The Project
BHP’s Kwinana Nickel Refinery produced pure nickel powder and nickel sulphate from a matte product supplied by the Kalgoorlie Nickel Smelter. Effluent from the nickel purification process was evaporated in ponds located in nearby Baldivis. In 2021 effluent levels in the ponds, along with increasing salinity, was restricting evaporation rates and hence posing a restriction on production.
In 2021, BHP conducted a strategic level review of existing water management practices and systems across their operations at the Kwinana Nickel Refinery, in which works were to be completed in two phases:
PHASE 1: conduct a baseline water review, including an assessment of water-related risks and knowledge.
PHASE 2: address long-term water-related risks and development of operational water plans.
Technical Solutions
WGA was engaged to conduct the first phase of works to assess the baseline process plant water balance. Our team investigated ten years of flow meter data and found that a large percentage of the water flow was directed to and accumulated in the refinery’s evaporation ponds. WGA concluded that by June 2022, the ponds would have reached their safe capacity.
Our team identified multiple opportunities to recycle, reuse, or treat and recycle effluent streams, minimising the amount that was directed to the evaporation ponds. WGA shortlisted three scenarios, with the potential to reduce the quantities of effluent generated each year by approximately 92%. Over the entire year, this would save approximately 75ML of effluent, otherwise sent to the evaporation ponds.
Following the conclusion of stage 1 and early into the stage 2 assessment, BHP determined to place Nickel West into care and maintenance, citing the reduced nickel price, and hence stopped the review.
Client Focus
WGA’s involvement would have been essential in ensuring the continued operations of the Kwinana Nickel Refinery if not for the declining market conditions. By identifying and implementing three solutions, BHP would have majorly reduced the quantities of effluent generated, addressed the water balance and effluent management challenges the refinery was facing, and ensured efficient and effective operations for the future.
Key Personnel
The Kwinana Nickel Refinery Transformational Water Review is included in the following sectors & services.
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