Depending on the leaching conditions, HPAL residue consists of mainly hematite (Fe2O3), with
imourities, including silicon dioxide (SiO2), natroalunite, (Na Al3(SO4)2(OH)6), and silicates,
such as serpentine (Mg3SiO5(OH)4), derived from the laterite ore. The residue may also contain
basic ferric sulfate (FeOHSO4), iron sulfate (Fe2(SO4)3), gypsum (CaSo4.2H2O) and iron
alumino chromite (AlxFe1-xCr2O4) as minor phases. Trace metals, such as manganese,
chromium, copper, and zinc are also present in the residue.
HPAL residue generally has a very fine particle size. The average size of hematite particles, a
major component in HPAL residue, is about 1μm. Other impuritiesincluding silicates and
gypsum, tend to have a larger particle sizes. The fine particle size of HPAL residue results in
very poor drainage properties. The moisture content of HPAL residue is about 60%. HPAL
residue has low permeability because of re-precipitation of Fe compounds, which results in
increased saturation in the tailing ponds. The high saturation of HPAL residue reduces the ability
of the impoundment to support the weight of the ground equipment on it.
Fresh HPAL residue generated from the autoclave is very acidic and contains a surplus of
sulfuric acid. The pH is adjusted to an appropriate level for solid-liquid separation by counter-
current decantation. The solid obtained from the counter-current decantation process has pH of
2-3 (measured in this work). Because of the high level of manganese (Mn) content and low pH,
HPAL residue can have a harmful impacts on the environment.23 Environmental concerns
related to HPAL residue have been a serious challenge for the HPAL process. Due to the
presence of heavy metals, such as Mn and Cr, in the slurry poses a threat to the underground
water system. Erosion, infiltration, and leaching into surface and ground water are the main
routes for transport into the environment.
Currently, HPAL residue has no commercial value, and it is currently stored in tailing
impoundments. At the present, there are two management options for the residue. The residue
can either be filtered and dry-stacked in a pit, requiring minimal or no structural containment, or
stored as wet slurry in conventional tailing pond or in-pit disposal.22 The process water is
usually not reused, as it has very high levels of sulfate and manganese. The construction of
HPAL tailing ponds requires careful design and engineering. HPAL residue tends to have a very
small particle size and this causes the material to have high saturation. A sturdy base is required
to withstand the weight of the residue. A complete environmental containment system, such as
base liner, drains, and closure cap is also required to resist physical, mechanical, and chemical
stress caused by HPAL residue, and prevent the wastewater from coming in contact with the soil
and underground water supply.
Main waste residue is 6.1 million dry metric tons tailings residue and it will be pumped to DSTP
(deep sea tailing placement) site in the form of slurry with the tonnage of 51.9 million tons. Land
Tailings application for Halmahera tropical region is less suitable. Halmahera tropical region,
particularly at Obi island, is an earthquake active area with 3,000 mm/year rainfall, and ±7,000
people living in the village downstream. Due to this condition, the cost of construction and water
control will be very high and is not feasible for the project economically.
The tailings residue neutralization is configured as one series. The main equipment includes 6
end-solution neutralization tanks arranged in series. The CCD thickener underflow, scrub water
of HPAL tail gas scrubbing, 2nd stage Ni/Co hydroxide precipitation thickener overflow and
other effluents from the refinery, etc. are put into the tailings residue neutralization tank, where
lime milk is added for neutralization treatment. The slurry pH value is adjusted to 8.1~8.5. After
neutralization, the slurry is pumped to DSTP site. DSTP system requires approval from the
Government of Indonesia
DSTP with 15km onshore and 0.7 km offshore pipelines in 40” diameter from refinery plant to
the sea canyon at the depth of > 200 m below sea level. Tailings will flow from pipeline outfall
to 1000-2000 m deep of the seabed below sea water level. Series of tests such as toxicity leach p
(TCLP), lethal concentration (LC50), up to sub-chronic test were conducted to ensure that
tailings cause no harm to the marine environment
