Proposed New Tailings Facility 5, Newcastle Chemical Park, Karbochem Rd, Newcastle, KwaZulu-Natal.

Brother CISA operates a chrome chemicals production facility that is situated within the Newcastle Chemical Park, Karbochem Road, Newcastle, KZN. Brother CISA proposes to construct a new tailings disposal facility (TDF), referred to as Tailings Dam 5 (TD5) at their Newcastle facility. The new facility will be required to accommodate residue arising from the chrome chemicals manufacturing process.

The chrome chemicals plant is authorised for a production capacity of 140 000 tonnes per annum (tpa) of Sodium dichromate (SDC) equivalents. The primary products from the chrome chemicals plant are:
• Sodium dichromate (SDC)
• Chromic oxide
• Sodium sulphate
Chromium chemicals are produced through the alkaline roasting of chromite ore in a rotary kiln. Chromite is a mineral consisting of iron, chromium and oxygen (FeCr2O4). With the assistance of sodium bicarbonate, the chromium it is oxidized from its trivalent state in the ore to its hexavalent state in the form of sodium monochromate (SMC). SMC is the basis for the production of sodium dichromate and other chrome chemicals.
The kiln product is introduced to a leach tank where sodium monochromate (SMC) is taken into solution. The insoluble material left after leaching is the referred to as process residue. The residue is passed over a belt filter to remove as much of the remaining SMC as practical. After the filter belt, the residue is split into two portions. One portion consists of 2/3 or the material, and this is recycled back into the kiln feed. The remaining 1/3 is for disposal. The residue is transferred to a residue treatment facility consisting of a series of vessels where it is treated with reducing agents to convert any residual Cr (VI) to Cr (III). This is done in a wet chemical process using SO2 Ferrous Chloride and Sulphuric acid.

This treated residue is subsequently disposed of at Brother’s operational tailing disposal facility. It is this material which will be disposed of to the proposed Tailings Dam 5 (TD5) which is the subject of the application.

Brother CISA proposes the establishment of the tailings dam facility which will require the supplementary infrastructure which includes:
• Contractor Site Camp (1 hectare)
• Fencing and access control
• Clearing of land
• Excavation of topsoil and subsoil
• Stockpiling area (3.86 hectares in extent)
• Access road (383 meters in length)

The proposed new TDF requires Waste Management Licensing in terms of the National Environmental Management: Waste Act, 2008 (Act 59 of 2008), as well water use licensing in terms of the National Water Act (Act 36 of 1998), and an Environmental Authorisation in terms of the National Environmental Management Act (Act 107 of 1998).

Project Need and Desirability:
The proposed project is intended for the safe disposal of hazardous waste in a strictly controlled facility. This reduces the need to transport and dispose of this hazardous industrial waste at municipal or other commercial hazardous waste landfills. The nearest hazardous waste landfills that might accept this waste are:
• Shongweni Landfill, 300 km away by road, in Pinetown, KZN.
• Holfontein Landfill, 300 km away by road, in Breswol, Gauteng.
• Vlakfontein landfill, 300 km away by road, in Vereeniging, Gauteng.

The establishment of a new tailings’ disposal facility will allow Brother CISA to continue operations at their Newcastle facility by ensuring that future residue is allowed to be deposited to a facility under their control that can be safely managed and rehabilitated effectively upon closure.

At present, the residue is an unavoidable waste produced by the chrome chemicals manufacturing process. Brother CISA has been undertaking various trials and tests to identify a viable means of transforming the waste into a commercial product, however to date these have not been proven to be feasible at scale. The residue must therefore be disposed of until such time as alternatives are proven to be technically and commercially feasible with viable off-takers.

The need and desirability of the proposed development is deemed to be integrally linked with the ultimate need and desirability of the Brother CISA operations; where the activities being applied for are supportive of the operations undertaken. The activities need and desirability thus lies in ensuring that the Brother CISA functions as an effective economic entity and thus contributes positively to continued employment in the region and contribution to the National GDP.

During the construction phase, the activities have a direct socio-economic benefit in respect of the benefits related to job creation, materials sourcing, and direct local expenditure. These include support to local businesses and direct employment of local personnel resources where applicable.

The operational phase of the activities being applied for do not necessarily have direct benefits to society in general, or the local communities in the vicinity thereof, but they do indirectly benefit society and surrounding communities indirectly through ensuring the efficient and effective functioning of Brother CISA operations, such that the continued employment opportunities and contribution to National GDP that Brother CISA offers are realized.

Brother CISA proposes the establishment of a fifth tailings facility which will require the
following infrastructure:
• Tailings disposal facility;
• Construction camp and laydown area (1 hectare);
• Topsoil Stockpile (3.86 hectares in extent);
• Access road (383m in length);
• Fencing and access control;

Need and Desirability of the Activity in the Context of the Preferred Location
The current preferred location is desired based on its proximity to the existing tailings disposal facilities and the Brother CISA site. Furthermore, the location would require less ancillary infrastructure and existing infrastructure that is used for the current tailings’ disposal facilities could be rerouted to the new tailings’ disposal facility.

Given that the preferred area is surrounded by existing disposal sites, a chemical park and an airport, it is unlikely to be suitable for purposes other than commercial or industrial or activity similar to or related to the existing surrounding land use.

The current preferred location is desired based on its proximity to the existing tailings disposal facilities and the Brother CISA site. Furthermore, the location would require less ancillary infrastructure and existing infrastructure that is used for the current tailings’ disposal facilities could be rerouted to the new tailings’ disposal facility.