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Projected Berkeley Pit management timeline (2015-2023).

Plan for treatment technology assessment

The guiding documents for Pit management require ongoing assessment and evaluation of the Horseshoe Bend Water Treatment Plant and the technology used to treat contaminated Pit water until several years prior to full-scale implementation. That implementation is required when water levels at any monitoring compliance point reach the Critical Level of 5,410 feet above sea level.

A review of treatment technologies is required 4 years before any compliance point is projected to reach the Critical Level. Current projections show that the Critical Level will be reached in 2023; therefore the technology review will start in 2017 and must be completed by 2019. AR and Montana Resources are already evaluating treatment alternatives, and this work will continue through 2017. This includes treatability studies and testing on the expected quantity and quality of contaminated water. Construction upgrades are scheduled for 2019 through 2021, with upgrades completed at least 2 years before the Critical Level is reached.

Projected Berkeley Pit management timeline (2015-2023) and significant past events.
Projected Berkeley Pit management timeline (2015-2023) and significant past events. Click on the image to view a larger version.
A piece of gypsum ‘scale’ removed from the Horseshoe Bend Water Treatment Plant.

Following up on the EPA’s 2010 five-year review

In 2010 EPA interviewed local citizens and reviewed the status of Butte area Superfund sites as part of a required five-year review (the full review report is available here). Five-year reviews determine whether remedies or other response actions are protective of human health and the environment in compliance with a site’s decision documents. Methods, findings, and conclusions are documented in five-year review reports that identify issues found and make recommendations to address them.

The 2010 review identified six main issues related to the Butte Mine Flooding Operable Unit (BMFOU), which includes the Berkeley Pit. All involved the performance of the Horseshoe Bend Water Treatment Plant, which was completed in 2003.

The plant currently treats contaminated surface water flowing in from the north. This water is diverted away from the Pit, slowing the rate of rise of the water. Eventually, when the water level at any compliance point reaches the Critical Level of 5,410 feet, the plant will pump-and-treat Pit water to keep levels below that critical point. A performance test was conducted at the plant in 2007, and that data was considered in the 2010 review.

All treated water is currently recycled to Montana Resources active mining operations and is not discharged to Silver Bow Creek or any other surface outlet, Consequently, EPA identified all issues in the review as potential future issues that do not effect the current protectiveness of the remedy. Montana Resources does not allow any water to discharge from the Berkeley Pit and active mine area.

Issue 1: pH

Water treated at the plant did not meet the final pH standard. pH measures the acidity of a liquid. The pH is purposely raised to over 10 in order for it to be used as operating water in Montana Resource’s mill. Discharge standards only apply when water is discharged to Silver Bow Creek.

Issue 2: Gypsum scaling

Gypsum scale build up on the lip of the treatment plant clarifier overflow.
This photo from EPA’s 2010 five-year review report shows gypsum scale build up on the lip of the treatment plant clarifier overflow.

During the water treatment process, gypsum sometimes builds up, or ‘scales’, on the inside of tanks and pipes. This leads to a need for additional maintenance, as parts of the plant must be shut down for a short period each year so that crews can remove the build up. Measures to help manage and reduce scaling are being evaluated, and gypsum concentrations are monitored weekly.

Issue 3: Cadmium

Testing showed that treated water at times did not meet the standard for cadmium, a toxic metal. After adjustments were made to increase the pH, the standard for cadmium was met.

Issue 4: Test did not include treatment of Pit water

The 2007 performance test measured treated surface water from Horseshoe Bend. While this water is similarly contaminated, Pit water has higher concentrations of toxic metals and sulfate.

Issue 5: Scale Inhibitors used to control gypsum may effect metals removal

This issue is closely related to issue 2. To reduce gypsum scaling on critical pipelines and pumps, scale inhibitors are used. These chemical additions make it more difficult for gypsum to precipitate out of treated water and build up in the plant. Their effect on metals removal was a concern, but studies have shown no discernable effect of inhibitors on metals removal.

Issue 6: Whole Effluent Toxicity

Whole Effluent Toxicity (WET) is a measure of the total toxic effect from pollutants in treated wastewater on aquatic life. In 2010, WET testing had not yet been performed on treated water. Treated water is currently recycled in active mining operations, so it is no threat to aquatic life. Preliminary WET testing was completed during pilot testing using Horseshoe Bend water. Results showed the chronic exposure concentration with the lowest observable effect was 75% treated water mixed with 25% dilution water. More WET testing is planned.

Recommendations

EPA recommended that an additional performance test be completed prior to the 2015 five-year review to investigate all six of these issues and possible solutions.

EPA also noted that operations and maintenance at the plant are now more focused on preventative care, and operations in general have been optimized. After adjustments, treated water met all discharge standards with the exception of pH (issue 1).

In order to be protective in the long term, the various water quality issues in treated Pit water will have to be resolved before discharge to Silver Bow Creek becomes necessary. As long as Montana Resources continues active mining at the Continental Pit, no discharge is expected to occur.

Recommendations for additional performance testing will be addressed by treatability studies starting in 2016 and concluded by 2019, well before any discharge would potentially occur.

EPA determined that the ongoing remedy for the Pit is functioning as intended. When the water approaches the Critical Level, additional testing will help to further refine plant performance. The 2015 five-year review of Butte area Superfund sites will be published later in 2015, and will be available online here and on the EPA’s Butte Superfund website.

Interested citizens should contact EPA with any questions or comments regarding the 2010 or 2015 site reviews.

The Berkeley Pit and connected tunnels act as a sink that collects groundwater in the area due to the fact that the basin of the Berkeley Pit lake is the lowest point in the groundwater system. Image from Google Earth.

Do Butte residents need flood insurance?

No. Butte residents don’t need to worry about flood insurance in regard to the Berkeley Pit and connected underground mine workings. The Berkeley Pit and connected tunnels act as a sink that collects groundwater in the area. Water levels in the Berkeley Pit and associated mine shafts are currently 175 to 200 feet below the rim of the Pit.

Elevations above sea level for Berkeley Pit water and surrouding Butte, Montana landmarks. Map image from Google Earth, graphic by Justin Ringsak.
Elevations above sea level for Berkeley Pit water and surrounding Butte, Montana landmarks. Image from Google Earth. Click on the image to view a larger version.

The lowest point on the Pit rim, on the east side near the Montana Resources concentrator, is 5,509 feet above sea level. As of June 2013, the Berkeley Pit water level was 5,310 feet, and the highest water level in the system, in the Pilot Butte shaft, was 5,335 feet.

Under the management plan for the Berkeley Pit, these water elevations will always be maintained at levels 100 feet or more below the rim. This will be accomplished by pumping and treating Berkeley Pit water. Pumping and treating will start when the water level at any one of the monitoring compliance points reaches the critical level of 5,410 feet. The Montana Bureau of Mines & Geology (MBMG) monitors water levels at all compliance points, as well as at several other monitoring sites, on a monthly basis. Based on the rate the Pit is filling now, that should happen around 2023.

Berkeley Pit groundwater monitoring locations and water levels, including wells and abandoned mine shafts, June 2013. Graphic by Justin Ringsak.
Berkeley Pit groundwater monitoring locations and water levels, including wells and abandoned mine shafts, June 2013.

The elevation of the Metro Storm Drain near the Pit at Texas Avenue and Continental Drive is 5,470 feet, about 60 feet above the highest water level allowed for the Berkeley Pit system.

For further comparison, a monitoring well at Greeley School has an elevation of 5,503 feet, about 93 feet higher than the critical level. The current water level in this well is 5,462 feet, about 52 feet higher than the critical level. This difference in water levels tells us that groundwater is flowing toward the Pit, and will continue to do so after the waters in the Berkeley Pit and connected mines reach their highest allowed levels.

In other words, water is flowing into the Berkeley Pit, and the Pit will be managed so that water is always flowing into it. Butte residents can rest easy knowing that the Berkeley Pit is not going to overflow, and that there is no need for flood insurance due to the Pit or underground mines.

This image illustrates how the Berkeley Pit, with the lowest water levels in the area, acts as a sink that collects groundwater. Water levels indicated for each monitoring point are from June 2013.
This image illustrates how the Berkeley Pit, with the lowest water levels in the area, acts as a sink that collects groundwater. Water levels indicated for each monitoring point are from June 2013. Click on the image to view a larger version.
A timeline projecting future Berkeley Pit management.

Will the Treatment Plant be able to meet the demand to pump-and-treat Pit water in the future?

A treatment pond at the Horseshoe Bend Water Treatment Plant (2009). Photo by Justin Ringsak.
A treatment pond at the Horseshoe Bend Water Treatment Plant (2009).

Yes, after a treatment technology review and upgrades to the plant are completed.

The 1994 EPA Record of Decision and 2002 Consent Decree require a review of treatment technologies when the Critical Water Level (5,410 feet) is about four years away. The review will consider the plant’s ability to treat both Pit water and water coming from the Horseshoe Bend drainage to the north. Based on the review, the Treatment Plant will then be upgraded to best treat the water.

Upgrades must be completed two years before the critical level is reached. Projections show water levels at one of the compliance points connected to the Pit will near the critical level around 2023, so a treatment review would take place in 2019, with any needed upgrades completed by 2021, as indicated by the timeline below.

This timeline reflects project changes agreed to in the Consent Decree that governs Berkeley Pit management. The timeline is reviewed and adjusted by the Montana Bureau of Mines & Geology each year. Any future timeline changes will be reported in PitWatch and on the PitWatch website at www.pitwatch.org. Graphic by Justin Ringsak.
This timeline reflects project changes agreed to in the Consent Decree that governs Berkeley Pit management. The timeline is reviewed and adjusted by the Montana Bureau of Mines & Geology each year. Any future timeline changes will be reported in PitWatch and on the PitWatch website at www.pitwatch.org. Click on the image to view a larger version.

 

Elevations above sea level for Berkeley Pit water and surrouding Butte, Montana landmarks. Map image from Google Earth, graphic by Justin Ringsak.

Could the Berkeley Pit ever overflow?

The Berkeley Pit will never overflow. In 1994 the EPA established the Critical Water Level (the maximum level the water will be allowed to reach) at 5,410 feet above sea level, which is one hundred feet below the rim.

Elevations above sea level for Berkeley Pit water and surrouding Butte, Montana landmarks. Map image from Google Earth, graphic by Justin Ringsak.
Elevations above sea level for Berkeley Pit water and surrounding Butte, Montana landmarks. Image from Google Earth. Click on the image to view a larger version.

Water levels are regularly monitored at the Pit, in historic underground mines, and in wells surrounding the Pit. Failure to keep the water below 5,410 feet would result in steep fines for the companies responsible for the site, BP-ARCO and Montana Resources.

In addition to careful monitoring, the Horseshoe Bend Water Treatment Plant was constructed to make sure water in the Pit remains below 5,410 feet. Pit water will be pumped, treated, and discharged when the level nears the critical point.

Even if the water was allowed to rise unchecked, it would still never reach the rim. The groundwater flow would reverse direction and, instead of flowing toward the Pit, as it does now, the water would flow away from the Pit, underground into the sandy aquifer beneath Butte’s valley.

Due to the underground flow, Pit surface water would never reach the rim. Considering the federal orders, potential fines, and frequent monitoring, Pit water will not rise unchecked.

How is the Horseshoe Bend Water Treatment Plant operating?

The plant treats about 3.4 million gallons of water per day. This water currently comes from the Horseshoe Bend drainage. Treated water is used in Montana Resources mining operations.

Sludge from the treatment process is returned to the Pit at a rate of 250,000 gallons per day. No water or waste leaves the Berkeley Pit or mine site.

The first stage reactor tank at the Horseshoe Bend Water Treatment Plant, which will eventually treat Berkeley Pit water. Photo from the EPA Five Year Review Report (2011) for the site.

Horseshoe Bend Water Treatment Plant Performance Test (2007)

The first stage reactor tank at the Horseshoe Bend Water Treatment Plant, which will eventually treat Berkeley Pit water. Photo from the EPA Five Year Review Report (2011) for the site.
The first stage reactor tank at the Horseshoe Bend Water Treatment Plant, which will eventually treat Berkeley Pit water.

A performance test of the Horseshoe Bend plant was completed in November 2007, as mandated by the Record of Decision. Based on the performance review, water discharged from the plant meets all discharge standards for contaminants of concern set by the EPA. Additional adjustments still need to be made to address pH. In general, plant operations are going as expected.

The following is EPA’s assessment of the performance test, excerpted from the 2011 Five Year Review Report on the site, pages 43-45:

System Operations/O&M

The influent water for the 2007 Performance Test consisted only of HSB (Horseshoe Bend) water, as water from the Berkeley Pit is not yet required to be pumped and treated in the plant. The results of this test indicated that all final discharge limits could be met except for effluent pH. In order to meet the cadmium limit, the pH in the final treatment stage needed to be raised to 11.2.

Consequently, the effluent pH did not drop to below the discharge standard of 9.5 through natural aeration. Methods for lowering the pH of the effluent to below the discharge standard of 9.5 have been evaluated on a conceptual level, but will require a more formal analysis before final discharge to Silver Bow Creek is necessary.

The results of the performance test also determined a need to revisit the applicability of the final performance standard for beta/photon emitters, which is expressed as a dose of 4 millirem per year (mrem/yr). There are approximately 179 radionuclides that need to be analyzed in order to calculate the actual beta/photon emitter dose, bringing into question the practicality of the laboratory procedures needed to meet the beta/photon standard.

Results of a 2007 performance test of the Horseshoe Bend Water Treatment Plant at the Berkeley Pit, taken from the EPA Five Year Review Report on the site (2011).
Results of a 2007 performance test of the Horseshoe Bend Water Treatment Plant at the Berkeley Pit, taken from the EPA Five Year Review Report on the site (2011). Click on the image to view a larger version.

Opportunities for Optimization

Based on the results of the most recent performance test and plant operations and maintenance activities, there are several areas where optimization is needed. They include:

  1. effluent pH adjustment (when discharge to Silver Bow Creek is necessary),
  2. equipment and pipeline scaling from gypsum and
  3. equipment corrosion issues.

Each of these issues is undergoing various levels of engineering evaluation and testing to determine the best long term course of action.

Early Indicators of Potential Issues

There are no indications of potential equipment problems or operational problems that would put the protectiveness of the HSB WTP at risk. However, it is unknown whether discharge of treated water saturated with gypsum will adversely affect aquatic life in Silver Bow Creek.

It is also possible that delayed precipitation of gypsum could cause exceedances of the TSS discharge standard. This issue will require further evaluation before discharge occurs.

Implementation of Institutional Controls and Other Measures

Based on the information obtained from a review of the site documentation in the administrative record and from interviews with the site RPM and other stakeholders, the ICs implemented for the BMFOU continue to effectively protect the remedy and the public. Publications such as the PITWATCH, inform the public as to progress on the BMFOU. The current DNRC order prohibits use of the BMFOU aquifer for domestic use. Enforcement and monitoring of this prohibition is important.

The Horseshoe Bend Water Treatment Plant, completed in 2003, captures surface water to slow the rate of fill of the Berkeley Pit lake. In the future, the plant will capture and treat water to prevent Pit water from rising further. Photo by Justin Ringsak.

Water treatment plant working as expected

The Horseshoe Bend Water Treatment Plant, completed in 2003, captures surface water to slow the rate of fill of the Berkeley Pit lake. In the future, the plant will capture and treat water to prevent Pit water from rising further. Photo by Justin Ringsak.
The Horseshoe Bend Water Treatment Plant, completed in 2003, captures surface water to slow the rate of fill of the Berkeley Pit lake. In the future, the plant will capture and treat water to prevent Pit water from rising further.

Looking northeast from the Berkeley Pit viewing stand, visitors can see one of the most important components in the future management of the Pit: the Horseshoe Bend Water Treatment Plant. Sitting on four acres near the former McQueen neighborhood, about 600 feet east of the Berkeley Pit, the treatment plant was constructed in 2002-2003. It sits on native land that is very stable, and the plant was built to withstand the maximum probable earthquake.

The facility was designed to treat up to seven million gallons per day, or about 5,000 gallons of water per minute. The facility cost approximately $18 million to build, and, depending on how much water is treated, operating expenses run about $2 million per year.

Once the Berkeley Pit water comes online, which is projected to happen in 2023, annual operation and maintenance costs could be as high as $4.5 million. Under the terms of the 2002 Consent Decree negotiated with the government, BP-ARCO and Montana Resources have agreed to provide financial assurances to pay operation and maintenance expenses in perpetuity. The two companies also paid all construction costs for the facility.

The actual construction of the treatment plant was a massive undertaking. It is estimated that workers put in 125,000 hours of total labor, and the facility also required more than 4,500 cubic yards of concrete.

The general construction contractor and subcontractors were all from Montana, with several from Butte, and, during the course of construction, they reported no safety incidents of any kind.

As per the schedule listed in the 1994 EPA Record of Decision and included in the 2002 Consent Decree, based upon current water level projections, a review of the Horseshoe Bend Water Treatment Plant design and operation would begin in 2019. Any necessary upgrades would have to be completed by 2021, two years before Pit water itself is currently projected to be pumped and treated in 2023.

In November, 2007, a performance review of the Horseshoe Bend plant was completed by Montana Resources, ARCO, and North American Water Systems, with cooperation from the Montana Bureau of Mines & Geology, the Department of Environmental Quality, and the EPA.

The performance test was undertaken to ensure that the treatment system is capable of meeting the water quality standards set in the Consent Decree for the site. For this test, only water from the Horseshoe Bend drainage was treated, as water from the Pit is not yet required to be pumped and treated at the plant.

The test began on November 18, 2007, and continued for 72 hours. All of the water quality standards for contaminants of concern were met. Additional adjustments still need to be made to address pH. For this test, the pH was kept at a high (basic or alkaline) level in order to effectively remove contaminants of concern and meet water quality standards.

The optimization of the plant in the future may result in a lower pH. Additionally, methods of adjusting the pH prior to discharge to Silver Bow Creek have been evaluated conceptually. Any method of adjusting the pH will be formally evaluated, if necessary, before any water from the plant is discharged to Silver Bow Creek.

A clarifier, drained for maintenance, at the Horseshoe Bend Water Treatment Plant. The plant will eventually be required to treat water from the Berkeley Pit. Photo from the EPA Five Year Review Report (2011) for the site.

Treatment technology thoroughly studied

The Berkeley Pit is literally world famous in the mine waste cleanup industry, and the final technology used in the Horseshoe Bend Water Treatment Plant, a High Density Solids (HDS) process, was selected after an assessment of tests and the demonstrated effectiveness of cleanup technologies from research groups around the world.

A clarifier, drained for maintenance, at the Horseshoe Bend Water Treatment Plant. The plant will eventually be required to treat water from the Berkeley Pit. Photo from the EPA Five Year Review Report (2011) for the site.
A clarifier, drained for maintenance, at the Horseshoe Bend Water Treatment Plant. The plant will eventually be required to treat water from the Berkeley Pit.

The Horseshoe Bend facility currently treats water from Horseshoe Bend, and will eventually be used to treat water from the Berkeley. The treatment plant utilizes a two-stage lime (calcium hydroxide) precipitation process in combination with HDS technology. Lime, aeration and polymer addition remove metals from the water. The fully automated facility generates about 10 times less sludge than a conventional lime treatment plant. HDS technology produces denser sludge through a recycling process in which the sludge generated in the water treatment process is sent through the system many times.

The process resembles a snowball effect. Each time sludge particles are sent through, they grow in size as new particles attach to the old ones. At the end, the final sludge product – like a watery mud – is much denser.

Horseshoe Bend Treatment Plant Sludge Reduction. Graphic by Justin Ringsak.
Horseshoe Bend Treatment Plant Sludge Reduction

The relatively low final volume of sludge – currently about 40,000 gallons per day in a 220,000-gallon slurry – is deposited in the Berkeley Pit, eliminating the need for a land-based sludge repository. Test results indicate that sludge disposal in the Pit may raise the pH of the water over a 10- to 20-year period, which could potentially decrease treatment costs for Pit water.

Due to the design of the system, treated water can easily be used in the concentration process at the adjacent Montana Resources mine, or, in the event that the mine ceases operations, discharged to Silver Bow Creek upstream from the confluence with Blacktail Creek near Montana Street. The volume of treated water should add about 4.5 cubic feet per second (cfs) of flow to the creek, which represents about a 50 percent increase to the base flow of 10 cfs.

A performance test of the Horseshoe Bend plant was completed in November 2007, as mandated by the Record of Decision. Based on the performance review, water discharged from the plant meets all discharge standards for contaminants of concern set by the EPA. Additional adjustments still need to be made to address pH. In general, plant operations are going as expected.

Montana Resources copper precipitation plant adjacent to the Berkeley Pit. A 2013 slough of material from the Pit wall into the water knocked out the 'precip' pump, and precip operations have since ceased. In precipitation, the copper-rich water is pumped over scrap iron, and, in a replacement reaction, the copper solidifies as sludge, while iron takes its place in the water. The water was returned to the Pit by gravity flow, thus not increasing or decreasing the total volume of Pit water. Photo by Justin Ringsak.

Montana Resources mines the water

The Past

Butte’s Memory Book tells the story of Jim Ledford, a miner who lived in a log cabin below the famed Anaconda Mine. Alongside his cabin was an old dump containing scrap iron and tin cans. Mine water ran downhill through the dump, and Ledford noticed a heavy sludge formation. Out of curiosity, he had the sludge assayed and learned that it was 98-percent-pure copper.

Legend has it that Ledford told no one about his discovery. Instead, he quietly secured a one-year contract to handle the Anaconda mine water. He set up tanks, filled them with scrap metal, and ran the water through them. The undated account said his efforts earned him $90,000 that first year. His contract was not renewed.

A professional paper from a 1913 Butte mining conference tells a slightly different story. It states that in 1890 a William Ledford obtained a contract to handle water from the St. Lawrence Mine. The story ends the same, however, once the Anaconda Company realized the value of mine water, it built its own copper tanks, and copper precipitation using scrap iron became standard operating procedure. Thanks to Al Hooper for loaning his copy of the 1913 mining conference proceedings.

A third version of the story was relayed in the April 18, 1906 edition of The Montana Standard as part of a series of articles on “Queer Spots in Butte.” According to this version, in 1888 an old Welshman named Morgan who lived on the Butte Hill noticed copper dust left behind from tin cans thrown into a gully filled with runoff water from the mines. Morgan had the dust assayed and learned that it was almost pure copper. He experimented with the concept and developed a rudimentary precipitation plant, but died a few months after he had his plant operating successfully.

The story goes on to claim that a Butte Dutchman named Fred Miller dug holes in the side hill in the gulch below the St. Lawrence mine. He filled these holes with tin cans and scrap iron, allowing mine runoff water to flow over them.

For the next two or three years, he would collect the resulting copper dust every few weeks. Miller fraudulently claimed a monopoly on this system, and on several occasions tried to bluff out others on the hill who were experimenting with precipitation. The story notes that at this point William Ledford secured a lease to the St. Lawrence water, and Miller’s heyday came to an end.

The Present

Montana Resources copper precipitation plant adjacent to the Berkeley Pit. A 2013 slough of material from the Pit wall into the water knocked out the 'precip' pump, and precip operations have since ceased. In precipitation, the copper-rich water is pumped over scrap iron, and, in a replacement reaction, the copper solidifies as sludge, while iron takes its place in the water. The water was returned to the Pit by gravity flow, thus not increasing or decreasing the total volume of Pit water. Photo by Justin Ringsak.
Montana Resources copper precipitation plant adjacent to the Berkeley Pit. A 2013 slough of material from the Pit wall into the water knocked out the ‘precip’ pump, and precip operations have since ceased. In precipitation, the copper-rich water is pumped over scrap iron, and, in a replacement reaction, the copper solidifies as sludge, while iron takes its place in the water. The water was returned to the Pit by gravity flow, thus not increasing or decreasing the total volume of Pit water.

This method of copper recovery was not new: it dates back to medieval Europe. The Anaconda Company used it for years to recover copper from the water pumped from the underground mines, and the method is still used today. Montana Resources has mined copper from the rich mineral waters of the Berkeley Pit since 1998, pausing when mining operations were suspended from 2000 through 2003, then resuming in 2004 until a Pit slough in 2013 knocked out the necessary pump. The mine pumped out roughly 13 million gallons of Pit water per day, or about 10,000 gallons per minute.

In copper precipitation, the Pit water is piped to the company’s precipitation plant, built in the 1960’s next to a similar one from decades earlier. The water flows into concrete cells filled with scrap iron, and then chemistry takes over. Simply put, the iron in the cells and the copper in the water trade places. The water is returned to the Pit with a higher iron content, and the copper precipitates, or solidifies out of solution, clinging to the remaining iron.

The waterfall formerly visible on the southeast rim of the Pit, seen here in 2004, created by returning Pit water that has gone through Montana Resources copper precipitation plant. Photo by Josh Peck.
The waterfall formerly visible on the southeast rim of the Pit, seen here in 2004, created by returning Pit water that has gone through Montana Resources copper precipitation plant.

The chemical reaction does not take long. Water stays in contact with the iron for only about an hour, and then it flows back into the Pit through a separate ditch along the old Horseshoe Bend channel, which could be seen from the viewing stand as the waterfall on the northeast rim of the Pit. Mine officials say that this constant circulation process should not affect the water level of the Pit, nor should the change in water chemistry have an effect on eventual water treatment operations.

Once per week, crews drain each cell to recover the precipitated copper. A front-loader scoops up the copper and scrap iron mixture and transports it to a vibrating screen. Water sprayed from high-pressure hoses knocks the copper through the screen into a tank below. Remaining iron goes back to the cells for reuse. The cement copper concentrate is then shipped to the concentrator and processed through a filter press to reduce the water content for rail shipment. By pumping water from the Berkeley, the company recovered about 400,000 pounds of copper per month.

The company also routed copper-rich Horseshoe Bend water through the precipitation plant from 1998 until the mine shutdown of 2000. The sale of this precipitated copper helped to offset water treatment costs. Once through the precipitation plant, Horseshoe Bend water was mixed with lime (calcium hydroxide) and pumped north to the Yankee Doodle Tailings Pond.

Since the treatment plant went online in 2003, this Horseshoe Bend water has been kept out of the precip plant circuit.

The equation below shows the main chemical reaction that takes place during the copper precipitation process:

Fe + CuSO4 becomes FeSO4 + Cu