone,
Shale,
Sand,
Furnace Dust Granules (“FDG”)(or an alternative iron source),

PPC Riebeeck West: Storm water Management Plan Page 33
Gypsum (two types, natural and synthetic),
Limestone extender (includes limestone, fly ash (high in silica or calcium),
condensed silica fume and slag),
Coal, and
Ground slag (required if Surebuild is to be produced) .
Raw materials (coal, sand, gypsum and FDG) delivered by rail are tipped into a hopper by a
side discharge wagon tippler and side arm charger. A road tip proximate to the rail tippler
receives certain incoming raw materials by road transport in emergency situations. Raw
materials delivered by road are tipped directly onto a surface feeder. Belt conveyors transfer the
raw materials from the feeder and rail tippler to the raw materials stockyard and onto the various
raw material stockpiles. The tippler design incorporates dust suppression.
Limestone (high and medium grade), limestone extender and shale are supplied from the
existing PPC quarry. The materials are crushed and screened through a multi-stage crushing
and screening process. Waste screening on the closed circuit crushers removes deleterious
materials containing high concentrations of alkalis. Crushed and screened materials are
transported to the raw materials stockyard via overland conveyors
1.9.3 Raw Material Storage
Figure 1.17: Raw Material Storage
The stockyard will consist of the following stockpiles.
Two limestone stockpiles, one stockpile for high grade and one stockpile for medium
grade limestone. Each stockpile is equipped with stacker and reclaimer. Reclaimed
limestone is transferred onto separate conveyor belts which feed the raw mill limestone
feed bins.
Coal storage stockpiles comprise two coal stockpiles. One for high grade duff coal
and the other for medium grade duff coal. The stockpiles are equipped with stackers
and reclaimers which transfer to the coal mill feed bins.
Clinker and cement raw materials are stored in a side scraper store spilt down the
middle by a dividing wall to keep the clinker and cement raw materials apart. The

PPC Riebeeck West: Storm water Management Plan Page 34
cement raw material stockpiles are; limestone extender and natural gypsum. The clinker
raw material stockpiles are; FDG, shale and sand. The stockpiles are fed by a common
tripper. Reclaiming is done by two reclaimers.
The reclaimed raw materials are transferred onto separate belt conveyors which feed the raw
mill and cement mill feed bins.
All stockpiles are roofed to keep materials dry and to contain dust generated during stacking.
1.9.4 Clinker Production
Figure 1.18: Clinker Production
The clinker production includes the raw milling facility, coal milling facility and the process units
associated with the main kiln line (raw meal homogenising silo, kiln feed, 6-stage preheater,
precalciner, kiln and grate-type clinker cooler).
Raw Milling Section
Raw materials; limestone, shale, FDG and sand, are proportionally withdrawn from the raw mill
feed bins and fed into a vertical roller mill (VRM). The raw mill utilises kiln exhaust gas for raw
material drying.
The milled material is transferred to a homogenising kiln feed silo by means of bucket elevators.
The silo is sized for a live capacity of 24-hours kiln feed.
The raw meal is automatically sampled / analysed by means of an online analyser. A
composite sample is pneumatically conveyed to the laboratory for analysis, the results of which
are used for overall quality control of the raw meal production process.
Coal Milling Section
Milled coal is used as fuel for the kiln and the precalciner. The process would make use of high
and medium grade duff coal. Coal from the stockyard would be milled by means of a Vertical
Roll Mill. The milled coal would be stored in separate bins capable of holding a minimum of 12hours
worth of fuel.

PPC Riebeeck West: Storm water Management Plan Page 35
Kiln exhaust gas is used to assist in the drying of the coal. The coal milling circuit is equipped
with a process bag filter to collect the milled coal and to clean the hot gas used to dry the coal
during milling.
1.9.5 Burning
Figure 1.19: Burning
Preheater, Kiln and Cooler
Raw meal extracted from the homogenising silo via a weighing system, combined with the dust
return from the main kiln/raw mill dust bag filter, is fed to the six-stage cyclone pre-heater
system, with a low NOx in-line calciner (ILC), by means of chain bucket elevators. The feed
system allows for feeding the raw meal into the sixth or fifth cyclone stages. The precalcined
material is fed into one end of the kiln, and pulverised coal is burnt at the other end. The raw
meal slowly cascades down the inclined kiln towards the heat and reaches a temperature of
about 1 450 °C in the burning zone where a process called clinkering occurs. The pre-heater is
about 130m tall, the tallest structure on the site, and makes use of hot air from the kiln to warm
up the raw meal to improve energy efficiency.
The clinker exits the kiln into a grate-type cooler fitted with a triple - roll crusher. The grate
cooler is sized to match kiln production including kiln flushes. Tertiary air may be drawn from the
kiln hood and / or the clinker cooler. Excess air from the grate cooler is passed through a heat
exchanger before being vented to the atmosphere through a bag filter.
The clinker is sampled by means of an automated sampling station located at the discharge
chute of the kiln feeding the clinker cooler. The samples are pneumatically conveyed to the
laboratory for analysis, the results of which are used for quality control of the clinker production
process.

PPC Riebeeck West: Storm water Management Plan Page 36
1.9.6 Clinker Transport Storage and Dispatch
Clinker discharging from the end of the grate cooler flows onto a steel pan conveyor. The pan
conveyor transports the clinker to the top of the clinker storage facility. The clinker storage
facility is designed to cater for a three week kiln shut down.
The clinker transport to the clinker storage facility is designed to cater for a capacity which will
allow for kiln flushes 1 .
The facility is fitted with two extraction tunnels. Each tunnel is equipped with extraction ports
that feed clinker onto a steel pan conveyor. The pan conveyors from both tunnels discharge
onto a common collection pan conveyor which in turn feeds a rubber belt conveyor. The clinker
on the belt conveyor will transfer the clinker to the cement mill material proportioning bins. This
facility also accommodates the receipt of clinker by road transport and front-end loader access.
A clinker reject handling system facilitates the temporary removal and storage of off-spec quality
clinker and the reintroduction of this material back into the process in a controlled manner. The
clinker reject bin is to have a drive through capability by 100 t truck.
1 When the kiln is completely emptied of all material.

PPC Riebeeck West: Storm water Management Plan Page 37
1.9.7 Cement Milling and Transport
Figure 1.20: Cement Milling and Transport
The plant will produce products as per the market demand, namely a CEM I 42,5N (Ordinary
Portland Cement or OPC) and a CEM I 42,5R Rapid Hardening Cement (RHC).
The production of cement is broken up into the following sub-processes:
Raw materials transport to cement mill feed bins,
Cement milling and transport to two multi-cell storage silos,
Cement storage.
Raw Materials Transport to Cement Mill Feed Bins
The raw materials required for the cement milling section are reclaimed from the stockyard and
transferred to the cement mill feed bins via covered conveyor belts. The feed bins would supply
two vertical roller mills (VRM) units. The facility is designed with a separate synthetic gypsum
feedbin at each of the VRM units, as well as allowing space for introducing ground slag into the
milling process (for use in producing SureBuild) in the future Cement Milling and Transport to
Two Multi-cell Storage Silos
The proportioning of the cement additives is done from the material feed bins located in
proximity to the VRMs. Bins for natural gypsum, limestone extender and clinker will allow for
proportioning and will be sized for approximately four hours milling capacity.
After milling all the materials, the cement is extracted from the mill, in a gas stream, by means of
induced draft fans 2 to the bag filter collection units. Each VRM has a dedicated bag filter unit.
The cement would be recovered at the bottom of the bag filter units and The cement is
recovered in hoppers below the bag filter plants and pneumatically conveyed the storage silos.
An automated sampling system is included on the bag filter discharge screw feeder of each unit.
The samples will be pneumatically conveyed to the laboratory on site for analysis.
2 Fans placed on the opposite side of the bag filters cause air to be sucked through the bag filters.

PPC Riebeeck West: Storm water Management Plan Page 38
Cement Storage
The produced cement is stored in road bulk loading multi-cell silos and rail loading multi-cell
silo.
Quality Assurance
Extensive sampling and testing during the manufacturing process ensures the consistency and
quality of the end product.
1.9.8 Cement Packing, Loading and Dispatch
Figure 1.21: Cement Packing, Loading and Dispatch
Cement is available in three forms, all of which are to facilitate dispatch by road and by rail.
Cement in 50kg bags;
Cement in 1.5 ton bulk bags; and
Cement in bulk.
A facility would be provided for the processing of incoming and outgoing goods by road. The
facility would provide for the capturing and processing of all relevant data, and would be
equipped on boththe incoming and outgoing lanes with weighbridges long enough to
accommodate any tanker/pup trailer and truck/trailer combination. This facility would also
include main access security.
Cement in 50kg Bags
The packing plant has a dedicated feed from the main storage silo, allowing feed from any of
the silo cells. The packer unit, would be housed in its own building, with the cement fed to the
packer by covered conveyor. The packer unit is designed for a guaranteed output of 3,000,
50kg bags per hour with automatic bag applicator suitable for paper and polypropylene bags.
The cement bags would be transferred by conveyor belt to a palletising facility for packing 40
bags on each pallet (2 tons). The palletising facility would be matched in capacity to that of the
packing plant. This facility is housed in the warehouse for the storage of palletised cement.
A palletised cement storage area, housed in the same building as the palletising facility, would
be provided for the storage of 1 500 pallets (or 3 000 tons of cement). The warehouse would

PPC Riebeeck West: Storm water Management Plan Page 39
provide for two separate loading lanes for road vehicles, and be positioned so as to facilitate the
loading of rail trucks. Appropriate equipment is provided for the handling of palletised cement
from the palletiser into storage, and from storage onto transport vehicles.
Cement in 1.5 ton Bulk Bags
The bag filling machine would be housed in its own building, with the cement fed to the bag
filling plant by covered conveyor. The bulk bag filling machine would have an output of 40 bulk
bags per hour and is serviced by a single service bin. A change of product requires flushing of
the service bin.
A storage area for bulk bags would be provided in a section of the warehouse for palletised
cement. All 1,500kg bulk bags are stored on pallets, but will be dispatched from site without
pallets. A single road loading lane with a covered storage area for approximately 450tons is
provided. A further covered area is provided for rail loading. The bulk bag warehouse section
would provide one loading lane for road vehicles, and be positioned so as to facilitate the
loading of rail trucks. It is envisaged that rail loading would share a rail line with that for
palletised cement loading.
Cement in Bulk
Two facilities would be provided for the loading and dispatch of cement in bulk, one for road
tankers beneath the main cement storage silo and one for rail tankers located underneath the
rail loading storage silo. The rail storage silo is designed to accommodate loading on two rail
lines. The loading lane is equipped with a weighbridge, and the discharge chute will be
equipped with a manual sampler. Two loading lanes will be provided, each equipped with a
weighbridge long enough to accommodate a road tanker with a pup trailer.
SUPPORTING PROCESSES
In order to ensure the smooth operation of the cement manufacturing plant, there is a
requirement for supporting departments. Although the services of the supporting
department will often be required for all 3 core processes individual departments resume
responsibility for the individual supporting processes.
1.10 LEGAL REQUIREMENTS
1.10.1 NATIONAL WATER ACT, 1998 (ACT 36 OF 1998)
The National Water Act (36 of 1998) identifies 11 consumptive and non-consumptive water uses that
must be authorised under a tiered authorisation system. Authorisation for water uses may be issued
as a General Authorisation (in terms of the General Authorisation in terms of Section 39 of the Water
Act, 1998 (Act No. 36 of 1998), Gazette No. 26187, No. 399, dated 26 March 2004), as a Schedule 1
use under NWA, or as a Water Use Licence. The authorisation system allows for the “Reserve” and
provides for public consultation processes in the establishment of strategies and decision making
and guarantees the right to appeal against such decisions.
Section 27 of the NWA outlines various factors to be taken into consideration by the responsible
authorities with regard to authorising a water use under a general authorisation or a license.
The list includes the following:

PPC Riebeeck West: Storm water Management Plan Page 40
Any catchment management strategy applicable to the relevant water resource;
The class and resource quality objectives of the water resource;
Investments made and to be made by the applicant in respect of the water use in question;
The strategic importance of the water use to be authorised;
The quality of water in the water in the water resource which may be required for the
Reserve and for meeting international obligations
The following water uses, outlined in Section 21 of NWA, 1998 generally have to be licensed:
Section 21(a) - taking water from a water resource;
Section 21(b) - storing water;
Section 21(c) - impeding or diverting the flow of water in a watercourse;
Section 21(d) - engaging in stream flow reduction activity contemplated in section 36;
Section 21(e) - engaging in a controlled activity identified as such in section 37(1) or
declared under section 38(1);
Section 21(f) - discharging waste or water containing waste into a water resource
through a pipe, canal, sewer, sea outfall or other conduit;
Section 21(g) - disposing of waste in a manner which may detrimentally impact on a
water resource;
Section 21(h) - disposing in any manner of water which contains waste from, or which has
been heated in any industrial or power generation process;
Section 21(i) - altering the bed, banks, course or characteristics of a watercourse;
Section 21(j) - removing, discharging or disposing of water found underground if it is
necessary for the efficient continuation of an activity or for the safety of people;
Section 21(k) - using water for recreational purposes;
The above highlighted water uses will be applicable to the IWULA for PPC Cement. Riebeeck
West PPC Appointed Ivusi Environmental Consultant to handle the IWULA application.
Section 26(1) of the National Water Act, 1998 (Act 36 of 1998) provides for the development of
regulations to, amongst others:
require that the use of water from a water resource be monitored, measured and recorded;
regulate or prohibit any activity in order to protect a water resource or in-stream or riparian
habitat; and
prescribe the outcome or effect which must be achieved through management practices for
the treatment of waste, or any class of waste, before it is discharged or deposited into or
allowed to enter a water resource.
When making regulations, the need for the following must be taken into account (section 26(4) of the
National Water Act):
promoting economic and sustainable use of water;
conserving and protecting water resources or, in-stream and riparian habitat;
preventing wasteful water use;
facilitating the management of water use; and
facilitating the monitoring of water use and water resources.

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In terms of the above, the Minister of Water Affairs and Forestry has promulgated the regulations in
respect of use of water for mining and related activities aimed at the protection of water resources on
4 June 1999 (Government Notice No. 704).
a) Existing Lawful Water Uses
An existing lawful water use is a water use that lawfully took place in the period two years before the
commencement of the NWA. This allows any water use that lawfully took place to continue until such
time as it can be converted into a licence.
Permit in terms of the Water Act 1956 (B33/2/710/2)
1) This permit authorises the use for industrial purposes at the Permit Holders premises, a quantity
of 602 250 m3 per annum of water made up as follows:
146 000 m3 of water removed underground in the mine
456 250 m3 of water obtained from the Berg River Government Water scheme
2) Disposal of water found underground may be disposed of into the same unnamed tributary of the
Berg River as utilised for the disposal of the purified effluent from the permit holders sewage
purification works.
3) Authorises the disposal of 100 400 m3 of purified effluent per annum
Permit in terms of the Water Act
1.10.2 NATIONAL ENVIRONMENTAL MANAGEMENT ACT (ACT 107 OF
1998)
Currently the EIA, EMPR Update and Water Use licence are being undertaken separately but in a
parallel process. This document forms part of the water use licence and the EIA and EMPR
amendment is being undertaken by Ninham Shand Consulting Services.
The application is currently in the EIA phase and one round of the public participation process has
been completed.
1.10.3 MINERAL AND PETROLEUM RESOURCES DEVELOPMENT ACT
(ACT 28 OF 2002)
In terms of the Mineral and Petroleum Resources Development Act, 2002 (Act 28 of 2002)
(“MPRDA”) and its regulations any person who has applied for a mining right in terms Section
22 must conduct an Environmental Impact Assessment (EIA) and submit and environmental
management programme (EMP) for approval by the competent authority.
1.10.4 ENVIRONMENTAL CONSERVATION ACT (ACT 73 OF 1989)
In terms of Section 20 (1) of ECA: No person shall establish, provide or operate any disposal site
without a permit issued by the Minister of Water Affairs. This permit was obtained by PPC on the 10
August 2005 and in terms of Section 20(5)(b) of ECA the permit aimed to control and manage the
disposal of certain types of waste.
a) Permit Number 16/2/7/G102/C2/Z1
1) The site may be used for the disposal of waste types in quantities contained in the definition

PPC Riebeeck West: Storm water Management Plan Page 42
for general communal sites (G:C:B+ and G:C:B-) and general small sites with negative climatic
balance (G:S:B-) and which are classified according to the minimum requirements for Waste
disposal by landfill.
1.10.5 PARALLEL PROCESS BETWEEN THE EIA AND MPRDA
The current limestone and shale mining operations are authorised through mining license ML
42 / 2002 and the current sand and clay mining operations are authorised through mining
license ML 43 / 2003. There are approved environmental management programme reports
(EMPR) which were compiled in line with the requirements of the Aide Memoir for both mining
operations. The mined products are used as the main raw ingredients for existing cement
manufacturing plant which has a permit for the maximum production of 630 000 tons of cement
per annum.
The aims of the EMPR amendment are as follows;
Make use of the processes being followed for the EIA to satisfy some of the
Department of Minerals and Energy (DME) requirements for the EMPR amendment.
The EIA in terms of NEMA for the new cement plant has required the completion of a scoping
report, numerous specialist studies, an extensive public participation process and an
environmental impact assessment report. These documents cover the requirements of
regulations 49 and 50 of the Mineral and Petroleum Resources Development Act, Act 28 of
2002 (MPRDA). By integrating the EMPR amendment process to the EIA only regulation 51 of
the MPRDA needs to be covered. The information gathered during the EIA process can be used
to mould applicable environmental management measures within this report.
Update the EMPR so that it satisfies the requirements of the MPRDA.
In terms of the transitional arrangements of the MPRDA, Riebeeck falls under the category of a
“used old order right” and hence the mine has until April 2009 to convert their mining licence
into a mining right. Section 10 of the transitional arrangements of the MPRDA gives guidance
for the continued use of the approved EMPR.
“10. (1) Any environmental management programme approved in terms of section
39(1) of the Minerals Act and in force immediately before this Act took effect and any steps taken in
respect of the relevant environmental performance assessment and duty to monitor connected with
that environmental management programme continues to remain in force when this Act comes into
effect.”
Ensure that this amended EMPR covers both the sand mining operation and the
limestone mining operation and consolidates all approved amendments to the original
EMPR.
Currently the limestone and sand mining operations have separate EMPR‟s even though the
mining is conducted by the same department over the same farms. This amended EMPR will
cover the environmental management measures for both the limestone and sand operations.
After approval of the original EMPR for both operations, there have been a number of
amendments which have been submitted and approved by the DME.
One such amendment was the future establishment Delectus pit. This amendment aims to
consolidate the management measures documented within the original EMPR and all
subsequent amendments into one document.
Update the management measures for the existing operation.
The management measures in the existing EMPR‟s are outdated and mainly focus on the
requirements of the mining operation and exclude the environmental management measures
associated with the cement manufacturing plant. This amendment will update the management
measures and include the environmental management and water commitments for the existing
Ongegund facility. Where possible the management measures will be integrated with the

PPC Riebeeck West: Storm water Management Plan Page 43
management requirements documented as part of the mines ISO 14001:2004 environmental
management commitment.
Cover the management measures required for the proposed new facility when it is
authorised through NEMA.
When the cement upgrade project gains authorisation through the EIA completed in terms of
NEMA, it will also have to be covered within the scope of the mining EMP required for the DME.
This EMP will include the management measure for both the construction and future operation
of the proposed new cement plant.

PPC Riebeeck West: Storm water Management Plan Page 44
2 APPROACH TO THE SWMP DEVELOPMENT
During the PPC “Se Kïka” EIA process (which has now been withdrawn) a number of specialist
studies were commissioned which has provided PPC Riebeeck with a detailed understanding of
their baseline environment. During this EIA, IVUSI environmental consultants was
commissioned to prepare a Integrated Water Use License application. This application, the
amended EMP
The Stormwater Management Plan is in the format provided in DWAF‟s Best Practise Guideline
G1 Storm Water Management, August 2006).
2.1 OBJECTIVES OF THE PROJECT
The objective of this integrated IWWMP is to take a holistic approach towards integrated and
optimized waste and water management in the day to day operations of PPC Riebeeck.
PPC Riebeeck was established in 1952 to meet the demand for cement in the Western Cape.
Due to the historical nature of the site and the development of more stringent environmental
legislation, PPC Riebeeck is in a state of continual improvement to ensure that all its facilities
comply with current legal requirements.
The objective of the Stormwater Management Plan is to provide PPC Riebeeck with a
consolidated plan for the complete water and water containing waste management cycle at PPC
Riebeeck over the lifetime of the operations.
The Stormwater Management Plan is therefore a living document that will be revised and
updated throughout the life of the operations to accommodate additional information and
improved technology to ensure that water and waste management is continually optimised and
adapted to the changing needs of the water management area.
The aim of the document is to identify all waste streams and water uses and to suggest the best
feasible options and best practices for the cement plant to efficiently control waste emanating
from activities on the land and minimise pollution of water, land and air, thereby, ensuring that
very little or no impact is made on the environment, surrounding environment, people, fauna or
flora.
The IWWMP will assist in ensuring resource protection as it is founded on the precautionary
principal. The IWWMP takes into account the hierarchy of decision-taking as suggested by
DWAF and illustrated in Figure 2.1:
The development of the IWWMP as a component of the WULA and ISO14001 accreditation is
part of this continual improvement.

PPC Riebeeck West: Storm water Management Plan Page 45
Figure 2.1 Hierarchy of decision-taking: DWAF
Due to the low risk natures of the operations taking place at PPC Riebeeck the water and waste
management practices that is proposed by this IWWMP, should and is focused mainly on
finding the best practises within the first two stages of the decision making hierarchy.
As this is a management tool for everyday workings at the cement plant it should be updated
regularly to ensure that any changes to the waste and water management is documented and
implemented.
2.1.1 Objectives and Strategies
a) Proposed water management strategy
The proposed water management strategy for the site is presented in Table 2.1.
The development of the strategy was based on the following:
DWAF‟s water management hierarchy;
Best Practice Guidelines for the mining industry;
IWULA, 2008
EMPR,2011
Findings of a water management audit conducted in August 2011 (SRK, 2011).
Table 2.1 Proposed water management strategy for PPC Riebeeck (EMP commitments
are indicated in brackets)
Objective: To use water effectively
DWAF‟s water management hierarchy of minimise, reuse/recycle, treat and
release will be followed.
PPC Riebeeck will manage, conserve, use, develop and control water in a
sustainable and cost effective manner.
Loss of water will be minimised by careful design and operation and regular
inspection, maintenance and feedback to management on the PPC Riebeeck's
water infrastructure and management systems

PPC Riebeeck West: Storm water Management Plan Page 46
All process water, potentially polluting water from the open quarry, plant areas
and overburden will be rapidly collected, contained and re-used where possible
e.g. for dust suppression on haul roads. PPC Riebeeck will develop a Re-use
and Reclamation Plan in accordance with the BPG H3. The development of the
plan will be based on optimal minimisation and prevention strategies
Where re-use is not possible, alternatives will be investigated to minimise
discharge to the tributary of the Berg River e.g. irrigation for crop production or
treatment as per BPG H4
Opportunities for the recycling of waste materials (domestic and industrial) will be
investigated and utilised wherever economically viable
As small an area as possible will be exposed at any one time during construction
activities.
Water and waste management tools (such as water and salt balances and
emergency protocols) will be developed and used in the implementation of this
water management strategy. Water and salt balances will be prepared in
accordance with BPG G2: Water and Salt Balances.
Objective: Prevent damage to the receiving environment from storm water
runoff
A Storm water Management Plan will be developed for the site in accordance
with BPG G1 and will address the impacts of the mining operations on the water
flow and water quality processes of the hydrological cycle and the associated
upstream and downstream environmental impacts, and in turn the impacts of the
hydrological cycle on PPC Riebeeck‟s operations, including effects such as loss
of production, costs, and impacts of both floods and droughts on the operations.
Clean water diversions and dirty water collection facilities will be established
before land clearing and construction commences, to prevent clean rainfall runoff
becoming contaminated by construction activities.
Dirty water collection facilities will be designed according to BPG A4 and clean
runoff will be released to the system from which it came in compliance with
GN704 (EMP update 2008).
Exposed surfaces within dirty areas (such as construction sites, plant and
materials handling areas and waste management facilities) will be kept to a
minimum to minimise the volume of dirty runoff generated (for example by careful
design, revegetation, etc.) and to minimise the potential loss of „clean‟ runoff to
the catchment.
Storm water management systems will be investigated and if necessary
designed and operated to minimise volumes generated, velocities and peak flows
discharging to the natural environment e.g. earth lined canals, energy dissipation
etc.
Storm water drains and evaporation ponds (settlement ponds) will be
investigated and if necessary designed to contain runoff up to the 1:50 year
event in compliance with GN704.
PPC Riebeeck must keep water systems clear of obstructions, so drainage
channels, inlets and outlets should be inspected regularly (at least quarterly and
after rain events). Unless problems are encountered during these inspections,
the water systems should be cleaned and maintained annually, which will include
desilting of channels and clearing of vegetation to the extent that free flow of

PPC Riebeeck West: Storm water Management Plan Page 47
drainage water is allowed to prevent flooding
PPC Riebeeck must prevent flooding from the water resources by storm water
runoff releases. The downstream water users must be protected against poor
quality runoff water. The water quality must be adhering to as indicated for
discharge for storm water.
Objective: Prevent damage to receiving watercourses from runoff arising
from the mine’s activities
Exposed surfaces within dirty areas (such as the plant and open quarry area) will
be kept to a minimum to minimise the volume of dirty runoff generated (for
example by careful design, revegetation, roofing etc) and to minimise the
potential loss of „clean‟ runoff to the catchment
Clean water diversions and dirty water collection facilities should be established
before land clearing and construction commences, to prevent clean rainfall runoff
becoming contaminated by construction activities
Clean runoff should be released to the system from which it came. The measures
envisioned are simple soil berms to prevent clean runoff entering dirty areas and
others to divert dirty water to holding dams (EMP update 2008).
Catch quarries and energy dissipation will be used to attenuate storm flows from
clean water diversions to reduce the risk of erosion of watercourses.
Dirty water drains will be designed according to the conceptual design criteria
given below.
Dirty water drains must be sized to manage the „dirty‟ water generated by a 1:50
year storm arising on contaminated areas
Dirty water must be directed into sumps or retention ponds, from where it can be
returned to the process water circuit. The storage facilities must have a minimum
freeboard of 0.8m above full supply level. (Note: this capacity requirement may
differ from that calculated using the previous condition -it is recommended that a
conservative estimate of whichever is the greater be used to ensure no spills.)
The width and height of the drains should be determined to ensure compatibility
with identified hydraulic requirements of the drain.
Objective: Limit erosion and the consequent degradation of soil and
pollution of air and water
The mine should rehabilitate all disturbed land throughout the life of the mine, as
soon as the disturbing force is removed. This is particularly relevant for the open
quarry area to minimise the production of quarry water.
Water systems, such as drains, canals etc. must be designed to prevent pollution
and minimise erosion or sedimentation i.e. in compliance with GN704.
Linear infrastructure (roads and pipelines) should be inspected on a regular basis
(ideally monthly) to check that the associated water management infrastructure is
effective in controlling erosion
All surface water management infrastructure constructed from soil (berms, canals
and bunds) should be inspected on a regular basis (ideally monthly), with more
frequent inspections during periods of high rainfall and after major rainfall events
(EMP update 2008).
Catch quarries and energy dissipation will be used to attenuate storm flows from

PPC Riebeeck West: Storm water Management Plan Page 48
clean water diversions to reduce the risk of erosion of watercourses. Energy
dissipaters should be constructed at points where there are concentrated
discharges of water to the environment that can cause significant erosion. Where
necessary, energy dissipaters should also be placed within water channels to
slow the speed of water (for example in the clean water diversions). The
effectiveness of these dissipaters should be checked on a monthly basis.
Energy dissipaters, such as rock packs and logs, should be placed in footpaths
where there are signs of erosion. The footpaths should be inspected on a regular
basis (ideally monthly), with more frequent inspections during periods of high
rainfall and after major rainfall events.
If any of the inspections detailed above identify eroded areas, these should be
repaired where necessary as soon as practicable.
Objective: Prevent damage to groundwater from seepage arising from the
PPC Riebeeck activities
The mine should rehabilitate all mined areas as soon as possible to minimise the
production of quarry water.
Clean water diversions around the quarry and overburden stockpiles, and dirty
water collection facilities, to rapidly remove quarry water, should be established
to prevent clean runoff entering the quarry and overburden areas and to divert
dirty water to pollution control dams.
Monitor pipe infrastructure for subsurface leakages.
Minimise ponding of potentially contaminated water by appropriate design of
infrastructure and cleaning up of spills as soon as possible.
Objective: Good housekeeping will be maintained to minimise the risk of
pollution
Operate in such a way as to prevent uncontrolled releases of potentially polluting
material.
Develop a contamination clean up plan to ensure that any spills are cleared as
soon as possible and to ensure disposal of spilt material in an appropriate way
Spillage from pipelines will be contained by means of bunds. These bunds will
direct spillage to areas where they may be cleaned up and returned to the
process. A contingency plan will be implemented to enable the early detection of
broken or burst pipelines
Ensure equipment is well maintained and fully operational.
Action any deficiencies in environmental compliance through the Corrective
Action Request (CAR) system
Carry out regular risk assessment to ensure that potentially hazardous materials
are appropriately stored, labelled and handled.
Where waste, other than mine residues, has to be disposed of, disposal will be in
line with legal requirements and carried out by a reputable waste contractor, with
periodic duty of care inspections by mine management.
Operate in such a way that there is zero-liquid effluent discharge associated with
runoff from contaminated areas
Ensure any sumps, silt traps, oil collectors etc. are regularly cleaned with any

PPC Riebeeck West: Storm water Management Plan Page 49
waste material being disposed of appropriately. Conduct regular inspections and
quality checks on the final outflow from these facilities to verify the effectiveness
of the silt and/or oil removal
Maintain a register of environmental impacts (Aspects and Impact Register).
Objective: Compliance monitoring and auditing
Monitoring of potentially affected water resources (G10Fand G10J quaternary
catchment area and groundwater) will take place regularly to assess whether the
PPC Riebeeck is having a negative impact on water resources and users of
these water resources. Site specific procedures to curtail any negative impacts
identified will be developed as required.
The efficacy of the measures when in place must be monitored and, if any
modifications and further additions to the systems are indicated, these must be
implemented as soon as practically possible.
Objective: Promote socio-economic development
PPC Riebeeck will identify and assess labour intensive methods for project
implementation.
PPC Riebeeck will engage with local government and the surrounding
communities to identify local social upliftment projects that PPC Riebeeck can
actively participate in.
Objective: Communication and engagement with stakeholders
PPC Riebeeck will engage with its I&APS in a public participation process to
ensure that I&AP concerns are addressed on a continuous basis.
PPC Riebeeck will co-operate with other water users, industries and local
government where these relationships support PPC Riebeeck's business
objectives in fulfilment of the IWWMP, for example, PPC Riebeeck may produce
excess potable water in future via desalination which could provide supply to
other users
Objective: Effective and efficient operation and maintenance
An adequate Maintenance Plan must be put into operation. Without this, some of
the mitigation measures currently being implemented and planned will become
inoperative and fail.
Regular maintenance measures must be programmed and enforced to ensure
the mitigation measures continue to be effective, for example the clearing of
stormwater culverts, sediment traps etc
Objective: Monitor and assess compliance with this strategy
Regular internal reviews and audits will be carried out to ensure the PPC
Riebeeck is operating in accordance with this strategy and its environmental
commitments with respect to the EMP.
The EMP will form part of all Contract Documents and contractors will be
informed of their environmental obligations during construction and operation. An
Environmental Site Officer will be appointed to monitor compliance with the EMP
and EMP Amendment
Water usage will be metered and recorded for development and maintenance of
a monthly water balance in accordance with BPG G2.

PPC Riebeeck West: Storm water Management Plan Page 50
The assessment of monitoring results, any changes to the water management
strategy and any significant incidents will be reported to station management and
DWAF
Bi-ennial audits of the EMP and this strategy will be undertaken as a minimum.
Annual audit results will be reviewed by top management and appropriate actions
implemented where required.
Objective: Plan for closure
In line with the requirements of MPRDA, a preliminary closure plan must be
prepared and this will be regularly reviewed throughout the life of mine. A final
closure plan will be drawn up in terms of the MPRDA and Regulations. Closure
objectives for minimising discharge and seepage of contaminated water to the
surface and groundwater environment, respectively include:
concurrent rehabilitation of the overburden stockpiles and surrounds including
control of screenings;
rehabilitation of all land disturbed by the PPC Riebeeck quarries;
prevention of ponding on rehabilitated areas to prevent ingress of water into the
perched aquifer;
topsoiling and vegetation of the overburden stockpiles where appropriate;
monitoring of rehabilitated areas and water resources (BPG G3) and reporting of
data to the regulatory authorities.
2.1.2 Strategic Actions of SWMP
The following strategic actions have been undertaken to facilitate integrated water and waste
management planning:
Identification of shortcomings in water management through site audits by external
parties;
Implementation of actions based on the recommendations following the site audits;
Assessment and review of the water metering system to ensure maintenance of an
accurate water balance and future development of salt balances;
Review of the water quality monitoring program;
Assessment of the discharge to the De Gift Dam and identification of alternatives to the
discharge;
Regular communication with stakeholders included those involved in the Berg catchment
management agency;
Development of this SWMP.

PPC Riebeeck West: Storm water Management Plan Page 51
3 CATCHMENT AREA
The Berg Water Management Area (WMA) is situated in the south-western corner of South
Africa and falls entirely within the Western Cape Province.
The National Water Resource Strategy (NWRS) makes use of three sub-divisions within the
WMA, as shown on Figure 5.1 These so-called areas of interest are used for the purposes of
describing the broad overview of the WMA and for assessing the reconciliation of water availability
and requirements. They are:
The Upper Berg sub-area, consisting of 8 quaternary catchments (G10A – G10H, G10J).
This area extends from the source of the Berg River in the Franschhoek Mountains to
Misverstand Dam, south of Piketberg.
The Lower Berg sub-area, consisting of 10 quaternary catchments (G10K – G10M, G21A –
G21F and G30A). The area includes the Berg River catchment between Misverstand Dam
and the Berg River mouth. It includes the smaller rivers which drain some West Coast
catchments direct to the sea, and the catchment of the Diep River.
The Greater Cape Town sub-area, consisting of 11 quaternary catchments (G22AG22K and
G40A). This area includes the urban rivers in the Cape Town Metropolitan area, the Kuils,
Eerste, Lourens and Sir Lowry's Pass Rivers, as well as the Steenbras River catchment.
The PPC Riebeeck West site falls within two catchment areas, the G10F and G10J quaternary
drainage region of the Berg WMA (Figure 3.2).
Figure 3.1 indicates the quaternary catchments within the Berg River WMA. Figure 3.1 indicates the
positioning of the PPC Riebeeck West site and the catchment divide that runs through it. Most of the
existing Ongegund facility drains towards the G10F quaternary drainage region. The Optimal Pit and
the new Delectus facility all drain towards the G10J quaternary catchment.
3.1 SENSITIVITY OF THE WATER RESOURCE
3.1.1 Determining Current Management Class for the Water Resource
The drainage line in the vicinity of the PPC Riebeeck West mine and plant is non-perennial and only
flows during high rainfall events. The municipal sewage works discharges to drainage region G10F
which impacts the overall sensitivity of the water resource.
DWAF has identified the Drainage Region G10J and G10F as being:
moderate in its Ecological Importance and Sensitivity (EIS) and
largely modified, Class D (G10F) and natural, Class B (G10J), in its Present Ecological
State (PES).
3.1.2 Determining Future Management Class of the Resource
The visioning process is part of the Resource Management Strategy, which is currently being
developed. Future Management Classes for quaternaries are therefore not available at present.

PPC Riebeeck West: Storm water Management Plan Page 52
3.1.3 Determining Sensitivity of the Water Resource in the Vicinity of the
Plant
In the short term, with the Future Management Classes not defined, the precautionary principle will
apply, and the vision for the catchment will be based on ecological criteria, as tabulated in Table 3.1.
Management Measures in the short term have been evaluated as B for drainage region G10J and as
D for drainage region G10F. The management measures will be to maintain the Present Ecological
State - Maintain.
Table 3.1 Management Measures in the Short Term
In the longer term, the catchment vision will be based on the current assessment and the future
Management Class, as tabulated in Table 3.2. Management measures in the longer term have been
evaluated as Maintain with a vision of a future Management Class II for drainage region G10J and
Management Class IV for drainage region G10F - Acceptable Quality.
Table 3.2 Management Measures in the Long Term
The sensitivity of the water resource is based on the management measures that will be employed
to affect the catchment vision. This has been tabulated in Table 3.3. The applicant proposes to
employ management measures with a view to maintain the resource class.

PPC Riebeeck West: Storm water Management Plan Page 53
Table 3.3 Sensitivity of Water Resources in the Vicinity of the Plant
3.2 SURFACE AND GROUNDWATER
3.2.1 Surface Water
The information concerning surface water characteristics of PPC Riebeeck has been
extrapolated from the following report.
Dr W.R Harding. February 2008. Proposed expansion of the Pretoria Portland Cement (PPC)
Manufacturing Facility in Riebeek West. Aquatic Study.
Ivusi Environmental Consultants (Pty) Ltd. August 2008. Integrated Water Use license of the
Pretoria Portland Cement (PPC) Manufacturing Facility in Riebeek West.
PPC Riebeeck falls within the Berg River catchment and within the quaternary catchment area
of G10F.
Most of the rivers in the ISP area rise in the Table Mountain Group (TMG) mountain catchments
which provide very good quality water with total dissolved solids (TDS) concentrations of about
60 mg/l. The quality of the water generally deteriorates further downstream.
The middle reaches of the Berg River receive effluent from various wastewater treatment works
as well as agricultural return flows and occasionally naturally high salinity runoff from tributaries
underlain by Malmesbury shales of marine origin. This leads to water quality problems in the
lower Berg River.
The surface water resources in the area are mainly used for farming activities downstream of
the PPC Riebeeck site. There is an existing WWTW works on the property adjacent to PPC
which belongs to the local municipality and the effluent from this impact on the stream that flows
along the Middelpos farm and has shown high ortho-phosphate levels in testing. There is
however three dams on this stream which help improve the water quality.
Description of the aquatic environment:
Four streams, two with associated in-line (or on-channel) dams and/or wetlands are located on
the PPC Riebeeck site. These are referred to as Stream A (Delectus property), Stream B
(Middelpos property), the “Vlakkerug stream” and the “Spoil site” stream (see Figure 5.8). The
characteristics of each of these streams are described below.

PPC Riebeeck West: Storm water Management Plan Page 54
Figure 3-1: Indication of the location of the various streams associated with PPC
Riebeeck

PPC Riebeeck West: Storm water Management Plan Page 55
Table 3-4: Summary of the Ecological Status of each stream.
Stream A (Delectus stream) arises in the Kasteelberg mountain and discharges onto the
Delectus property at the boundary of the Ongegund/ Delectus properties. Previously, this
stream would have crossed the R311 in the vicinity of the current pit, but has been diverted both
upstream and downstream of the R311 culvert.
The stream picks up stormwater runoff from the R311 as well as mine water discharge from Pit
B and then flows via an artificial channel over the Delectus property into a farm dam.
Downstream of the dam, a fairly extensive wetland comprising common facultative wetland

PPC Riebeeck West: Storm water Management Plan Page 56
plants has developed due to seepage and overflow from the dam, as well as from a spring. The
stream has a Present Ecological Status (PES) of C, i.e. moderately modified with some loss of
natural habitats.
Stream B starts on the Kasteelberg and runs through wheat fields to the south of Pit A. There
are three small dams across the stream, which receives treated effluent from the wastewater
treatment works, runoff from the Ongegund village and also excess water from Pit B
dewatering. Water is abstracted from Dam 2 for irrigation on Middelpos farm. A wetland exists
between Dams 2 and 3. The stream also has a Present Ecological Status (PES) of D-E, i.e.
largely to extensively modified.
The Vlakkerug stream is a small tributary of Stream B and joins it just downstream of Dam 3.
The stream / channel follows an artificial alignment between the fields from the Vlakkerug hill.
The stream also has a PES of E, i.e. extensively modified.
The Spoils site stream emerges at the gabion-supported toe of the existing overburden dump.
The stream is deeply incised and shows evidence of groundwater inputs. The stream has a
higher PES, i.e. B which suggests that it is largely natural with few modifications, but with some
loss of natural habitats.
All the steams on the site have been highly degraded by previous agricultural, urban and mining
activities, and the creation of farm dams, while the discharge of treated sewage effluent and
water from the mine has resulted in artificial more perennial aquatic systems.
Water quality:
A detailed assessment of the water quality is presented within the aquatic study referenced at
the beginning of this section. All of the aquatic environments assessed contained elevated
concentrations of nitrogen and, particularly, phosphorus.
Nutrient enrichment of Stream B is partially influenced by the disposal of wastewater effluent.
This condition is not expected to worsen as no increase in effluent disposal is anticipated – and
the wastewater treatment facility will eventually be closed down circa 2020. Improvements to
the current attenuation of nutrient loading from the works are deemed possible through the
creation of a tiered, cascading slope wetland between the works and the second dam on
Stream B.
3.2.2 Groundwater
Information concerning the current groundwater conditions has been extrapolated from the
following report.
SRK Consulting. February 2008. PPC Riebeek West Expansion Project: Specialist
Hydrogeological Assessment
The site is underlain by rocks of the Malmesbury Group, while the Kasteelberg Mountain to the
west is composed of Table Mountain Group rocks. Figure 2.9.

PPC Riebeeck West: Storm water Management Plan Page 57
Figure 3-2: Geological cross-section of the Kasteelberg between Riebeek-Wes and
Riebeek Kasteel
Aquifer types: The aquifers in these two rock types are of the secondary or fractured type, and
typically they have median borehole yields of 0.5 to 2.0l/s, i.e. low to moderate yields. The
reason for the relatively high yield of the Malmesbury aquifer in this vicinity is due to the
favourable influence of the TMG aquifer, and particularly the increased recharge of good quality
water in the TMG due to the increased orographic rainfall on the Kasteelberg Mountain (see
Figure 2.8). According to the Aquifer Classification Map of South Africa (Parsons and Conrad,
1998) the aquifers in the study area are classed as Minor Aquifers
Borehole information: The hydrocensus conducted revealed some 33 boreholes within the
vicinity of PPC Riebeeck (Figure 2.10). All of the boreholes exploit the Malmesbury aquifer,
with borehole depths ranging from 60 to 100m 3 . Depth to water level in these holes varies from
1.5m to 35m below the surface. Most of the groundwater is abstracted by means of windpumps
and is used for stock watering, although some is used for domestic purposes and irrigation.
Due to the low yields of the aquifer, as well as the relatively poor water quality, groundwater is
not used for any large scale irrigation in the vicinity of the facility.
Direction of groundwater flow:
Groundwater levels measured during the hydrocensus have been used to draw-up a
groundwater level contour plan, as shown in Figure 2.11 below. Inferred groundwater flow
directions are shown as black arrows (perpendicular to contour lines). The main features are:
The quarry acts as a „sink‟, with inflows at the main bench level of 120 mamsl.
Approximately 200 m3/day is pumped out of the sump in summer (pers comm. A Gricius);
Groundwater flow to the east from the TMG of the Kasteelberg, a main recharge source;
A „ridge‟ of groundwater between VG002 and MI001, probably related to the topographic
high in this area;
During the hydrocensus some landowners complained that the quarry has affected water levels
in their boreholes, particularly Vlakkerug, with some apparently even drying up.
3 One borehole on Bassiersvlei is however drilled to 150m deep.

PPC Riebeeck West: Storm water Management Plan Page 58
Figure 3-3: Indication of the location of boreholes in and around PPC Riebeeck

PPC Riebeeck West: Storm water Management Plan Page 59
Figure 3-4: Indication of groundwater flow at PPC Riebeeck.

PPC Riebeeck West: Storm water Management Plan Page 60
Groundwater quality:
Table 2.2 below provides an indication of the quality of various boreholes tested within the region.
See Figure 2.10 above for an indication of the location of the boreholes.
Table 3-5: Summary of groundwater quality.
The table shows that there is quite a range in quality. EC ranges between 96 and 1040 mS/m and
seems to vary without pattern and over small distances, e.g. LI001 and LI002, with EC‟s of 860 and
96 mS/m, respectively. There is a possible indication that the shallower groundwater is of poorer
quality than the deeper, e.g. LI001 vs BI001.
The groundwater is a sodium chloride type, typical of the Malmesbury Aquifer and mostly neutral to
slightly alkaline. Iron concentrations are medium to high in many boreholes, particularly VG002 and
004 with 9.9 and 8.8 mg/ℓ Fe, respectively. High iron content is a common feature of the Western
Cape‟s ground waters, especially in the TMG Aquifer and adjacent aquifers.
Groundwater drawdown / Quarry inflow:
The current quarry depth of 78 m has caused a zone of drawdown in groundwater levels in the
surrounding Malmesbury aquifer, extending ~5 km to the east but a smaller distance to the west,
because of recharge from the TMG Aquifer of the Kasteelberg. Current groundwater inflow is ~200
m3/day, with an EC of 260 to 310 mS/m. Recharge from the Kasteelberg will tend to provide a
natural buffer against effects of deepening of the quarry in areas to the west and south. Areas with
existing shallow groundwater levels, including the town of Riebeek West, are unlikely to be affected
by deepening of the quarry.
Table 2.3 below provides an indication of the anticipate impact of the deepening of the quarry over
time.

PPC Riebeeck West: Storm water Management Plan Page 61
Table 3-6: Indication of anticipated impact of the deepening of the quarry
As the zone of drawdown extends to the north-east and east, it will encroach on the area of
poorer groundwater quality.
3.3 DETERMINING MINE RISK
Classification of Mines
Category A
Any gold or coal mine;
Any mine with an extraction metallurgical process, including heap leaching; or
Any mine where sulphate producing or acid generating material occurs in the mineral deposit.
Category B
Any mine where significant impacts may occur on water quality or quantity of affected water;
Category C
All other mines not covered by A or B.
Riebeeck West is classified as a Category B Mine.
The mine risk has been determined as L based on the information as tabulated in Table 3.4.
Table 3.7 Mine/Industrial Risk

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Figure 3.5 Quaternary Catchments

PPC Riebeeck West: Storm water Management Plan Page 63
Figure 3.6 PPC Quaternary Catchments

PPC Riebeeck West: Storm water Management Plan Page 64
4 WATER BALANCE
PPC Riebeeck West use municipal water on site within the facility for all process and domestic use.
Of this water the water used for domestic use will go to the proposed WWTW for treatment before
being discharged to the receiving environment. The activities on site are regarded as a closed
process meaning that there is no effluent produced from the activities.
The storm water falling on the existing Ongegund facility is discharged to an unnamed tributary of
the Berg River and into the Delectus Dam which discharges into a tributary of the Berg River.
Groundwater entering the pits as well as any rainwater will need to be removed in order for the safe
continuation of the mining activities. Of this water some will be used for dust suppression, irrigation
and for the crusher and screenings. The remaining volume will be discharged to an unnamed
tributary of the Berg River.
See Figure 4.1 for an indication of the current water balance diagram for PPC Riebeeck.
Figure 4-1: Current water balance of the operation.

PPC Riebeeck West: Storm water Management Plan Page 65
Surrounding
For a full description of the current water use and an indication of the water management
requirements, the submitted Water Use License Application should be consulted. In summary, the
water use license covers the following water license applications:
Table 4-1: Summary of Water Uses to be licensed

PPC Riebeeck West: Storm water Management Plan Page 66

PPC Riebeeck West: Storm water Management Plan Page 67
5 GN704 AND OTHER REQUIREMENTS
5.1 INTEGRATED WATER USE LICENSE REQUIREMENTS
MONITORING REQUIREMENTS FREQUENCY
Water Quantity Monitoring
The quantity of water flow / discharge will be measured through the
installation of water flow meters to measure the following volumes;
Dewatering from any of the Pits – separate flow meters for separate
dewatering points.
Water re-used by the mine from the pit and storm water settlement dams -
such as for dust suppression or gardening purposes (separator flow meters
for separate re-use points).
Process water used in the plants (from the cooling ponds)
Municipal water used.
Water released from the storm water system associated with the existing
plant.
All recorded water flows will be used to update the water balance diagram
which will be used as a management tool.
Flow meter requirements
Self registering flow meters must be installed in the delivery lines at easily
accessible positions near the points of abstraction.
The flow metering devices shall be maintained in a sound state of repair
and calibrated by a competent person at intervals of not more than once in
two years. Calibration certificates shall be available for inspection by the
DWA act Regional Head or his/her representative upon request.
Calibration certificates in respect of the pumps must be submitted to the
DWA act Regional Head after installation thereof and thereafter at intervals
of two years.
River Diversions and Crossings
PPC Riebeeck will submit a set of as-built drawings (not schematic layouts)
to the act Regional Head of all river diversions, road crossings and weirs.
Within 30 days after completion of the activities referred to, PPC Riebeeck
West shall inform the DWA act Regional Head thereof and together with
this notification include a signed certificate of approval by a competent
person to the effect that the construction was completed according to
drawings.
A suitably qualified person, appointed by the licensee, and approved, in
writing, by the DWA act Regional Head, must be responsible for ensuring
that the structures are maintained in line with the drawing specifications.
PPC Riebeeck will monitor the diversion structures and the drainage line
once a year to:
ensure that all mitigation measures are effective;
ensure that alien invasive species are not allowed to colonise;
assess the habitat to ensure the sustainability of the diversions;
Record
Continuous
Report on
monthly
Ongoing
Quarterly

PPC Riebeeck West: Storm water Management Plan Page 68
ensure compliance with all conditions within the Water Use
License.
Groundwater Quality Monitoring
In order to determine the impact Riebeeck is having on the ground water, PPC will monitor
the depth of groundwater from surrounding boreholes
Riebeeck will monitor and record the depth of the ground water from the
boreholes using continuous level loggers
The depth results will be presented in such a fashion that seasonal
variations can be determined.
Riebeeck will monitor the following parameters of the water from the
boreholes:
Electric Conductivity (EC) in mS/m
Calcium (Ca) in mg/l
Potassium (K) in mg/l
Chlorides (Cl) in mg/l
Sulphates (SO4) in mg/l
Sodium (Na) in mg/l
Magnesium (Mg) in mg/l
Nitrates and Nitrites (N) in µg
Quarterly
Monthly
Quarterly

PPC Riebeeck West: Storm water Management Plan Page 69
6 WATER CONSERVATION PROGRAMMES
This section provides a brief overview of the water conservation measures of the PPC Riebeeck
site. It is important to remember that the site has seen extensive mining operations since 1956 and
the description contained herein reflects this point.
The WDM and water conservation measures described below have been considered.
Regarding the plant operations the following measures were considered.
Stopping operation units which are water intensive when the demand to product is not
required.
Improved reticulation design and plumbing standards
Replacing potable water with ground water inflow and runoff accumulated in the Mine water
sumps.
Replacing potable water used in irrigation systems with mine sump water.
Re-use of oil separator runoff water
Regarding plumbing fittings the following measures were considered for implementation in the
changerooms and toilets:
Dual-flush or interruptible toilets;
User-activated taps;
User activated urinals;
Low flow shower heads; and
Tap controllers.
Dual-pipe systems were considered so that recycled water could be used for purposes such as
toilet flushing.
Measures considered to reduce the water used for gardening include:
Water-wise indigenous plants;
Mulching,
Efficient irrigation systems,
Irrigation scheduling,
Rain harvesting by setting up a rainwater tank for capturing of the rainwater
Capturing of rainwater from the gutter and roof; and
Recycling of wastewater for use in gardens.
The rainwater could also be used for toilet flushing and outdoor use.
In addition, in an attempt to reduce the loss of water through leaks in the plant will be encouraged
(through the awareness talks and newsletter) to take responsibility for the checking and repairing of
leaking taps, toilets and hot water geysers. All leaks is reported as part of the incident management
system and plant maintenance system.

PPC Riebeeck West: Storm water Management Plan Page 70
Furthermore, the reduction of the use of water in houses/flats by implementation of the following:
Installation of water meters at each house/flat
Encourage the use of grey water systems
Communication and education campaigns on how to conserve water and reduce water
wastage;
Improved reticulation design and plumbing standards for houses and flats; and
High levels of operation and maintenance should be maintained with rapid response to
bursts and leaks.
Use of mine sump water for irrigation at
o Smuts house
o Rugby field and training centre gardens
6.1 WATER CONSERVATION MEASURES IMPLIMENTED
The conservation of water PPC Riebeeck is the responsibility of all employees. It is important for
everyone to be involved in implementing feasible and practicable water saving technologies in
order to achieve the required water conservation levels, as each party has a role to play in ensuring
that water wastage is reduced and the necessary water demand management measures are
implemented to ensure that water conservation takes place.
PPC Riebeeck have however committed to the following WDM and water conservation measures:
Monthly monitoring of water usage in the plant
Stopping of water intensive operation units (Riebeek Kiln 2) which are more water intensive
when the demand for product is low.
Use of high pressure cleaning system at wash bay
Use of mine sump water for irrigation at
o Smuts house
o Rugby field and training centre gardens
Use of mine sump water for toilets at production for flushing

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7 MONITORING
7.1 WATER MONITORING
General requirements concerning monitoring of quantity and quality of water:
All water quantity flows recorded by the mine will be presented within an updated water balance
diagram. Riebeeck will ensure that:
All quantity values are within the permitted allowances as provided within the water license.
All water quality results are presented in a manner which;
Shows seasonal variations
Provide an indication of DWAF guideline limits not to be exceeded.
If the monitoring results indicate that pollution levels are observed to be increasing, the following
steps must be taken:
Determine the source of the pollution.
Determine if this is a once off incident or a routine event.
If this is a once off incident determine how it can be avoided in the future. Implement .
If this is a routine event, determine how it can be managed in future. Implement*.
The success of mitigation measures must be confirmed through the quarterly sampling.
If it is observed that pollution continues after three months of monitoring, alternative
mitigation measures must be implemented and further monitoring undertaken (as described
above).
Should additional mitigation measures not work, the mine must contact DWAF for
assistance.
The surface water quality results should be compared to the South African water quality
guidelines for livestock watering (as per the recommendations from the SRK letter dated
15/10/2010 – ref:421546).
The surface water quality monitoring programme has been extrapolated from the
reccomendations made within the SRK report dated 10/03/2011 – ref: 421546/2)
7.2 SURFACE WATER MONITORING PROGRAMME:
Sampling points:
The implementation of appropriate measures will be dependant on the practicality and cost of the proposed measures.

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Figure 7-1: Surface water sampling points

PPC Riebeeck West: Storm water Management Plan Page 73
Table 7-1: Sampling point locations
Sampling schedule:
It is recommended that samples are collected once every 2 months. During the collecting of the
samples the condition of the waster body should also be captured. The table below provides an
indication of the analytes that should be tested for each different sample.
Table 7-2: Schedule of analytes

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Sampling protocol:
Below is a recommendation of the sampling protocol that is implemented

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7.3 ENVIRONMENTAL MONITORING REQUIREMENTS
The following section provides a description of the environmental monitoring that will be
implemented by the mine. The need for monitoring to ensure good environmental performance and
compliance to legal requirements are part of the ISO 14001:2004 commitments.
Riebeeck will make use of their environmental monitoring results to ensure continual improvement
in environmental management.
All results from monitoring will be used to guide future environmental management on the
mine and used to aim for continual improvement in terms of environmental performance.
For all monitoring activities, the following will be implemented:
Ensure monitoring service providers provide in writing the following information about the
monitoring activities:
- Method of monitoring,
- Location of monitoring points (GPS) and provided on a plan.
- Frequency of monitoring,
- Minimum list of parameters to monitor for,
- Analysis of results (what guidelines and / or standards to use as performance indicators)
- Storage and use of results.
Ensure all monitoring service providers in writing:
- Provide a reason for using the guidelines and / or standards against which they compare
the results. This is particularly important for water sample analysis as the guidelines used
as indicators will vary depending on a number of site-specific factors.
- Present the results of the monitoring in a manner that easily indicates when guidelines and /
or standards have been exceeded.
- Present the results in such a manner that seasonal variations can be determined.
- Assist in identifying the cause of the guidelines and / or standards being exceeded.
- Present guidance regarding what action to be taken in the event of the appropriate
guidelines and / or standards being exceeded.
In the event of a major breach of environmental legislation and permit conditions as determined
by the monitoring results, a report will submitted to the relevant authorities in writing within 30
days:
- details of the incident
- corrective action plan
- time frame/schedule for implementation of corrective action.
All monitoring locations will be shown on a plan to provide a visual representation of where
monitoring will be performed.

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GENERAL PERFORMANCE MONITORING AND REPORTING REQUIREMENTS
MONITORING REQUIREMENTS FREQUENCY
ISO 14001:2004 Management Review
As part of the commitments required for the continued implementation of
the ISO 14001:2004 environmental management system, Riebeeck will
undertake an annual review of its systems to identify where continually
improvements in environmental management can be made.
Bi-annual internal audits will be undertaken to ensure the success of the
implementation of ISO 14001:2004. The frequency of auditing various
activities will be based on the significant impacts associated with the
activity
Legal Audit
As part of the commitment to at minimum ensure compliance with all
applicable environmental legislation, Riebeeck will employ an external
environmental lawyer to undertake legal assessments of the site.
Plans will be drawn up and implemented to rectify any legal non
conformances discovered.
Reporting on the integrated water use license
Riebeeck will report back to DWAF on its commitments contained within
its integrated water use license as and when required. This includes but
not limited to;
Water balance
Water quality monitoring results
Reporting on the permitted waste disposal site
Riebeeck will report back on its waste disposal site using Annexure E of
its permit approval letter.
Environmental Performance Assessment Reports
Every 2 years Riebeeck will commission an independent consultant to
undertake an environmental assessment of the approved environmental
management programme in terms of regulation 55 of the MPRDA.
CONSUMPTION MONITORING
Water
Location:
Flow meters at all extraction
points
Annual
Management
Review
Internal
audits every 6
months
Every 2 years
As and when
required.
When
required
Annually
Every 2 years
MONITORING REQUIREMENTS FREQUENCY
Parameters:
Volumes purchased from
municipality.
Volumes used (ℓ)
Pit water reused
Volumes dewatered
Continuous /
reported
Monthly

PPC Riebeeck West: Storm water Management Plan Page 77
Electricity
Location:
On major electrical using
equipment
Fuel
Location:
Fuel storage tanks
Waste Generation
Parameters:
Parameters:
Units of electricity used
Parameters:
The volume still remaining in the
tank.
The volume of fuel dispensed.
Waste inventory on a spreadsheet (domestic, recyclable, hazardous etc)
Quantity generated
Quantity of waste disposed.
Monthly
Daily
Daily
Weekly
Monthly

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8 KNOWLEDGE GAPS
Baseline Environment:
During the PPC “Se Kïka” EIA process (which has now been withdrawn) a number of specialist
studies were commissioned which has provided PPC Riebeeck with a detailed understanding of
their baseline environment. The specialist studies included;
Air Quality;
Agricultural Study;
Aquatic Study;
Botanical Study;
Economic Study;
Geotechnical Study;
Health Study
Heritage Study;
Hydrogeological Study;
Noise Study;
Transport Study;
Social Study; and
Visual Study.
As a result of all the specialist studies commissioned PPC Riebeeck has a good understanding of
their baseline environment and the potential impact of the mine on the baseline environment. Over
time through implementation of monitoring programmes, the knowledge concerning the baseline
environment can be improved.
Mining activities:
At the time of compiling this Stormwater Management Plan, there are uncertainties on the best
manner to handle the dirty water from the mining and production process.The correct design for
water re-use management must be determines
These uncertainties need to be addressed before implementation.

PPC Riebeeck West: Storm water Management Plan Page 79
9 ENVIRONMENTAL MANAGEMENT PROGRAMME
The following section provides the core of the environmental management programme:
management plans for the following aspects:
Operational environmental management plans for implementation;
Management plans for potential emergencies; and
Monitoring management plans.
The operational environmental management plans is guided by the following Sections and
Regulations of the MPRDA. Section 39 of the MPRDA states that:
39(3) An applicant who prepares and environmental management programme or an
environmental management plan must –
(d) describe the manner in which he or she intends to –
(i) modify, remedy, control or stop any action, activity or process which causes pollution or
environmental degradation;
(ii) contain or remedy the cause of pollution or degradation and migration of pollutants;
and
(iii) comply with any prescribed waste standard or management standards or practices.
The MPRDA Regulations state that an EIA must…
50 (e) determine the appropriate mitigation measures for each significant impact of
the proposed mining operation. [and include a]
(h) description of the arrangements for monitoring and management of environmental
impacts
51 An environmental management programme … must include…
(b) an outline of the implementation programme…
The action plans for each activity as described in Section 3 has been set out providing:
The description of the goals and objectives of the mitigation measures for each activity;
The actions that must be implemented to mitigate the impacts associated with the activity; and
The time frames for implementation of the actions.
Over time these documented management measures may change as the mine continually strives
for improvement as part of their commitment to the implementation of a successful ISO
14001:2004 environmental management system. These changes will be noted as part of the
environmental performance assessment reports and included in amendments to the environmental
management programme every 5 to 10 years or earlier as required.
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9.1 MANAGEMENT PLAN – MINING DEPARTMENT
The following management measures are to be implemented to prevent, minimise or mitigate
impacts associated with the mining activities as described in Section 3.1. Initially generic
environmental management measures have been described followed by the management
measures for the individual activities which make up the mining department.
GENERIC MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Good housekeeping.
In order to implement good housekeeping the mine will:
Ensure that no waste is left lying around the mining area and that waste is
disposed of in the correct manner. (See waste management Section 9.8.3).
Limestone spillages (at any of the crushers) will be recycled through the
crusher onto the limestone stockpiles.
Bins are provided for both domestic and hazardous waste and regularly
emptied.
Oil drums are stored in the designated areas.
Inspections of the mining areas will be undertaken to ensure compliance with
the good housekeeping commitment.
Oil spills:
The mining department will maintain a supply of suitable absorbent to soak up
oil spills.
Should a spill occur the following steps will be implemented:
The source of the spill will be stopped.
The spill will be contained using suitable absorbent.
Once contained the spill and absorbent will be removed and disposed of in a
waste bin and temporarily moved to the hazardous waste store until removal
by the appropriate waste removal company.
Daily
Weekly
Ongoing
As and when
a spill occurs
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9.1.1 Mine and resource planning
Although there are no negative impacts associated with resource planning the negative impacts of
not implementing effective planning are significant.
Goals and objectives: To optimise utilisation of mineral resources within the mining right area.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Quarry planning meeting:
The mine will implement quarry planning meetings where the following will be
discussed:
Planning for the next year‟s mining requirements based on the requirements
for the kiln production through the creation of a short-term mine plan.
Environmental issues to be address in the short term mine plans will include
(but not limited to);
Dewatering / Storm water control
Alien vegetation removal
Topsoil removal and storage
Overburden removal / dumping
Concurrent rehabilitation requirements
Fire break requirements
No-go areas which include but not limited to
Smuts cottage area
Renosterveld conservation area
The medium conservation area on the Delectus property
Short-term mine plans will be implemented by the Mine Manager.
Mine plans:
The mine will update and submit to the Department of Minerals and
Resources the statutory mine plans using a surveyor to identify the extent of
mining undertaken.
Aerial photographs will be taken to provide proof of the concurrent
rehabilitation that has been implemented by the mine.
9.1.2 Haul road construction / maintenance:
Annually
Ongoing
Annually
Annually
The following management measures will apply to the construction of new haul roads and
maintenance of existing haul roads within the mine.
Goals and objectives: To position the route of haul roads to ensure that all haulage requirements
follow the shortest possible route (to save fuel) and do not traverse through sensitive
environmental features. Upon completion of haul roads they will be maintained in an acceptable
standard.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Haul road construction:
All new haul roads will be planned so as to take the shortest possible
distance to access the required limestone reserves or overburden dump
position, as determined by the mine plans, while avoiding sensitive
During
planning
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environmental features such as;
Known heritage resources (See heritage specialist report).
Sensitive floral habitats (See botanical specialist report)
Water resources. (See water use license application)
During the construction of a haul road, topsoil will be removed ahead of the
haul road development and stockpiled in a topsoil storage berm or used
immediately in concurrent rehabilitation projects.
During haul road construction the following environmental parameters will be
considered;
Free draining of rain water falling on the haul roads
Allow for natural drainage of surface water underneath, using culverts if
necessary.
Appropriate compaction to reduce the generation of dust as and when in use
by haulage trucks.
Raising of the haul road above the natural topography to ensure runoff does
not flow over the haul road.
Haul road maintenance:
All haul roads in use by the mine will be monitored for;
Free draining of rain water falling on the haul roads.
Surface ponding adjacent to the haul road
Potholes and corrugation on the surface of the haul road
Build up of fines
As and when any of the above are identified during monitoring, maintenance
of the haul road will be implemented, which could include:
Should ponding be discovered either on the road or adjacent to the road, the
mine will create the appropriate diversion channel to stop future ponding.
All potholes will be fixed as and when identified.
As and when surfaces become uneven from usage (as determined by the
haulage drivers) they will be re-graded.
Build up of fines will be removed by the grading / compaction.
9.1.3 Stripping of topsoil and overburden
During
construction
Ongoing
As and when
required
The following management measures will apply to the stripping of topsoil and overburden to
expose the mineral reserves suitable for mining.
Goals and objectives: The goal is to only strip topsoil and overburden as and when required (no
more than 12 months prior to anticipated mining of an area). Topsoil must be stripped separately
to the underlying subsoil / overburden layer.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Topsoil:
Riebeeck will establish and maintain a topsoil register which will record the
following:
Amount of topsoil stripped from an area (tonnage).
The quality / quantity of the topsoil prior to stripping based on taking
observations and completing analysis
The use / storage of the topsoil (tonnages).
Establish
during 2011
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If stored, the frequency of the monitoring of the stored soil for signs of
erosion and establishment of alien vegetation.
To prevent pollution of soil through oil spillages from vehicles,
All vehicles used for stripping and handling topsoil / overburden will be
maintained as per the maintenance schedule (on average every 250 hours)
Vehicles will be inspected daily for signs of oil leaks prior to commencement
of a shift. If discovered the leak will be fixed prior to using the vehicle.
Refer to generic management measures for an indication on how oil spills
are dealt with.
9.1.4 Drilling, blasting and secondary breaking
As per
maintenance
schedule
Daily
Drilling and blasting has serious health and safety considerations as well as environmental
impacts. The management measures below are in relation to the environmental impacts.
Goals and objectives: The environmental goal during drilling operations is to contain dust created
as a result of drilling operations. The environmental goals and objectives of blasting operations are
to have an insignificant impact on surrounding land owners as a result of the blast vibrations, air
blast and noise while achieving the desired fragmentation of the rock.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Drilling:
All drilling to be conducted in accordance to a drill plan as approved by the
Mine Manager.
The drill rigs used on the mine will be fitted with the appropriate dust
extraction equipment.
Drill rigs will be maintained as per a preventative maintenance schedule.
Large Oil spills (greater than 2m in diameter) created during drilling operations
will be cleaned up as per the generic oil spill management measures.
All blasting waste to be dealt with as per the waste management plan.
No blasting waste to be left in the mining area.
Groundwater draw down:
The impacts lowering of the topography has on ground water will be
monitoring via recording the depth of the ground water in the mining area. See
Section 9.11 monitoring requirements
9.1.5 Loading and hauling / conveying
Daily
Ongoing
As required
As required
Ongoing
See
monitoring
section
Goals and objectives: To minimise the amount of dust from vehicle entrainment along haul roads
and to maximise fuel efficiency of the haul vehicles.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Upkeep of mine vehicles:
All vehicles used in loading and hauling exercises will be maintained in a good
condition as per a maintenance schedule.
Prior to the commencement of a shift the vehicle operator will be responsible
to undertake a check of his / her vehicle to ensure that the vehicle is in a good
condition. This includes oil leaks and excessive emissions.
If an oil spill is discovered under a vehicle it must be cleaned up and the
vehicle repaired.
Maintenance
schedule.
Before shift.
As and when
required
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Managing dust from vehicle movement.
Speed limits of a maximum of 60km/h will be implemented on the haul roads
The generation of dust from active haul roads will be reduced through wetting
the road from a water tanker on all non rainy days.
Improvements to dust suppression on haul roads will be investigated.
Economically feasible options will be implemented
All mobile equipment operators will be responsible for determining if and when
haul road maintenance is required.
9.1.6 Stockpiling limestone / shale
Daily
Non rainy
days
Annually
Daily
Goals and objectives: To reduce dust, to reduce the likelihood of contamination of storm water
and to ensure stockpiling takes place in a manner that is ideal for clinker production.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Storm water management around stockpiles:
All storm water will be directed away from the stockpile area by
implementation of appropriate storm water management system.
Storm water management channels will be checked for build up of fines and if
necessary cleaned.
9.1.7 Concurrent rehabilitation / conservation
Ongoing
Every 6
months
Goals and objectives: To make concurrent rehabilitation an integral part of day to day mining
activities. To reduce the visual impact associated with the mine through the implementation of
concurrent rehabilitation.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
A concurrent rehabilitation plan will be developed and implemented
annually. Future drafts of this plan will detail the following:
Rehabilitation of overburden dumps including historic dumps
Backfilling of mined out areas
Alien vegetation removal
Management of Renosterveld area
Fire break management
Greening of exposed areas within the plant.
Monitoring requirements of rehabilitated areas
This plan will detail the concurrent rehabilitation requirements for the year and
will complement the short term mine plan and overburden dumping plan.
Concurrent rehabilitation of overburden dumps:
The goal for overburden dumps is to return the land back to a state where it is
suitable for agricultural purposes.
The goal for the lag distance between completion of dumping overburden and
rehabilitation of the exposed dump will be defined in the overburden dump
rehabilitation plan.
As and when a section of an overburden dump is deemed completed, it will be
top-soiled and left in a condition which is suitable for agriculture.
Rehabilitated land will be leased to the farmers in the area, for utilisation for
agricultural purposes.
Developed
during 2011
and
implemented
Annually
As and when
required.
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Rehabilitated areas will be monitored for signs of erosion, storm water control
and alien vegetation establishment.
If erosion or alien vegetation is noted, the erosion must be fixed and the
cause of the erosion rectified and the alien vegetation must be removed by
hand pull methods.
Backfilling of mined out areas:
In mined out areas, where backfilling will not result in future sterilization of
mineral reserves, and is not prohibitively expensive it will be implemented.
Backfilling will include the filling of an area with overburden, compaction, and
then covering with topsoil and re-vegetating.
All back filled areas will be monitored for establishment of natural vegetation,
erosion and alien vegetation
Alien vegetation removal plan: (See Annexure) for a current copy of the
plan.
Riebeeck will implement an alien vegetation removal programme for the
following species:
Rooikrans (Acacia cyclops),
Port Jackson (Acacia saligna),
Longleaf wattle (Acacia longifolia), and
Mesquite (Prosopis sp.)
The plan will be updated annually and show areas which are to be cleared of
alien vegetation The plan will initially focus on the removal of alien vegetation
from:
Historic topsoil dumps,
The Renosterveld area and
From areas close to water courses such as storm water channels
The plan will detail the removal method which will utilize either / or a
combination of mechanical, chemical and biological control methods.
A record of area cleared of alien vegetation must be kept.
Follow up control, on areas cleared of alien vegetation must be implemented
until an area does not show signs of alien vegetation for 3 consecutive
seasons.
The mixing, handling and disposal of pesticides for alien vegetation removal
will take place in accordance with the applicable work instruction.
Greening of exposed area in the plant:
The mine will aim to grass and plant woody vegetation in around exposed
areas in the plants which do not form part of long term mine plans.
Monitoring:
All rehabilitation completed will be subjected to an ongoing monitoring and
follow up control to ensure success of rehabilitation.
Ongoing monitoring will form part of the annual concurrent rehabilitation plan.
9.1.8 Mining supporting services
Ongoing
Annually
Annually
Ongoing
Annual
In order to successfully implement the mining activities described above, there are a number of
supporting services dedicated to the mining department. The management measures for the
supporting services are described below.
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Fuel depot:
Goals and objectives: To ensure that no surface water pollution emanates from the fuel depot
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
All diesel tanks to be kept within a bunded area .
The valve on the bunded area to be kept closed unless needed in the case of
a spill or heavy downpour of rain.
Bunded area to be kept clean of debris.
The integrity of the bunded area to be checked annually and if necessary
repaired or reinforced.
All employees refuelling vehicles will be trained on the procedure to follow to
ensure that the risk of spills is minimal.
Suitable absorbent material will be available at the fuel depot to be used in the
case of a spill.
Should a spill occur it will be logged as a non conformance.
The refuelling area will be visually checked on a weekly basis and any signs of
spills will be cleared and removed as hazardous waste.
Vehicle parking:
Daily
Annually
Annually.
Ongoing
Weekly
Goals and objectives: To ensure that there is no potential for pollution of surface water runoff
from hydrocarbon spills in the vehicle parking area.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The area used to park mine vehicles will be inspected weekly for signs of
hydrocarbon spills.
Vehicle operators to inspect under the vehicles at the parking area for signs of
oil leaks. If discovered the oil spill must be cleaned up and the vehicle
repaired.
Spills discovered will be cleared, placed in a waste bin and moved to the
temporary hazardous waste store for removal by the appropriate subcontractor.
Vehicle maintenance in the workshop:
Weekly
Daily
As and when
discovered
Goals and objectives: To prevent pollution of surface water resources from the vehicle / plant
servicing activities that take place in the workshop.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
All vehicles will be maintained as per the preventative maintenance schedule
(on average every 250 hours). A maintenance record will be kept for each
vehicle.
All vehicle maintenance will be conducted within the concreted workshop
facilities which has the correct storm water control measures (if not possible
drip trays to be available and used in emergency situations)
An oil separation system at the workshop will be maintained for continued
effectiveness. Water from the oil separator system will be tested bi-annually to
prove effectiveness. If the results indicate the system is not effective then the
applicable maintenance will be implemented.
The channels / pipes directing dirty water from the workshop to the oil
Per vehicle.
Ongoing
Bi-annual
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separator will kept free of fines and blockages. Monthly checks will be
performed.
All water from vehicle washing area to be directed through the oil separation
system.
All used oil to be collected and recycled.
All used oil tanks (4 x 2000 litre tanks) will be kept in a bunded area which has
110% the capacity of the tank. Bunded area to be kept clean of debris.
All drums containing lubricants to be stored in a concreted bunded area.
Water accumulated in bunded area if clean must be drained, and if polluted
must be contained within drums and removed as hazardous waste
All oil spills must initially be contained and then cleaned up as described in
generic management measures.
Oil filters, oil contaminated rags, oil contaminated sweepings must be
accumulated in 210L drums and stored within the concreted hazardous waste
store before being collected and disposed of by a recognised waste removal
company.
All batteries in the workshop to be stored on a concreted area.
All old batteries will be returned to the supplier for recycling
Any spillages from a battery will be diluted with 10 parts water.
Storm water control / Quarry de-watering:
Monthly
Ongoing
Ongoing
Ongoing
Ongoing
When
required
When
required
Ongoing
Ongoing
Ongoing
Goals and objectives: The objective is to ensure compliance to the requirements of Government
Notice 704 through the separation of clean and dirty water streams.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Storm water management within the Quarry:
Riebeeck will maintain a berm along the perimeter of the mining area to divert
any “clean” storm water outside the mine away from the mining area. Capacity
to handle a 1 in 50 flood event
Diversion channel around the overburden dumps will be implemented during
construction and maintained during the life of the mine.
All haul roads will be constructed in such a way that water runs off the roads
Storm water accumulating within the quarry will be directed to the in-pit sumps
/ settling ponds. Where possible reeds will be encouraged within the settling
ponds.
All storm water channels will be inspected and if necessary cleaned and
maintained.
Quarry dewatering:
During the ongoing development of the quarry, the Mine Manager will always
ensure that there is a sump(s) which allows for the collection of the
groundwater / rainwater within the quarry.
The sump will be dewatered as and when required.
Accurate monitoring of volumes and quality of groundwater pumped from the
quarry will be undertaken (See monitoring requirements).
The mine will investigate the possibility of re-using the water from the quarry
for ongoing operations.
Viable options which comply with the Water Use License will be implemented.
Ongoing
Bi-annually
Ongoing
When
required
Ongoing
Ongoing
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Waste disposal site:
The waste disposal site is authorised for general waste only. The definition of “general waste” is as
follows: – “means waste that does not pose an immediate threat to human life of the environment,
and includes such waste as household waste, builders rubble, garden waste, dry industrial and
commercial waste.”
Goals and objectives: To ensure that the disposal site never acts as a future source of pollution.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The mining department will resume overall responsibility for the management
of the waste disposal site.
Only general, domestic waste to be disposed of within the general waste
landfill site. This includes;
Process waste: Spilt raw materials which cannot be recycled back into the
process.
Garden waste / household waste / building rubble
Domestic waste in plastic bags
Contractors will take the waste to the demarcated disposal site area as and
when required.
Contractors responsible for the removal for the waste will be trained on the
waste types that can be disposed.
Any waste identified which should not be disposed of will be removed from the
waste disposal site and taken to the appropriate disposal location.
The waste disposal site will be on the most southern area of the current
overburden dump.
As and when a section of the waste disposal site has been covered in the
waste, it will be covered with overburden prior to another layer of waste being
disposed of.
Ongoing
Daily
When
required
Bi-annually
When
required
Ongoing
Daily
Ensure management and monitoring of the site is per the permit requirement. Ongoing
Annual feedback report concerning the site will be submitted to the
Department of Water Affairs and Forestry. Proof of submission will be kept on
file.
The environmental manager / risk manager of Riebeeck will undertake a 2
weekly inspection of the waste disposal site to ensure that the permit
conditions and the applicable management measures are being effectively
implemented.
Records of the inspections will be kept on file.
Annually
Every 2
weeks
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9.2 MANAGEMENT PLAN –PRODUCTION DEPARTMENT
The management measures for the Production Department are applicable for the existing cement
production facility. Many of the environmental impacts associated with the production department
can be reduced through the implementation of cleaner technology which will be used for the plant
upgrade project.
GENERIC MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Good housekeeping.
Housekeeping in the plant area will be maintained by implementing the
following:
Uncontaminated (by other raw products) spillages of raw materials must be
returned to their respective stockpiles.
Spilt material to the extent where the material identity is unknown is to be
removed to the permitted waste disposal site.
Clinker spills to be recycled back to the clinker store in the crane shed.
Cement spillages to be recycled into the cement silos or cement mills.
Waste management to be implemented as per Section 9.8.3
Bins are provided around the clinker and cement department for general
waste.
Bins are emptied and waste to be removed as per waste management plan.
Operators are trained to ensure that minimal mixing of raw material spills
takes place when cleaning in an effort to encourage the recycling of the
materials.
Encourage efficiency of the plant:
Efficiency of the plant will be maintained through the implementation of a
preventative maintenance schedule by the Engineering Department.
Storm water:
All storm water will be directed away from the plant by means of the storm
water channels currently in place.
Storm water channels will be inspected and if necessary cleaned.
Oil spills:
The Production Department will maintain a supply of absorbent to soak up oil
spills.
Should a spill occur the following steps will be implemented:
The source of the spill will be identified and further spillage prevented.
The spill will be contained using suitable absorbent.
Once contained the spill and absorbent will be cleared, disposed of in a
waste bin and temporarily moved to the hazardous waste store until
removal by the appropriate waste removal company.
9.2.1 Raw stockpiles:
As and when
required
Ongoing
Biannually
Ongoing
Goals and objectives: Reduce dust generation when handling raw materials. Minimise loss of
raw materials through correct handling procedures. All spills to be recycled.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The following management measures are specifically designed to reduce the
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impact on surface water / ground water as a result of material handling.
Coal stored within a concreted area.
Maintenance of a storm water management system that directs surface
water away from stockpile areas.
Visual checks to ensure that all the various raw materials are stored within
their designated areas.
9.2.2 Processing supporting services:
Fuel tank:
Daily
Daily
Weekly
Goals and objectives: To ensure that no surface water pollution emanates from the diesel tanks.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The diesel tanks will be kept within a bunded area which has at least 110%
the capacity of the single largest tank or 25% of the total volume, whichever is
greater.
The valve on the bunded area to be kept closed unless needed in the case of
a spill or heavy downpour of rain
Bunded area to be kept clean of debris.
The integrity of the bunded area to be checked and if necessary reinforced.
All employees using the diesel for the kiln start up will be trained on the
procedure to follow to ensure that the risk of spills is minimal.
Suitable absorbent material will be available at the diesel tanks to be used in
the case of a spill.
Should a spill occur it will be logged as a non conformance.
The refuelling area will be visually checked after re-fuelling has taken place
and any signs of spills will be cleaned up and removed as hazardous waste.
Daily
Annually
Annually.
Ongoing
After re-fuelling
9.2.3 Plant upgrade project:
Upgrade certain sections of the existing PPC Riebeeck cement manufacturing plant with the view
to increase the clinker production capacity from the current 570 Kiloton/annum to 800
Kilotton/annum via:
Replacing the existing two kilns with one new kiln line;
Decommissioning and removing the two existing kilns;
Upgrading the existing raw milling facility to accommodate the increased production rate;
Installing a new coal mill for indirect firing and inert operations;
Upgrading the existing cement milling facility to increase the current capacity to accommodate
the increased production rate;
Converting each mill to a closed circuit operation via the installation of a high efficiency
separator;
Upgrading existing conveying equipment to meet the increased production rates; and the
Installation of emission abatement technology to improve air quality.
Goals and objectives: To implement the plant upgrade project.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The upgrade will only take place after gaining all the relevant legal Upon approval of
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authorisations.
All management measures determined by the separate EIA authorisation
process and the terms of conditions of the approval of the EIA will be
implemented.
the EIA process
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9.3 MANAGEMENT PLAN - PACKING AND LOGISTICS
The following management measures are to be implemented to prevent, minimise or mitigate
impacts associated with the Packing and Logistics Department.
GENERIC MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Good housekeeping.
Housekeeping in the Packaging and Logistics area will be maintained by
implementing the following:
Raw material spills to be recycled back onto respective stockpiles.
Clinker spills to be recycled back to the clinker store in the crane shed.
Cement spillages to be recycled into the system.
Spilt material to the extent where the material identity is unknown is to be
removed to the waste dump site.
Waste management to be implemented as per Section 9.8.3
Bins are provided around the Packaging and Logistics department for
general waste.
Bins to be checked and if necessary emptied weekly
Open areas to be cleaned on a daily basis.
Operators are trained to ensure that minimal mixing of cement spills takes
place when cleaning thus allowing for the recycling of the cement.
Oil spills:
The packaging and logistics department will maintain a supply of suitable
absorbent to soak up oil spills.
Should a spill occur the following steps will be implemented:
The source of the spill will be identified and further spillage prevented.
The spill will be contained using suitable absorbent
Once contained the spill and absorbent will be cleared and disposed of in
a waste bin and temporarily moved to the hazardous waste store until
removal by the appropriate waste removal company.
9.3.1 Bulk loading
As and when spill
occurs
Ongoing
Weekly
Daily
Per training
matrix
Ongoing
As and when a
spill occurs
Goals and objectives: To reduce the amount of spillages / dust as a result of bulk loading activities.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Dust resulting from bulk loading activities is reduced through the following
measures:
De-dusting systems with bag filters are fitted and operated at the bottom
of all bulk loading points.
Bulk loading takes place on a weighbridge and is automatically stopped
based on weight. A sensor which determines when a bulk container is full
acts as a backup.
When filling a tanker, visual inspections by the bulk loader operator will
ensure that the seal between the bulk loading point and the tanker is
effective and minimal cement escapes.
When a container is full it will be sealed by the operator.
Any cement spillages at the bulk loading points will be recycled
immediately back into the system.
Daily
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Good housekeeping around bulk loading transfer points will be implemented
daily.
Regular maintenance of all dust suppression equipment, and the bulk loading
process will be implemented by the engineering department.
Bulk containers will be weighed prior to dispatch from Riebeeck
9.3.2 Clinker loading (if and when required)
Daily
Maintenance
schedule
As and when
required
Goals and objectives: To reduce the amount of spillages as a result of clinker loading activities.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Good housekeeping around clinker loading transfer points will be
implemented.
When filling rail wagons / road trucks with clinker the crane driver will ensure
that drop heights are kept to a minimum.
All rail wagons / road trucks containing clinker will be covered with a tarpaulin
prior to dispatch from Riebeeck.
As and when
required
As and when
required
9.3.3 Supporting services
The following additional management measures are applicable to supporting activities associated
with Packing and Logistics Department. Some of the generic management measures cover the
requirements for supporting activities and hence have not been repeated.
Mobile equipment (forklift, shunter, tractor, tipper truck):
Goals and objectives: To ensure that the vehicles are maintained in an acceptable standard that
does not result in unnecessary pollution.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
All mobile equipment maintenance will be performed by the vehicle garage.
The mobile equipment will be maintained on a maintenance schedule as
determined by the mechanics.
All mobile equipment operators undertake a pre-shift inspection to ensure the
vehicle is in good working order prior to the shift.
All refuelling of mobile equipment to take place at the underground diesel
tanks adjacent to the workshop.
As and when
required
Daily
9.4 MANAGEMENT PLAN - QUALITY ASSURANCE
The purpose of the Quality Assurance Department is to ensure quality control of the cement
produced at Riebeeck. In addition, this Department ensures that the quality of the raw products
used in the cement manufacturing process, are ideal to ensure that excessive emissions are not
created through the use of raw material which is not of suitable quality.
See Table 9.1 below for an indication of the current sampling frequency undertaken at Riebeeck.
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Goals and objectives: To ensure that the quality of the cement is in line with EN specifications and
to ensure that all chemicals are handled and disposed of in the correct manner.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The laboratory will reduce the chance of an impact on surface water quality by:
Ensuring that all chemicals disposed down the sink are diluted to a point
where by there is no significant impact.
Periodic testing of the wastewater at the municipal sewage plant will be
undertaken to prove there is no impact on water quality.
Should the results of water testing indicate the water quality is of unacceptable
quality compared to an applicable guideline document then Riebeeck will
implement amended management practices.
The likelihood of a spillage will be reduced through:
Ensuring chemicals are stored within a locked store room and only those
trained in the use of the chemicals have access to the store room.
The impacts associated with a spillage will be reduced by ensuring:
All personnel in the laboratory are trained on the procedure to implement
depending on the chemical that is spilled.
All activity in the laboratory that results in noxious fumes will be performed
within an operational fume cupboard.
9.4.1 Material Safety Data Sheets (MSD sheets)
Daily
Bi-annual
As and when
required.
Daily
Ongoing
Goals and objectives: Riebeeck will ensure that it has a copy of all applicable MSD sheets for all
chemicals stored and used on site. The storage, handling and disposal specifications within the MSD
sheets will be implemented.
Daily
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The quality department shall be responsible for the acceptance of all
chemicals on the site.
No chemical can be brought onto the site without the appropriate MSD sheet
being provided.
A master copy of all MSD sheets will be kept by the quality assurance
department.
Copies of the applicable MSD sheets will be kept at all areas which store and
use the applicable chemicals.
It is the quality assurance departments‟ responsibility to ensure:
All chemicals are stored correctly (i.e. in bunded areas if necessary)
No potentially reactive chemicals are stored together.
All people who utilize the chemicals have a copy of the MSD sheet and
are aware of its content in terms of PPE for use, storage requirements and
the acceptable disposal methods of the chemicals.
An audit on chemical acceptance, storage, use and disposal in accordance
with the applicable MSD sheet will be completed on a bi-annual basis.
Any deficiencies noted during the audit process will be rectified with the
As and when
required
Ongoing
Bi-annual
As and when
required
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PPC Riebeeck West: Storm water Management Plan Page 95
applicable training.
All personnel who work with hazardous chemical substances shall be trained
in the hazards associated with the use of all forms of hazardous chemical
substances, and also the actions and reactions in the event of a mishap.
During training
9.5 MANAGEMENT PLAN - ENGINEERING
The Engineering Department is responsible for the upkeep and maintenance of all plant / mining
equipment. Maintenance scheduling is based on the risk of failure of the equipment and is
captured on a computerised scheduled maintenance plan. Through implementing preventative
maintenance, Riebeeck is essentially reducing the likelihood of potential negative impacts
occurring.
See Section 3.6 for an indication of how the maintenance plan is developed and implemented on a
daily base.
GENERIC MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Good housekeeping.
Housekeeping for the Engineering Department will be maintained by
implementing the following:
All waste metal / empty drums and shavings to be stored in the scrap yard.
All chemicals will be stored as per the requirements documented in the
applicable MSD sheet.
Waste management to be implemented as per Section 9.8.3
Bins to be provided around the Engineering Department for general waste.
Workshops to be cleaned on a daily basis.
Bins to be emptied and waste to be removed as per waste management plan.
Training on the handling, use and disposal of the chemicals used by the
Engineering Department will be implemented.
Oil spills:
The Engineering Department will maintain a supply of suitable absorbent to
soak up oil spills.
Should a spill occur the following steps will be implemented:
The source of the spill will be identified and further spillage prevented.
The spill will be contained using suitable absorbent
Once contained the spill and absorbent will be cleared and disposed of in
a waste bin and temporarily moved to the hazardous waste store until
removal by the appropriate waste removal company.
Redundant buildings;
Annually the Engineering Department will evaluate all infrastructure
associated with the mine.
A plan will be drawn up and implemented for the removal / demolishing of
any infrastructure that is deemed redundant with no future use either for
the operating of the mine or the benefit of society at the end of life of mine.
Calibration checks:
Calibration checks of maintenance equipment and feeders are the
responsibility of the Engineering Manager. These checks will be performed as
and when required.
Details on the requirements for calibration of equipment will be kept on the
Ongoing
Daily
Per training
matrix
Ongoing
Annually
As and when
required.
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PPC Riebeeck West: Storm water Management Plan Page 96
computerised maintenance system.
Equipment used to calibrate, is labelled to indicate the next time it needs to be
calibrated.
Cooling ponds:
The cooling water will be kept within a concrete bunded area housed within a
building
The applicable chemicals will be added to ensure that the water is best suited
for its purpose (cooling of plant equipment)
Only chemicals approved by the Quality Department will be used. Chemicals
will be stored, handled and used in accordance to its MSD sheet.
The MSD sheet for the chemicals used will be available at the place of storage
of the chemicals.
The cooling water ponds and the storage area for the chemicals use to treat
the water will be inspected weekly.
Any problems / bad housekeeping identified during the inspections will be
rectified as soon as possible.
Ongoing
Daily
Weekly
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9.5.1 Planning
All maintenance is scheduled through detailed planning. The planning sub-department directs all
the maintenance needs of the operation to the sub-sections within the Engineering Department.
The planners within the Engineering Department produce short term schedules for the
implementation of ongoing maintenance. Planning is based on;
pro-active maintenance to prevent negative impacts associated with the wear and tear of
equipment occurring.
Reactive non urgent maintenance in relation to the breakdown of equipment.
Reactive urgent maintenance.
9.5.2 Mechanical
The mechanical sub-department will implement the maintenance activities as indicated in the short
term schedules for;
Water reticulation systems
Storm water management channels
Infrastructure
Dust suppression equipment – the target for control equipment availabilities is that it is
maintained at 98% operational or more.
9.5.3 Electrical
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Transformers / PCB contaminated oils:
All transformers will be checked for PCB contamination.
If there is no contamination, the appropriate labelling will be shown.
If there is PCB contamination, then the contractor must remove the oil and
replace it will clean oil.
When transformer oils are cleaned by a contractor it must be assured that the
equipment used by the contractor is absolutely free of PCB's. Oil
contaminated with PCB's to be drained and sealed in 210 Litre drums and to
be stored in the temporary hazardous waste store. Safe disposal procedure
for these PCB's to be followed.
Energy savings:
Maintenance will be responsible to measure energy consumption.
Discussion concerning possible energy saving measures that can be
implemented in the different sections of the mine will be held, recorded and
filed.
Implement any viable energy saving measures resulting from the annual
discussions
Riebeeck will undertake an analysis of power demand and supply of all major
energy consuming units
Radio-active sources
Riebeeck will at all times have an appointed radiation protection officer whose
duties will include:
Ensure that all persons who may work near the installation are fully aware
of the associated radiation hazard and are familiar with correct work
procedures.
Every 5 years
As and when
required
Ongoing
Annually
As and when
required.
Every 5 years
Ongoing
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Ensure that radioactive sources are appropriately sign posted.
Ensure the transfer of a radioactive measuring system from one place to
another must take place under the guidance of the radiation protection
officer.
When the radioactive source is removed from service, the radiation
protection officer must ensure that it is immediately removed from site by
an approved contractor. The source can be contained within the safe for a
maximum of a 24 hour period.
No person is allowed to do maintenance work on a radioactive measuring
system which directly involves the radioactive source (e.g. replacing
defective sources).
Stock levels to be check and audited annually and stock forms submitted
to the Department of Health
A source container in which a radioactive source has been installed must be
tested at least every second year for contamination. This is done by a leak
test, which is performed by an accredited company who offers a leak testing
service.
If the source is found to be “leaking”, the department of health must be notified
immediately.
If a source has decayed to below its useful activity, it is not necessarily
radioactive waste, but nevertheless it has to be disposed of in an orderly
manner.
The company shall not dispose of a sealed source, or a radioactive measuring
system containing a sealed source without the written approval of the
Department of Health. “Dispose” here includes the sale, lending, donation,
exchange, as well as the return of the source to the supplier.
Annual
Biennial
As and when
required.
9.5.4 Services
The services department is responsible for both special projects such as the implementation of
cleaner technology and the maintenance of the railway infrastructure.
Goals and objectives: Maximise the efficiency of the plant and aim to improve environmental
performance through the process re-engineering.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The services department will assess process re-engineering options, to
improve both the efficiency of the plant and the overall environmental
performance of the mine. The environmental impacts recognised as the most
significant, and therefore receive most attention in terms of reducing impacts
will included, but not limited to:
Emissions
Energy use (both coal and electricity)
Fuel usage
Dust generation
Water use / reuse
Minimising / recycling waste products
Economically viable options will be implemented.
If necessary, legal permits and permissions will be obtained prior to the
implementation of a new process.
Rail Activities:
The services department will assume overall responsibility for the
Ongoing
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maintenance and up keep of the rail activities dedicated to Riebeeck. The
environmental aspects will include;
Ensuring there are no spills of diesel / oil from the diesel engines.
The location where diesel engines spend most time on site will be
inspected monthly.
If regular spills are noted in one position, Riebeeck will place a soak mat in
the area to catch future spills.
Polluted ballast must either be cleaned with a suitable environmentally
friendly chemical or replaced. Polluted ballast to be regarded as
hazardous waste.
Build up of fines along the railway lines will be kept to a minimum through
appropriate cleaning.
Railway lines will be kept clear of vegetation growth.
Monthly
inspections
9.6 MANAGEMENT PLAN – ADMINISTRATION
The environmental impacts associated with the Administration Department are all linked to waste
management requirements which are covered in Section 9.8.3 and the potential impacts
associated with the stores.
Goals and objectives: To ensure all chemicals are stored, distributed, handled and disposed of in
the correct manner.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
All chemicals stored will be done so in line with the applicable requirements
documented in the MSD sheet.
All hazardous chemicals will be stored within secure areas and only the
responsible person whom is aware of the correct handling procedures will
have access to this area.
Liquid hazardous chemicals will be stored within a bunded area.
The stores will have the capacity to handle the chemicals required for
scheduled maintenance activities.
No chemicals which could potentially react together will be stored together.
Upon delivery of chemicals to be stored, they will be transported into the
correct storage area immediately after delivery.
Forklift truck drivers who transport hazardous chemicals will be made aware of
the potential dangers of spillages of the chemicals.
When a chemical is issued, the person receiving the chemical will sign
confirmation that they have access to copy of the MSD sheet for the chemical,
in the section where it is used.
The stores will be responsible for monthly fuel reconciliations. Any significant
discrepancies identified will be communicated to the environmental
department to investigate for possible spillages.
Ongoing
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9.7 MANAGEMENT PLAN - RISK MANAGEMENT
9.7.1 Health and Safety Training
Riebeeck implements a comprehensive health and safety training programme for all employees.
This EMP is not intended to cover the full spectrum of health and safety requirements for the mine.
All the environmental training requirements for the mine have been presented as part of the
environmental awareness plan in Section 11.
9.7.2 Implementation of Occupational Health and Safety Monitoring
The Risk Department is responsible for implementing all the required occupational health and
safety monitoring requirements.
9.7.3 Implementation of Risk Assessments
For any new activity or change of activity implemented at Riebeeck it is subjected to a risk
assessment performed by the Risk Department in accordance with the Mine Risk Assessment
methodologies.
Goals and objectives: Ensure that environmental risks (Aspects & Impacts) are considered in
risk assessments.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Each risk assessment will consider the following environmental
parameters (in addition to the health and safety parameters).
The need for any environmental permit / legal permission.
The potential environmental impacts of the activity to all environmental
parameters (Climate, geological features, topography, soil, surface
water, ground water, atmospheric impacts, noise, heritage sites, flora,
habitats (fauna), socio-economic impacts such as possible concerns
from I&AP‟s)
The waste management requirements of the activity being assessed.
An assessment of the risk of an impact of on an environmental
parameter and the potential significance of this risk.
If the risk is deemed significant, the risk department in conjunction with
the environmental department must develop appropriate management
measure to mitigate the potential for the risk to materialise.
9.7.4 Clinic
Goals and objectives: Ensure good waste management at the clinic.
When required
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
All medical waste is stored within a bio-hazardous container before being
removed by an authorised sub contractor.
The clinic is responsible to undertaking the required medicals of the employees.
All medical records are kept on site.
Clinic is responsible for ensuring the calibration of the alcohol tester.
Daily
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9.7.5 Security / external parking area
Goals and objectives: Ensure that vehicles entering the site are in a good condition
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Security guards at the access gate are responsible to ensure that all vehicles
entering and exiting the site are in a good condition. This includes:
Ensuring that the vehicles are not leaking any oil / diesel
Ensuring that the emissions from the vehicles are not excessive.
Vehicles which are in an unacceptable condition are not allowed to enter the
mining property.
The registration number of vehicles in an unacceptable condition is noted. Upon
the same vehicle returning to PPC Riebeeck, the vehicle will be inspected to
ensure that the problem has been rectified.
Daily
9.7.6 Sub contractors
Riebeeck recognise that the impacts that sub-contractors could have need to be recognised and
managed. The following management measures will be implemented by Riebeeck to ensure good
environmental practices are followed by their sub-contractors.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Environmental compliance will form part of the contractual arrangements
between sub contractors and the Riebeeck.
As and when contracts between Riebeeck and sub contractors are signed or
renewed, a risk assessment will be performed to identify the potential risks
associated with the activities that the sub contractor will be responsible.
If there are specific significant environmental risks identified during the
assessment, then the management of these risks will be documented and
signed off.
All sub-contractors will be subjected to environmental awareness training.
Riebeeck will generate and implement an audit schedule to audit the
environmental compliance of sub contractors. The frequency of the auditing will
depend on the significance of the impact the sub-contractors activities could
have. i.e. more significant impacts, more frequent auditing.
Should persistent non performance be recorded during the audits of the subcontractor
then Riebeeck will consider the termination of the contract.
Where sub contractors are performing a task which requires legal authorisation,
copies of the applicable legal permits must be provided and kept on file.
As and when permits expire new valid permits must be provided. E.g for
permit for disposing hazardous waste in a licensed landfill site Riebeeck must
have a copy of the licensed landfill sites permit.
For each
contract
For each
contract
By 2010
Ongoing
9.8 MANAGEMENT PLAN - ENVIRONMENTAL MANAGEMENT
The Environmental Management Department resumes overall responsible for ensuring the
implementation of all environmental measures on the mine.
9.8.1 Environmental Monitoring
All the environmental monitoring requirements for the mine have been presented within Section
9.11.
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9.8.2 Environmental Training
All the environmental training requirements for the mine have been presented as part of the
environmental awareness plan in Section 10.
9.8.3 Waste management
Waste is generated throughout the operation. Riebeeck has a waste management spreadsheet
which documents all waste generated, and how it is disposed. The focus is to: reduce the
generation of waste, to where possible, recycle material and thirdly if recycling is not possible then
to temporarily store and dispose of waste in a legally acceptable manner. The impacts associated
with waste include visual, and the impact on soil, surface water and ground water. The following
management measures will be implemented to mitigate and minimise the potential impacts.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
General waste requirements:
Riebeeck will continuously seek alternative methods of reducing / recycling
waste. This will be achieved through an annual review of the current waste
management measures and identifying where improvements can be made.
As and when new waste products are generated, Riebeeck will include the
waste on the waste management spreadsheet. This spreadsheet will
document the legally required handling and disposal methods of all waste
streams generated at Riebeeck.
The volume of the different waste streams created will be recorded on the
waste management spreadsheet.
Disposal records of waste being removed from site will be maintained as
proof of legally acceptable removal.
All MSD sheets for all chemicals used, will be easily available to all
personnel.
Waste receptacles will be placed in strategic locations around the mine and
will be appropriately labels with obvious signage to ensure separation of
waste streams. Red for hazardous and black for other waste.
The need for waste separation will be covered in environmental awareness
training.
Waste receptacles will be checked and if necessary emptied weekly.
Good housekeeping will be maintained by ensuring that all waste is stored
within its labelled designated place prior to disposal. No waste will be left
lying around the mine.
Riebeeck will ensure that the waste dump site for inert waste remains legal
and permit conditions are met.
Riebeeck will maintain the following waste storage areas:
Bunded tanks for recycling of old oil.
Salvage yard area for potential salvageable material. Any salvage material
which is oily will be stored over drip trays or in a concreted bunded area.
Skip(s) for scrap metal – located on concreted areas
Temporary hazardous waste store.
Store for old tyres / conveyor belts
General waste disposal site.
The capacity of the waste storage facilities must be large enough to handle the
waste generated on site prior to disposal.
All waste storage areas will be inspected weekly to ensure that all waste is
Annual
As and when
required.
Ongoing
Ongoing
Ongoing
As and when
required
During
training
Weekly
Ongoing
Ongoing
Ongoing
Ongoing
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being stored correctly prior to disposal.
Waste storage areas will have the appropriate storm water management system
which keeps “clean water” out of the waste storage area and “dirty water” within
the storage area.
The storm water diversion channels will be monitored for effectiveness.
Inadequacies will be rectified as and when discovered
Hazardous waste requirements:
To demonstrate legal disposal of hazardous waste, Riebeeck must document
the movement of hazardous material from their use, through to their ultimate
disposal. Such a documented system must provide for the following aspects:
All hazardous chemical substances in storage or distribution must be
identified, classified and handled in accordance with SANS 10228 and
10229.
Records of waste generated (including quantities, class and hazard rating);
The manner in which such waste is stored prior to disposal;
Proof that the hazardous waste is transported to the hazardous landfill site
in compliance with the Road Traffic Act.
The name and designation of the person charged with the responsibility of
ensuring that waste is correctly handled, stored and disposed of;
A mechanism whereby waste generated and waste disposed can be
reconciled;
Adequate documentation to verify the safe disposal of all waste removed
from the site.
Disposal records of hazardous waste will be kept indefinitely.
Temporary hazardous waste store:
A temporary concreted hazardous waste store adjacent to the vehicle
garage will be used before the waste is removed by the appropriate
subcontractor.
This store must be bunded, fenced (locked) and covered to protect it from
the elements. Different hazardous waste must be stored separately.
No hazardous waste to be stored for more than 90 days.
WASTE HANDLING FOR SPECIFIC ITEMS:
Weekly
Ongoing
Biannually
As and when
required.
Ongoing
Indefinite
Ongoing
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The following waste will be recycled / reused:
Scrap Metal / Electrical waste: To be placed in demarcated bins for
recycling. This includes compacted empty tins. Approved scrap metal dealer
to recycle.
Paper: Paper recycling bins available in all officers. Waste paper recycling
company to remove paper as and when required.
Printer cartridges: To be stored in designated containers and sent back to
supplier for recycling.
Vehicle batteries: Sent back to the supplier for recycling
Cleaning solvent container: To be sent back to the supplier for recycling
Oil drained from vehicles: All used oil which can be collected during
services will be pumped into a bunded oil container and recycled through an
authorised subcontractor. This includes oil drained from oil filters.
Old conveyor belts: To be stored within a designated place and
intermittently sent back to the supplier for recycling / reuse.
As and when
required
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Tyres: Old tyres to be sent back to the supplier for recycling as and when
new tyres are purchased.
The following inert general waste can be disposed of at the legal onsite waste
disposal site
Building rubble
Broken pallets
Kiln bricks which are not sold.
Garden waste
Household / domestic waste
Raw meal / undefined raw materials (where possible all raw materials to be
recycled back into the process.)
Broken cement bags
Disposal of hazardous waste streams:
Medical waste:
Stored within designate bio-hazardous bins and disposed of at least every 3
months.
Fluorescence tubes:
Mercury vapour lamps and fluorescent tubes are collected by the electrical
department will be crushed into a designated drum.
When fluorescent tube drum is full it is removed from site for disposal at
Vissershok hazardous waste disposal site.
Other batteries excluding vehicle batteries (torch light etc)
Taken to the electrical workshop where it will be collected in supplied
containers.
These containers with batteries will be disposed at Visserhok hazardous
waste disposal site.
Oil / diesel contaminated material (such as oil rags, drained oil filters
contaminated oil / diesel absorbent material)
Oil filters to be allowed to drain and then crushed prior to disposal. Drained
oil to be recycled.
Contained within a 210litre drum within the hazardous temporary waste
store until removal by approved sub-contractor.
Asbestos waste
Riebeeck will develop an asbestos inventory detailing the location of all
asbestos sheeting.
The asbestos sheeting on the inventory will be assessed annually. As and
when required asbestos sheeting will be replaced by a suitable substitute.
All handling, storage and disposal of asbestos will take place in accordance
with the “Asbestos Regulation documented in GN R 155 of 10 February
2002”.
Asbestos cuttings must be put into double strength plastic bags and marked
with the words "ASBESTOS WASTE”.
cuttings:
Appropriate PPE to be worn when handling asbestos waste
Asbestos cuttings must be put into double strength plastic bags and marked
with the words "ASBESTOS WASTE”.
The asbestos waste should then be temporarily stored in the Hazardous
Store until it can be disposed of at Vissershok Waste Disposal Site
sheets:
Where large amounts asbestos needs to removed from structures or needs
to be disposed of a contractor licensed and registered by the Department of
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Labour as a accredited asbestos removal company will be contacted and
remove and dispose of the asbestos.
A work plan, as drawn up by the contractor, must be submitted to the
Department of Labour together with an application for approval to remove
asbestos material at least 30 days prior to planned date of commencement
of the contract.
Pesticide Containers:
Contained within the hazardous waste store and disposed of as hazardous
waste.
PPE:
The disposal of all contaminated PPE will be in the hazardous waste bin and
collected and transported by the Cleaning Contractor to the demarcated
hazardous waste storage area.
The various waste associated with the laboratory will be handled as follows:
Acids:
Disposed-of into the drainage system in the diluted form or after being
neutralised with a basic substance.
The dilution factor should always be 10:1. Containers that contained acid
must at least 3 times be washed with water. A hole should be punched in the
bottom of the container so as to make it unusable.
Only after that may the container be placed in the hazardous waste bins for
removal to the waste dump.
Ethylene glycol
Retained in drums and disposed as hazardous waste.
Methanol
Retained in drums and disposed as hazardous waste.
Hexane
Hexane is highly flammable and is stored separately in fire-proof containers.
During grinding of the sample the liquid is fully absorbed and evaporates
when the sample is dried in the extraction hood.
Used/empty glass containers:
The glass bottles containing wastes and residue contents are rinsed and
recycled. Glass recycling company to remove as and when required.
Solid waste:
Broken concrete cubes, limestone and raw meal and all other solid wastes
are recycled .
Used aluminium cups are disposed off into scrap skip.
Blasting waste:
All explosive waste is burnt by the holder of a blasting certificate.
As and when
required
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9.8.4 Water management
The details concerning the water licensing requirements is included within the integrated water use
license. The following management measures have been extrapolated from the license application
and will be implemented by Riebeeck. Riebeeck will ensure that all current water uses at the mine
are legal and will implement measures to ensure that any future water use is legalised, if required.
GENERAL WATER MANAGEMENT MEASURES:
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The integrated water use license will be submitted and Riebeeck will comply
with the permit requirements once approved.
The permit specifications will be reviewed and if necessary revised every 5
years.
The water monitoring campaign as prescribed in Section 9.11 will be
implemented.
Riebeeck shall update their water balance annually and calculate loads of waste
emanating from their activities.
Riebeeck shall submit the results of analysis for all monitoring requirements to
DWA on a biennial basis.
Riebeeck shall conduct an annual internal audit on compliance with the
conditions of the license issued by DWA.
Riebeeck shall appoint an independent external auditor to conduct a biennial
audit on compliance with the conditions of the license issued by DWAF.
For any new activity or an amendment to old activities taking place at the mine
(outside the scope of the WULA application), it must be assessed to identify the
water implications and whether a license or exemption in terms of the National
Water Act or Government Notice 704 is required prior to the activity been
implemented.
Should a license or exemption be required it must be applied for.
Water course buffer zones:
All streams, except the Vlakkerug stream, will be provided with a 30m buffer.
The Vlakkerug stream is located within the footprint of the proposed overburden
dump and thus cannot be retained.
A minimum buffer area of 25 m should be maintained around the wet-edge of the
wetland zones
Management measures – Water usage process and potable
Ongoing
Every 5 years
See Section
9.11
Annually
Biennial
Annually
Biennial
Prior to
implementation
of new or an
amended to an
activity
Ongoing
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The mine will record the flow of water using flow meters.
Flow meters will be positioned to indicate water use by the various
departments of the mine and to determine the amount of water discharged
from the site. The flow meters will complement the water balance diagram.
Flow meters will be maintained by the engineering department as and when
required.
The water balance diagram will be updated monthly based on the readings from
the flow meters which will be recorded. After updating the water balance diagram
the mine will:
Ensure that overall water usage remains within permitted amount per year.
Identify the monthly variability in water use.
Should there be a 20% increase on water usage from the average monthly
Ongoing
Monthly
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usage (as determined over time as records are kept), the mine will;
Investigate the cause of the fluctuation.
Once the cause of the increased usage is determined, the mine will implement
a plan to reduce the usage.
An amended water balance based on previous year‟s water flows will be
developed.
Where possible, the main water reticulation system (cooling ponds, municipal
reticulation and pipelines) will be visibly inspected for signs of leaks.
Any leaks discovered will be fixed immediately.
Should anybody communicate the discovery of a water leak to any team leader,
the leak will be fixed immediately.
Cooling water will be treated in the cooling ponds to make it suitable to act as a
coolant.
Potable water will be obtained from the municipality
Potable water will be tested to ensure that it is fit for human consumption.
Annually Riebeeck will investigate the water use / reticulation system and
identify where improvements can be made in terms of minimising water use /
reusing water.
Viable improvements will be implemented (such as greater use of the water
captured within the quarry)
Management measures – Storm water
Bi-annually
Annually.
MITIGATION & MANAGEMENT MEASURES TIME FRAMES
Existing storm water system:
The existing storm water system in the plant must be inspected and where
necessary cleaned of debris / fines build up.
There should be no mixing of clean and dirty water systems.
All storm water canals within the quarry area / overburden dumping area must
be planned prior to mining occurring in an area.
Storm water planning will aim to ensure that “clean water” falling outside the
mining area, overburden dump area and the plant is diverted away from “dirty
water” falling in the current mining area, overburden dump area and the plant.
Storm water control will be annually audited.
If negative findings are identified mitigation measures will be implemented to
prevent the negative finding re-occurring.
Stormwater falling within the plant and raw material stockpile area must be
directed towards the discharge point that directs the water into a sequence of 3
dams.
The water quality of the discharge point will be monitored.
If monitoring results prove necessary, Riebeeck will implement additional
management measures to alleviate the cause of the unacceptable monitoring
result.
Management measures – River Diversions and River Crossing
Bi-annually
During quarry
planning
meetings
Ongoing
MITIGATION & MANAGEMENT MEASURES TIME FRAMES
Riebeeck will submit a set of as-built drawings (not schematic layouts) to the
Regional Director of the Department of Water Affairs of all river diversions, road
crossings and weirs prior to undertaking the required activity.
All river crossing must be designed to cater for a 1:50 year, one day (24 hour)
As and when
required
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PPC Riebeeck West: Storm water Management Plan Page 108
flood event.
A suitably qualified person, appointed by the licensee, and approved, in writing,
by the Regional Director, must be responsible for ensuring that the structures
are maintained in line with the design specifications
Any new water course will be protected from erosion by using any suitable
means. This erosion protection will carry through for another 10m in the existing
water course where the water flow will have stabilised.
Riebeeck will monitor the diversion structures and the drainage line to:
ensure that all mitigation measures (erosion) are effective;
ensure that alien invasive species are not allowed to colonise;
assess the habitat to ensure the sustainability of the diversions;
ensure compliance with all conditions within the Water Use License.
Should non conformances be noted during the annual assessment, mitigation
measures will be implemented to mitigate the non conformance and ensure that
future non conformances of the same nature do not re-occur.
Coupled to any river diversions Riebeeck will investigate the recreation of
wetland and dams to replace any loss, in order to ensure water quality
protection for downstream environment.
Management measures – Dewatering from the pits
Annually
MITIGATION & MANAGEMENT MEASURES TIME FRAMES
The impact Riebeeck is having on the ground water quality and depth will be
determined through the implementation of the monitoring activities described in
Section 9.11.
If Riebeeck is responsible for the drying up of groundwater resources or
impairing the quality of the water for surrounding existing lawful users then
suitable mitigation (in consultation with ground water specialists) measure will be
implemented, which could include;
drilling the affected parties' boreholes deeper to a depth of 150 metres or
drilling additional boreholes
piping water from the quarry to them or
supply parties with acceptable water from their municipal source
The following information will be used for the update of the water balance;
monitored and recorded volumes of water being reused from the pits.
Monitored and recorded volumes of water being discharged.
Riebeeck will annually assess the opportunity to reuse the water from the quarry
to minimise dewatering and any viable solution will be implemented.
Should the change in water use trigger a legal requirement, the applicable
permits will be applied for prior to implementation.
Management measures – Overburden dumps
See monitoring
As and when
required
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Riebeeck will ensure that prior to the development of the footprint of the
overburden dump or a new overburden dump, the required storm water
management berms / channels are in place to ensure that all clean water is
diverted away from the footprint of the dump.
Erosion control on the dumps will be controlled through the implementation of
concurrent rehabilitation. See overburden dumping plan.
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9.8.5 Communicating with interested and affected parties
MANAGEMENT MEASURES – INTERESTED AND AFFECTED PARTIES
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Riebeeck will maintain open relations with all interested and affected parties by:
Riebeeck will maintain a database of all surrounding landowners /
stakeholders.
The database will reviewed and if necessary updated with changes annually.
(i.e. change of personnel in government departments)
Riebeeck will facilitate stakeholder meetings for all I&AP‟s to raise any
concerns (minimum 1 per annum).
PPC will compile monitoring feedback reports to be presented at the
stakeholder forums.
In response to complaints, more detailed reports will be compiled as and when
necessary.
All meetings will be minuted and the minutes kept on file.
As and when Riebeeck implement future activities that require an additional
environmental authorisation an independent consultation process, with
interested and affected parties, as governed by applicable legislation, will be
implemented.
Ongoing
Annually
1 per annum
As above
As and when
necessary
Ongoing
As and when
required
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9.9 MANAGEMENT PLAN - POTENTIAL EMERGENCIES
Potential emergencies can result in major environmental problems and hence measures should be
in place to reduce the likelihood of an emergency occurring and if it does occur then measures are
in place to reduce the impact of the emergency. The management measures for emergencies will
be discussed for all anticipated potential environmental emergency scenarios, for PPC Riebeeck
which includes:
Off site spillages
Large hydrocarbon / hazardous substance spillages
Burst of diesel / paraffin tanks
Leaking transformers or transformers catching fire
Fires
Flooding
Run away chemical reactions
Radiation leak from one of the radioactive sources
Excessive air pollution
GENERIC MANAGEMENT MEASURES FOR EMERGENCY PROCEDURES INCLUDE:
MITIGATION & MANAGEMENT MEASURES FOR ALL EMERGENCIES TIMEFRAMES
Throughout the year, Riebeeck will conduct mock exercise of emergency
incidents to practice and perfect a response which minimises the risk of safety
and the environment in the case of a real emergency. (e.g. fire drills)
These mock exercises will be recorded and should they highlight deficiencies in
the procedures, procedures will be amended.
Known assembly points in the case of an emergency must be documented and
communicated to all employees.
Emergency numbers and the location of emergency assembly point to be
posted in obvious locations.
At all times Riebeeck will have;
A designated emergency controller
An emergency coordinating committee
Evacuation marshals
Fire marshals
First aiders
The emergency controller with the assistance with the emergency coordinating
committee will implement and manage all actions required depending on the
type of emergency.
Should an emergency arise which does not fall into the category of the ones
discussed below an appropriate emergency plan will be developed and
implemented by the emergency controller.
As and when an emergency incident occurs, depending on the nature of the
incident the relevant government / municipal departments will be contacted as per
legal requirements.
Emergency incidents involving water resources will be communicated to the
relevant DWA official
Emergency incidents involving emissions will be communicated to the Chief Air
Pollution Control Officer.
Ongoing
Ongoing
As and when
required
As and when an
emergency
occurs.
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PPC Riebeeck West: Storm water Management Plan Page 111
Management measures for specific identified environmental emergencies are listed below:
OFF SITE SPILLAGES
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
When an offsite spillage is reported, it will be forwarded to the risk manager.
The risk manager will immediately visit the scene of the spillage and determine
the necessary action, which could include;
Inform the relevant authorities
Undertake a cleanup operation to remediate the immediate effects.
Assess the long terms effects of the incident and implement measures to
mitigate these effects.
Implement applicable measures to ensure that the incident does not re-occur.
The responsible person, must, within 14 days of the incident, report to the
Director-General of the Department of Water Affairs, provincial head of
department and municipality such information as is available to enable an initial
evaluation of the incident, including:
the nature of the incident
the substances involved and an estimation of the quantities released and their
possible acute effect on persons and the environment and data needed to
assess these effects;
initial measures taken to minimise impacts;
causes of the incident, whether direct or indirect, including equipment,
technology. system, or management failure; and
measures taken and to be taken to avoid a recurrence of such incident.
LARGE HYDROCARBON SPILLAGES
As and when
they occur.
Within 14 days
of the incident
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
To prevent spillages occurring, the mine will implement a preventative
maintenance programme on all equipment and vehicles used at the mine.
Should a spill occur outside bunded areas, the mine will;
contain the spill by constructing earth walls or using “barriers” provided in the
spill kits or cement fines.
Use an environmentally acceptable absorbent to spread over the spill.
The soil / spill will then be removed from the site and disposed of by a
subcontractor whom deals with hazardous waste.
The mine will have a constant supply of environmentally acceptable absorbent
(spill sorb) at locations where potential spills may occur.
All oils / greases required for maintenance will be stored within bunded
concreted facilities until required.
The mine will ensure that the capacity of the bunded concreted facilities for the
storage of hydrocarbons can handle oil / grease needs for scheduled
maintenance.
LEAKING DIESEL TANK
Ongoing
As and when
required
Daily
Daily
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
To prevent a major incident associate with a diesel, petrol or paraffin tank, the
mine will ensure that all tanks (existing and potential new ones) are bunded to
Ongoing
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PPC Riebeeck West: Storm water Management Plan Page 112
contain at least 110% of the capacity of the tank.
Bunded areas will be kept clean of debris and free of water build up due to rain.
The integrity of the bunded area, will be checked annually and if required fixed.
Valves on bund wall will be checked to ensure they are closed.
In the event of the tank bursting of leaking, the Mine will:
Immediately organise for the remaining fuel in the tank to be pumped out.
Uncontrolled petrochemical spillages must be reported immediately to the
supplier. It is the responsibility of the suppliers to bring their own team for
control/minimisation pollution.
Should the bunding facilities fail, the mine will contact a suitable company to
undertake the removal and cleaning / treatment of the polluted soils. It is
recommended that soils are treated at a bioremediation facility.
LEAKING TRANSFORMER OR A TRANSFORMER CATCHING FIRE
Daily
Annually
Weekly
As and when
required.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
FIRE
All transformers that contain PCB‟s (Polychlorinated Biphenyls) will be indicated
by signboards and contained over a concreted area.
All transformers will be tested every 5 years for PCB contamination.
Should a leak be discovered the mine will:
Inform the electrical specialist to repair the leak
Place a drip tray under the leak
Construct temporary bunded area using limestone fines / or other suitable
material
Soak up any leak using absorbent material
Place contaminated absorbent material plus any other contaminated product
in a container marked hazardous waste.
Remove hazardous material using an appropriate sub contractor.
Check leak has been fixed by electrician
Should a transformer catch fire the mine will:
Notify the emergency controller to sound fire alarm
In addition to normal fire procedure, the fire team must wear masks to protect
from fumes.
After fire is put out, any oil spillage must be cleaned as above.
All soot and residue of building on fire must be treated as hazardous waste.
Ongoing
Every 5 years
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Riebeeck will have a trained fire fighting team available to deal with fires on
standby throughout the year.
All employees will undergo fire drill training and the use of fire fighting
equipment
Veld fires will be controlled as follows:
Veld fires started on the property are likely to start as a result of negligence by
staff. These fires will not endanger the mining infrastructure, plant, workshop
or diesel tank as there is no dry vegetation around any of these facilities that
could potentially catch fire.
Ongoing
Annually
As and
when
required
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Annually fire breaks around the perimeter of the mining area and clearing of
vegetation around buildings that is potentially a fire hazard will be undertaken
All uncontrolled veldt fires on Riebeeck property must be reported to the
emergency controller. It‟s the responsibilities of all the employees to inform
about a fire if discovered.
Fires in buildings will be prevented / controlled by:
Fire extinguishers will be available in all buildings.
These extinguishers are checked against work instruction requirements every
month to ensure they are in working order.
The fire extinguishers will be checked by a professional contracted annually.
If the fire cannot be controlled by the person discovering the fire, it will be
report to the emergency controller for appropriate action.
EXTREME FLOODING EVENT
Ongoing
Monthly
Annually
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
The mine has implemented storm water prevention measures by constructing
storm water channels, berms and catchment dams throughout the mining
property to ensure that all storm water is directed away from the plant and areas
where flooding would be a problem.
These storm water channels and berms will be annually inspected and if
necessary cleaned and repaired.
When an abnormal flood occurs at Riebeeck the emergency controller will
arrange a proper action plan to deal with the situation.
RUNAWAY CHEMICAL REACTIONS
Ongoing
Annually
As and when
required.
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
All chemical will be stored within the appropriate bunded / protected
environment to reduce the potential of a reaction.
No chemicals that could react together will be stored in the same location.
All MSD sheets will be available for all chemicals stored on the site.
In case of an accident that may result in toxic or hazardous chemicals to run
away and pollute the environment, the emergency controller must be contacted.
The emergency controller must without delays arrange an action plan to bring
the pollution under control. For this purpose the Quality Assurance Manager
and other personnel may be called upon.
POTENTIAL FOR A RADIATION LEAK
Daily
Daily
Ongoing
As and when
required
As and when
required
MITIGATION & MANAGEMENT MEASURES TIMEFRAMES
Riebeeck will at all times have an appointed radiation protection officer whose
duties will include:
Ensure that all persons who may work near the installation are fully aware of
the associated radiation hazard and are familiar with correct work procedures.
The transfer of a radioactive measuring system from one place to another
must take place under the guidance of the radiation protection officer
When the radioactive source is removed from service, the radiation protection
officer must ensure that it is immediately locked away in the approved
isolation container.
Daily
Daily
Ongoing
As and when
required
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No person is allowed to do maintenance work on a radioactive measuring
system which directly involves the radioactive source (e.g. replacing defective
sources).
A source container in which a radioactive source has been installed must be
tested at least once every two years for contamination. This is done by a leak
test, which is performed by an accredited company who offers a leak testing
service.
If an incident occurs that may have affected a radioactive source, a leak test
must be commissioned immediately.
If the source is found to be “leaking”, the Department of Health must be notified
immediately. Measures as directed by the Department of Health must be
implemented.
Once the emergency has been dealt with, persons who were in the vicinity of
the source container should gather in a central place (control room). Clothing
and shoes suspected of being contaminated must be removed and placed in a
plastic bag and sealed.
As and when
required
Every 2
years
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UNDERTAKING
I, ……………………………………….(in my capacity as General Manager and on behalf of
Pretoria Portland Cement (Pty) Ltd – Riebeeck Operation), hereby declare that the above
information is true, complete and correct. I undertake to implement the measures as described in
the Environmental Management Programme. In addition to the implementation of the
Environmental Management Programme, Riebeeck will comply with the provisions indicated in the
Minerals and Petroleum Resource Development Act, Act 28 of 2002 and the regulation thereto. I
understand that this undertaking is legally binding and that failure to give effect hereto will render
me liable for prosecution in terms of Section 98 (b) and 99 (1)(g) of the Mineral and Petroleum
Resources Development Act, 2002 (Act 28 of 2002). I am also aware that the Regional Manager
may, at any time but after consultation with me, make such changes to this programme as he/she
may deem necessary.
Signed on this ………day of ………….…..……… 20……..at ………………………………..…..(Place)
……………………………………………………
(Signature of authorised person)
APPROVED BY THE REGIONAL MANAGER: WESTERN CAPE DEPARTMENT OF MINERALS AND ENERGY
Signed on this ………day of ………….…..……… 20……..at ………………………………..…..(Place)
……………………………………………………
(Signature of authorised person)
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10 REFERENCES
Ninham Shand Environmental Impact Assessment Reports
Dr W.R Harding. February 2008. Proposed expansion of the Pretoria Portland Cement (PPC)
Manufacturing Facility in Riebeek West. Aquatic Study.
SRK Consulting. February 2008. PPC Riebeek West Expansion Project: Specialist
Hydrogeological Assessment
Ninham Shand (14 March 2007). Environmental Impact Assessment: Proposed Construction of a
New Cement Factory and Extension to The Existing Mining Operation in Riebeek West,
Western Cape~ Draft Scoping Report. Report No: 4315/ 401585.
Ninham Shand (August 2007). Environmental Impact Assessment: Proposed Construction of a
New Cement Factory and Extension to The Existing Mining Operation in Riebeek West,
Western Cape~ Final Scoping Report. Report No: 4458/ 401585.
Ninham Shand (September 2007). Environmental Impact Assessment: Proposed Construction of
a New Cement Factory and Extension to The Existing Mining Operation in Riebeek
West, Western Cape~ Public Participation Process Relating to the Final Scoping Report.
Report No: 4458B/ 401585.
Ninham Shand (November 2007). Environmental Impact Assessment: Proposed Construction of a
New Cement Factory and Extension to The Existing Mining Operation in Riebeek West,
Western Cape~ Draft Environmental Impact Report. Report No: 4515/ 401585.
Ninham Shand (August 2008). Environmental Impact Assessment: Proposed Construction of a
New Cement Factory and Extension to The Existing Mining Operation in Riebeek West,
Western Cape~ Final Environmental Impact Report. Report No: 4515C/ 401585.
Ninham Shand (January 2009). Environmental Impact Assessment: Proposed Construction of a
New Cement Factory and Extension to The Existing Mining Operation in Riebeek West,
Western Cape~ Addendum to the Final Environmental Impact Report. Report No:
4515D/ 401585.
Ninham Shand (March 2009). Environmental Impact Assessment: Proposed Construction of a New
Cement Factory and Extension to The Existing Mining Operation in Riebeek West,
Western Cape~ Annexure to the Final Environmental Impact Addendum Report. Report
No: 4515E/ 401585.
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PPC Environmental Management Programme Reports
Pretoria Portland Cement – Riebeeck Cement Plant. May 2000. Riebeeck Quarry Environmental
Management Programme Report.
Pretoria Portland Cement – Riebeeck Cement Plant. September 2001. Amendment 1 – Delectus
extension and village exclusion.
Pretoria Portland Cement – Riebeeck Cement Plant. September 2002. Amendment 2 – Sand and
Clay Mining on Ongegund 508.
Pretoria Portland Cement – Riebeeck Cement Plant. October 2004. Amendment 3 – Plan to
protect the Renosterveld.
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11 ANNEXURES
Annexure A: Integrated Water Use license
Please find attached the following report.
JJN Lambrechts. November 2007. Proposed construction of a new cement facility and extension to
the existing mining operation in Riebeek West, Western Cape. Agricultural Assessment.
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Annexure B: Waste Disposal Site permit
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Annexure C: Current Alien Vegetation Removal Plan
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Annexure D: List of current waste streams generated at Riebeeck
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Annexure D: Minutes of the meeting from the stakeholder forum in May 2011
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