Goro Nickel is a world-class mining project and a key part of Vale’s growth strategy. The project is located on the
South Pacific island of New Caledonia, an overseas territorial community of France. Goro is among the richest
undeveloped laterite ore bodies in the world, with excellent average grades, 55 million tonnes of estimated measured and
indicated mineral reserves, and a very large resource base. The expected annual capacity of the Goro nickel project is
60,000 metric tonnes of nickel and 4,300 to 5,000 metric tonnes of cobalt. Vale holds a 69% interest in the Goro project. Remaining interests are held by New Caledonia and Sumic Nickel
Netherlands (owned by Japan’s Sumitomo Metal Mining Co. Ltd and Mitsui Co. Ltd).
In 1999, Hatch was retained to undertake a scoping study of the Goro project, and was subsequently appointed as project
manager and engineer to undertake the bankable feasibility study for the greenfield nickel development in the South
Province. At that time, the capital cost of the project was estimated to exceed US$1 billion.
The project consisted of open-cut mining of a nickel laterite deposit and processing of the ore through a high-pressure acid
leach plant. Both the limonite and saprolite ores forming the deposit were to be processed. After screening and pulping,
the ore is pumped to the process plant. After thickening, the ore slurry is pressure acid leached in autoclaves followed by
counter-current decantation, purification, solvent extraction and pyrohydrolysis. The resultant products are a nickel oxide
and cobalt carbonate.
The bankable feasibility study included all ancillary plant and support infrastructure. The ancillary plant was to include an
integrated acid plant, steam boilers and power plant together with lime kilns and lime slurry plant. Infrastructure included
port facilities, offices, workshops, warehousing, site accommodation, water supply, limestone supply and other services.
The bankable feasibility study also included a technical hazard evaluation as part of the project scope. To meet the needs
of the client and established professional standards, a preliminary hazard analysis (PHA) was conducted to identify
potential hazards at a time when they can be corrected with minimal cost or disruption.
Hatch has continued to provide minor and specialized consulting services to the project to date.
In addition, Hatch was invited to assist with the management of the Goro Nickel plant commissioning early 2008 (port,
ancillaries, feed preparation, leach and refinery facilities). The Hatch team assumed commissioning management in July
2008. Commissioning to be resumed later this year. Hatch will also be responsible for start-up support of the project.
The hydrometallurgical plant involves several novel processing steps, which were tested at the New Caledonia integrated
pilot plant adjacent to the future commercial process plant site.
Hatch completed extensive preliminary risk assessments as part of the bankable feasibility study as well as leading the
HAZOPs for the process plant during the implementation phase of the project up to November 2002.
