Vol 1 Sec 5 Mine Design - Alberta...Syncrude Canada Ltd. Mildred Lake Extension Project Volume 1 – Project Description December 2014 Page 5-1 5.0 MINE DESIGN 5.1 Introduction This

Syncrude Canada Ltd. Mildred Lake Extension Project Volume 1 – Project Description December 2014

Table of Contents

SECTION 5.0 – MINE DESIGN TABLE OF CONTENTS

PAGE

5.0 MINE DESIGN ............................................................................................................... 5-1

5.1 Introduction ......................................................................................................... 5-1

5.2 Mine Design Summary ....................................................................................... 5-1 5.2.1 Mining Technology ............................................................................. 5-4 5.2.2 Geotechnical Design Basis ................................................................ 5-5 5.2.3 Road/Ramp Design ............................................................................ 5-8 5.2.4 Safe Operating Procedures ............................................................. 5-11

5.3 Design Assumptions ......................................................................................... 5-11 5.3.1 Bitumen Production .......................................................................... 5-12 5.3.2 Construction Materials ..................................................................... 5-12

5.4 Mining Equipment ............................................................................................. 5-13

5.5 MLX–W Mine Plan ............................................................................................ 5-14 5.5.1 Preproduction Activities ................................................................... 5-14 5.5.2 Timber and Reclamation Material Salvage ...................................... 5-15 5.5.3 Ore Production ................................................................................. 5-15 5.5.4 Overburden and Interburden ............................................................ 5-17 5.5.5 Mine Status ...................................................................................... 5-18

5.6 MLX–E Mine Plan ............................................................................................. 5-19 5.6.1 Preproduction Activities ................................................................... 5-19 5.6.2 Timber and Reclamation Material Salvage ...................................... 5-19 5.6.3 Ore Production ................................................................................. 5-19 5.6.4 Overburden and Interburden ............................................................ 5-20 5.6.5 Mine Status ...................................................................................... 5-23


Table of Contents

TABLE OF CONTENTS (cont)

PAGE

LIST OF TABLES

Table 5.1-1: MLX Project Summary Information ..................................................................... 5-1 Table 5.2-1: Production Schedule .......................................................................................... 5-4 Table 5.2-2: Geotechnical Criteria .......................................................................................... 5-5 Table 5.2-3: Geotechnical Setback Distances ........................................................................ 5-8 Table 5.3-1: MLX Production Summary ............................................................................... 5-12 Table 5.3-2: Construction Material Use Summary ................................................................ 5-13 Table 5.4-1: MLX Project Equipment Profile......................................................................... 5-14 Table 5.5-1: MLX–W Mineable Resource Summary ............................................................ 5-15 Table 5.5-2: MLX–W Overburden/Interburden Volumes ...................................................... 5-17 Table 5.5-3: MLX–W Construction Material Schedule .......................................................... 5-17 Table 5.5-4: MLX–W Overburden/Interburden Placement Schedule ................................... 5-18 Table 5.5-5: MLX–W Development Milestones .................................................................... 5-18 Table 5.6-1: MLX–E Mineable Resource Summary ............................................................. 5-20 Table 5.6-2: MLX–E Overburden/Interburden Volumes ....................................................... 5-20 Table 5.6-3: MLX–E Construction Material Schedule ........................................................... 5-22 Table 5.6-4: MLX–E Overburden/Interburden Placement Schedule .................................... 5-22 Table 5.6-5: MLX–E Development Milestones ..................................................................... 5-23

LIST OF FIGURES

Figure 5.1-1: MLX–W Proposed Site Layout ........................................................................... 5-2 Figure 5.1-2: MLX–E Proposed Site Layout ............................................................................ 5-3 Figure 5.2-1: MLX–W Geotechnical Field Data Sources ......................................................... 5-6 Figure 5.2-2: MLX–E Geotechnical Field Data Sources .......................................................... 5-7 Figure 5.2-3: Permanent Mine Haul Road – Typical Cross-Section ........................................ 5-9 Figure 5.2-4: Temporary Mine Haul Road – Typical Cross-Section ...................................... 5-10 Figure 5.5-1: MLX–W Mining Sequence ................................................................................ 5-16 Figure 5.6-1: MLX–E Mining Sequence ................................................................................. 5-21


Page 5-1

5.0 MINE DESIGN

5.1 Introduction

This section provides the mine design basis for the Mildred Lake Extension Project (MLX Project). It includes mine plan principles and assumptions, safe operating procedures, equipment profile, road design assumptions and a description of the ore preparation facilities. Detailed plans specific to the MLX West (MLX–W) and MLX East (MLX–E) mining pits and overburden disposal area (ODAs) follow the summary of common elements. Mineable resource in the MLX Project area is estimated at 117 Mm3 of recoverable bitumen. Development of this resource will extend the duration of mining activity on the Mildred Lake leases by approximately 14 years. For the proposed site layout for MLX–W, see Figure 5.1-1, and for MLX–E, see Figure 5.1-2. For MLX Project summary information, see Table 5.1-1.

Table 5.1-1: MLX Project Summary Information

Project Area MLX–W MLX–E

Mine pit area 1856 ha 769 ha

Bitumen in place (BIP) 101.1 Mm3 35.8 Mm3

Diluted ore grade 10.53 wt% bitumen 9.94 wt% bitumen

Recovered bitumen 87.3 Mm3 30.1 Mm3

Ore 941 MT 349 MT

Waste (excluding soil salvage) 780 Mbcm 159 Mbcm

Waste/Ore ratio 1.8 1.0

TV/BIP cutoff 12:1 12:1

TV/BIP design 14:1 14:1

The objective of the MLX mine design is to maximize recovery of surface mineable resource at Lease 17 and Lease 22. Design objectives are to:

minimize disturbance footprint;

provide reliable and consistent supply of ore to the processing plant;

minimize ore sterilization;

maximize progressive reclamation opportunities; and

support the Life-of-Mine Closure Plan.

5.2 Mine Design Summary

The MLX Project proposes the development of additional mining areas at the Mildred Lake Project site. The MLX mine plan assumes continued use of truck/shovel mining technology, and use of the crushers and ore preparation facilities currently in place at Mildred Lake. The MLX–W pit will be phased-in over four years, starting in 2023. On depletion of North Mine in 2026, the MLX–E pit will be opened up to supplement MLX–W production, maintaining bitumen production rates from Mildred Lake at 184,000 barrels per calendar day. A nominal increase in truck fleet size will be required to accommodate longer haul distances as production transitions and progresses into these new mining areas. For the MLX Project estimated production schedule, see Table 5.2-1.

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Operating and ApprovedOil Sands Development

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Mine Components

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Project Footprint

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Overburden Advance

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Page 5-4

Table 5.2-1: Production Schedule

Year Ore (Mt)

Overburden (Mt)

MLX–W MLX–E Total MLX–W MLX–E Total

2022 0 0 0 39 0 39

2023 19 0 19 96 0 96

2024 48 0 48 79 0 79

2025 63 0 63 73 0 73

2026 67 0 67 167 43 210

2027 94 26 120 166 28 194

2028 60 60 120 164 28 192

2029 60 60 120 135 61 196

2030 60 60 120 128 53 181

2031 76 44 120 126 41 167

2032 120 0 120 128 0 128

2033 102 18 120 127 32 159

2034 60 60 120 128 47 175

2035 99 21 120 78 4 82

2036 13 0 13 6 0 6

Total 941 349 1,290 1,640 337 1,975

5.2.1 Mining Technology

Shovel/truck mining technology has evolved to become the industry standard for oil sands surface mines because the technology:

has a high availability factor;

is flexible, allowing for rapid redeployment of the fleet to priority areas;

provides a high degree of selective mining capability to limit ore dilution and meet resource conservation expectations;

allows for blending of ores to optimize extraction performance; and

has proven to be cost-effective at the scale associated with oil sands surface mining developments, and suitable for the range of weather conditions experienced in northeastern Alberta.

Continued use of large-scale shovel/truck technology is assumed for excavation and material transport at the MLX Project. Continued use of this technology enables an efficient transfer of equipment used at North Mine, as well as continued use of the ore preparation and extraction facilities currently in place at the Mildred Lake site. Oil sands will be crushed and mixed with hot water at the Mildred Lake ore preparation plant (OPP) and hydraulically transported to the existing extraction facilities for bitumen recovery.


Page 5-5

5.2.2 Geotechnical Design Basis

The geotechnical stability of pit walls and ODAs relies on understanding the key subsurface geological features. Generally, the stratigraphic units governing geotechnical design for the project features are the presence and thickness of the Clearwater Formation and Pleistocene deposits. Information for geotechnical analyses and design is derived from the following sources:

geological drill core information;

auger and sonic drilling information;

geotechnical sampling and testing results, and geotechnical information from similar materials found at the Mildred Lake operation; and

geologic model. For the locations of MLX–W geotechnical field data sources, see Figure 5.2-1, and for MLX–E, see Figure 5.2-2. Geotechnical criteria for mining and associated project components were developed based on available information. For a summary of the geotechnical criteria used to develop the mine plan for the MLX Project, see Table 5.2-2.

Table 5.2-2: Geotechnical Criteria

Component Sub-Component MLX–W MLX–E

Pit Walls Minimum safety berm width 10 m 10 m

Oil sands slope 28 degrees (~2H:1V) 42 degrees (~1.1H:1V)

Overburden slope 6H:1V 6H:1V

Overburden Disposal Areas Overall slope 14H:1V 14H:1V

Maximum height 40 m 40 m

Reclamation Stockpiles Overall slope (cover soil) 15H:1V 15H:1V

Overall slope (subsoil) 16.25H:1V 16.25H:1V

Maximum height 40 m 40 m

In-Pit Berms Highway berm slope n/a 6H:1V

Cake berms downstream 8H:1V upstream 6H:1V

n/a

Note: n/a = Not applicable.

For geotechnical setback distances for MLX Project components and existing features adjacent to the proposed development, see Table 5.2-3.

MacKay River

Dover River

RGE 12 RGE 11 W4

TWP 94

TWP 93

MLX-W Pit

ODA-N

ODA-S

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Page 5-8

Table 5.2-3: Geotechnical Setback Distances

Project Area Setback Location Setback Distance

(m) From To

MLX–W Pit (crest) South ODA (toe) 250

North ODA (toe) 250

Reclamation Stockpiles (toe) 250

MLX–E Pit (crest) Mildred Lake Settling Basin (toe) 200

Mildred Lake Reservoir (crest) 200

Geotechnical conditions will be monitored to identify and mitigate areas of potential concern. Final designs for ODAs, stockpiles and pit slopes, including detailed monitoring plans, will be provided before construction, as per Oil Sands Conservation Regulations.

5.2.3 Road/Ramp Design

Components of the mine road system include:

permanent haul roads;

temporary haul roads;

ramps;

safety berms; and

service roads. Permanent and temporary haul roads are designed with a running surface width of 40 m, adequate for two-way haul truck traffic. The finished road surface is crowned at 2% from the centreline. Construction materials for permanent haul roads include a subgrade of interburden, Clearwater overburden or Upper McMurray overburden, followed by a sand sub-base and a cap of pit-run and surfacing gravel, as shown in Figure 5.2-3. Temporary haul roads typically include similar subgrade and capping materials, but exclude the sand sub-base, as shown in Figure 5.2-4. Haul road ramps are designed to a maximum gradient of 8%, to support safe and efficient operation of loaded haul trucks. The cross-sectional design of ramps is generally consistent with those of the affiliated road type. Safety berms are an integral part of the design of both permanent and temporary haul roads. They are generally constructed of sand, till or interburden. Berms are constructed to a minimum of half the height of the tire of the largest haul truck designed to travel on the road. Safety berms will contain breaks every 25 m to facilitate drainage into adjacent ditches. Service roads are required for light vehicle traffic, and are designed fit for purpose.

Figure 5.2-3

Permanent Mine Haul Road -

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5.2.4 Safe Operating Procedures

For a discussion on Syncrude’s commitment to safety, see Volume 1, Section 2.10. Safe operating procedures are in place for all aspects of the operation. In all cases, these procedures comply or exceed requirements specified in Alberta Occupational Health and Safety Regulations. The following safety standards will be applied at the MLX Project:

mandatory “Driving in the Mine” training: all personnel driving in the mine areas must have completed this training program;

cell phone use: the use of cell phone, including hands free, is prohibited while operating equipment or driving in the mine;

equipment operation: all equipment will be operated by trained and qualified workers, or under the direct supervision of a competent worker during training;

highwall berms: safety berms must be in place along all highwalls and open faces;

face height: single-bench working face height will not exceed maximum reach of excavation equipment by more than 1.5 m;

face access: walking or parking is not allowed within a distance equivalent to two times the height of the face, except for authorized mining equipment and personnel; and

brake checks: annual brake tests are done on at least 30% of the rubber-tired, self-propelled equipment. All such equipment undergoes brake testing within a three-year period.

Blasting of the mine faces occurs as needed, typically to deal with frozen ground conditions in late winter. Blasting is performed by certified personnel.

5.3 Design Assumptions

The following design principles guided development of the mine plans and production estimates for the MLX mining areas:

location of facilities, infrastructure and ODAs to minimize disturbance footprint and avoid ore sterilization;

mining selectivity of 3 m;

cutoff ore grade of 6 wt% bitumen;

nominal shovel bench height of 15 m, varying from a minimum of 3 m to a maximum of 18 m;

use of multi-benching as required in localized areas;

nominal working bench width of 400 m, with a minimum of 50 m;

cutoff total volume to bitumen in-place ratio of 14:1 in areas where the mining boundary is not constrained by lease boundaries, geotechnical requirements, river offsets or other significant physical features;


Page 5-12

minimum setback of 100 m from Athabasca and MacKay River escarpments;

in-situ density of Clearwater and McMurray materials 2.1 t/m3;

swell factor of Clearwater and McMurray materials 10% to 20%;

swell factor of muskeg 30%; and

extraction recovery estimates consistent with those assumed in AER Directive 082: Operating Criteria: Resource Recovery Requirements for Oil Sands Mine and Processing Plant Operations.

5.3.1 Bitumen Production

Bitumen recovery estimates are consistent with those assumed in AER Directive 082. For an estimate of bitumen recovery and produced bitumen from the MLX–W and MLX–E developments, see Table 5.3-1.

Table 5.3-1: MLX Production Summary

Year

MLX–W MLX–E Total

Oil Sands (Mt)

Average Grade (wt%)

Oil Sands (Mt)

Average Grade (wt%)

Oil Sands (Mt)

Average Grade (wt%)

Recovered Bitumen (Mbbls)

2023 19 9.4 0 0.0 19 9.4 9.7

2024 48 10.7 0 0.0 48 10.7 28.3

2025 63 11.3 0 0.0 63 11.3 39.7

2026 67 11.1 0 0.0 67 11.1 41.9

2027 94 10.8 26 9.0 120 10.4 69.0

2028 60 10.4 60 10.3 120 10.4 69.3

2029 60 10.4 60 9.6 120 10.0 65.8

2030 60 10.4 60 9.8 120 10.1 66.9

2031 76 10.7 44 10.0 120 10.4 69.6

2032 120 10.3 0 0.0 120 10.3 69.0

2033 102 9.2 18 9.6 120 9.2 57.6

2034 60 10.4 60 10.2 120 10.3 68.4

2035 99 11.4 21 10.6 120 11.2 75.5

2036 13 10.7 0 0.0 13 10.7 7.9

Total 941 10.5 349 9.9 1,290 10.4 738.6

5.3.2 Construction Materials

To the extent practical, overburden and interburden materials with suitable properties will be used for dyke construction. Clearwater Formation (predominantly Kcw) and McMurray Formation overburden and interburden are typically suitable for construction of high-specification elements of containment dykes. Most materials are acceptable for use in low-specification zones. Overburden and interburden benches will be designed to maximize


Page 5-13

availability of material types that meet the geotechnical requirements of planned structures, while maximizing ore recovery. Estimated availability of total construction material is adjusted to reflect weather and operational restrictions. For estimated construction material use for the MLX Project, see Table 5.3-2.

Table 5.3-2: Construction Material Use Summary

Year High Spec. Overburden / Interburden Low Spec. Overburden / Interburden

Available Planned Available Planned1

Mbcm Mbcm Mbcm Mbcm2021 0.0 0.0 0.0 0.0 2022 5.6 0.0 13.7 0.0 2023 14.5 0.0 32.0 0.0 2024 11.8 0.0 26.0 0.0 2025 10.4 3.0 24.7 15.3 2026 26.5 4.7 74.3 34.1 2027 26.6 2.8 66.6 26.3 2028 28.0 2.9 63.8 27.8 2029 26.1 7.5 68.1 39.7 2030 25.4 4.9 61.4 13.2 2031 24.6 3.3 55.5 5.6 2032 20.9 7.7 40.6 45.2 2033 21.0 3.8 55.3 41.1 2034 24.3 0.7 59.3 17.7 2035 11.9 0.0 27.1 0.0 2036 0.9 0.0 1.8 0.0

Total 278.5 41.3 670.2 266.0

Notes: 1 High-specification material not used to meet the requirement of high-specification construction areas is

typically used in low-specification construction zones. Planned low-specification volumes reflect the placement of high-specification material in low-specification areas.

5.4 Mining Equipment

The mining fleet comprises four categories of equipment:

primary equipment – shovels and haul trucks (240 t payload or greater);

major support equipment – dozers, graders, water trucks, excavators, and support haul trucks (100 t payload or less);

minor support equipment – small dozers or excavators; and

auxiliary equipment – light vehicles, service vehicles, welders, generators, compressors, pumps, cranes, forklifts, light towers, and emergency response equipment.

Calculations of primary equipment requirements are based on proposed mining rates and estimated performance metrics such as loading and hauling productivity, haul distance, payload, and mechanical availability. Support and auxiliary equipment fleet estimates are based on both


Page 5-14

design considerations and current operating experience. For key equipment required for the MLX development, see Table 5.4-1. Much of this equipment fleet will transition from North Mine to the MLX Project areas over four years.

Table 5.4-1: MLX Project Equipment Profile

Equipment 20

20

2021

2022

2023

2024

2025

2026

2027

2028

2029

2030

2031

2032

2033

2034

2035

2036

Mining Equipment:

Electric cable shovel – 58 yd3 – – – 2 4 5 9 12 11 10 9 9 9 9 9 9 8

Hydraulic shovel – – 3 6 2 1 6 4 2 5 5 5 4 5 5 3 –

Haul truck – 391 t – – – 31 50 62 76 90 108 109 109 109 110 101 91 70 54

Haul truck – 320 t – – – – – – 5 4 – – – – – – – – –

Haul truck – 240 t – – 20 25 - - 25 10 6 6 6 6 6 15 3 – –

Mine Support Equipment:1

Dozer (250 to 800 hp)

Pre-production support equipment

(variable)

1 3 4 4 8 8 8 8 8 8 8 8 8 8

Grader (16H or 24H) 1 1 1 1 2 2 2 2 2 2 2 2 2 2

Loader 1 2 2 2 4 4 4 4 4 4 4 4 4 4

Backhoe 1 2 3 3 5 5 5 5 5 5 5 5 5 5

Scraper 1 1 1 1 2 2 2 2 2 2 2 2 2 2

Cable Reeler 1 1 1 1 2 2 2 2 2 2 2 2 2 2

Cable Tractor 1 1 1 1 2 2 2 2 2 2 2 2 2 2

Water Truck 1 1 2 2 3 3 3 3 3 3 3 3 3 3

Haul Truck (50 t) 1 2 2 2 4 4 4 4 4 4 4 4 4 4

Cake Transport:

Haul truck (cake) – 240 t Cake placement in tailings facilities at North Mine 78 78 78 78 84 87 84

Reclamation Equipment:

Reclamation loader 2 3 2 3 4 6 3 2 4 3 2 2 2 2 2 - -

Haul truck (reclamation) – 100 t

14 20 8 13 26 53 23 15 26 25 12 10 13 11 8 - -

Note: 1 Profile includes support equipment directly associated with mining operation activities; additional support equipment could be

required for other activities and projects.

5.5 MLX–W Mine Plan

Development of the MLX–W resource will require progressive excavation of a mine pit, permanent construction of two out-of-pit ODAs and interim construction of two reclamation material stockpiles (see Figure 5.1-1). Excavation of the mine pit will be followed by progressive infill and reclamation activities.

5.5.1 Preproduction Activities

Site development (preproduction) activities are scheduled to begin in 2018 (five years before bitumen production). Site development includes the following sequence of activities:

bridge and access road construction;

merchantable timber salvage;

clearing and grubbing;

surface drainage;


Page 5-15

reclamation material salvage;

overburden removal from opening cut; and

haul road construction. Bridge and access road construction, merchantable timber salvage, clearing and grubbing, surface drainage, and reclamation material salvage activities are scheduled to begin in 2018.

5.5.2 Timber and Reclamation Material Salvage

During steady-state operation, merchantable timber salvage, and clearing and grubbing activities will take place during the winter months, three years ahead of overburden removal. Similarly, reclamation material salvage activities precede overburden stripping activities by one year. For details on timber salvage, clearing and grubbing, and reclamation material salvage, see Volume 1, Section 9.3.

5.5.3 Ore Production

The proposed MLX–W pit is defined by economic limits at the south, west and north of the ore body. To the east, the pit limit is defined by a minimum 100-m setback from the MacKay River escarpment. For the proposed MLX–W pit limit, see Figure 5.1-1. For a summary of mineable resources, see Table 5.5-1.

Table 5.5-1: MLX–W Mineable Resource Summary

Year Ore Grade

Water Content

Solids Fines Recovered Bitumen

Tonnage (Mt)

Volume (Mm3)

wt% wt% wt% wt% of solids

Mbbls

2023 19 9 9.4 5.1 85.5 21.0 10 2024 48 23 10.7 5.1 84.2 19.9 28 2025 63 30 11.3 5.1 83.6 19.8 40 2026 67 32 11. 5.1 83.8 20.7 42 2027 94 45 10.8 5.1 84.1 21.7 57 2028 60 29 10.4 5.1 84.5 24.4 35 2029 60 29 10.4 5.1 84.5 24.3 35 2030 60 29 10.4 5.1 84.5 21.3 35 2031 76 36 10.7 5.1 84.2 22.8 45 2032 120 57 10.3 5.1 84.6 22.6 69 2033 102 49 9.2 5.1 85.7 28.5 48 2034 60 29 10.4 5.1 84.5 21.6 35 2035 99 47 11.4 5.1 83.5 20.0 63 2036 13 6 10.7 5.1 84.2 26.7 8

Total 941 450 10.5 5.1 84.4 22.5 550

Mining will advance northward, with an extension to the west in the latter years of the mining sequence. For an illustration of the mining sequence, based on overburden advances, see Figure 5.5-1. Mining areas are prioritized to meet blending requirements and to meet dyke construction requirements.

ú

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Dover River

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Figure 5.5-1

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Fig05.05-01 W Annual Mine Advance14-10-03

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Page 5-17

5.5.4 Overburden and Interburden

For a summary of the annual overburden and interburden volumes mined at MLX–W, see Table 5.5-2. For MLX–W overburden and interburden construction material schedule, see Table 5.5-3. For the overburden/interburden placement schedule, see Table 5.5-4.

Table 5.5-2: MLX–W Overburden/Interburden Volumes

Year Overburden Interburden Total Plant Rejects

Mbcm Mbcm Mbcm Mbcm 2022 19 0 19 0.0 2023 38 7 45 0.2 2024 30 8 38 0.4 2025 27 7 34 0.5 2026 67 12 79 0.6 2027 67 12 79 0.8 2028 64 14 78 0.5 2029 59 5 64 0.5 2030 60 1 61 0.5 2031 57 3 60 0.6 2032 54 7 61 1.0 2033 59 2 61 0.8 2034 57 3 61 0.5 2035 27 10 37 0.8 2036 2 1 3 0.1

Total 687 92 780 7.8

Table 5.5-3: MLX–W Construction Material Schedule

Year

Kcw/Marine Oil Sands and Interburden Kc Clays OB1Mbcm Mbcm Mbcm

High Spec Low Spec High Spec Low Spec Low SpecAvailable Planned Available Planned Available Planned Available Planned Available Planned

2022 0.1 0 0.2 0.0 5.5 0.0 12.0 0.0 3.3 0.0 2023 3.1 0 8.6 0.0 11.3 0.0 24.5 0.0 4.1 0.0 2024 2.8 0 8.0 0.0 9.1 0.0 19.6 0.0 2.6 0.0 2025 2.8 0 8.0 2.1 7.6 1.9 14.5 11.0 3.7 3.3 2026 5.4 0 14.5 3.9 19.7 4.7 37.9 23.2 7.1 7.1 2027 5.1 0 13.8 0.0 20.2 2.8 40.9 19.7 6.6 6.6 2028 5.2 0 14.6 3.9 20.2 2.9 40.8 19.3 4.7 4.7 2029 3.0 0 7.5 0.0 18.6 2.9 37.3 28.4 4.4 0.0 2030 2.0 0 4.2 0.0 18.6 0.1 40.1 0.0 4.9 1.5 2031 2.8 0 6.3 0.0 18.4 0.0 39.9 0.7 2.3 0.0 2032 3.1 0 8.4 3.2 17.8 4.3 34.2 33.6 2.3 2.3 2033 2.3 0 4.9 1.5 17.5 3.8 34.2 33.5 6.1 6.1 2034 2.1 0 5.2 4.2 17.8 0.7 37.7 8.0 5.5 5.5 2035 2.5 0 8.2 0.0 9.1 0.0 19.6 0.0 2.1 0.0 2036 0.1 0 0.4 0.0 0.8 0.0 1.6 0.0 0.1 0.0

Notes: Operational and environmental capture rates are applied to total material from the shovel face. Unused high-spec material becomes available for placement in low-spec zones.


Page 5-18

Table 5.5-4: MLX–W Overburden/Interburden Placement Schedule

Year Structures Overburden Disposal Areas

Misc.1 Cake Berm 1 Cake Berm 2 ODA-S ODA-N In-Pit

Mbcm Mbcm Mbcm Mbcm Mbcm Mbcm2022 0.0 0.0 19.3 0.0 0.0 0.0 2023 0.0 0.0 46.4 0.0 0.0 0.0 2024 0.0 0.0 37.8 0.0 0.0 0.0 2025 18.3 0.0 1.4 15.4 0.0 0.0 2026 38.8 0.0 0.0 37.9 3.7 0.0 2027 25.5 3.6 0.0 46.5 4.2 0.3 2028 27.1 3.6 0.0 47.7 0.0 0.3 2029 24.4 6.9 0.0 16.7 16.9 0.3 2030 1.6 0.0 0.0 56.3 3.5 0.3 2031 0.0 0.7 0.0 22.3 37.4 0.3 2032 0.0 43.5 0.0 0.0 17.8 0.3 2033 0.0 44.8 0.0 0.0 16.1 0.3 2034 0.0 18.4 0.0 0.0 42.8 0.3 2035 0.0 0.0 0.0 0.0 37.2 0.3 2036 0.0 0.0 0.0 0.0 2.4 0.3

Notes: 1 Overburden for roads, ramps and other site requirements.

Material not used for structures is placed in in-pit or out-of-pit disposal areas.

5.5.5 Mine Status

For MLX–W development milestones, see Table 5.5-5. For status maps showing the MLX–W development from preproduction through to closure, see Volume 1, Section 7.1.

Table 5.5-5: MLX–W Development Milestones Year Development Milestones

Preproduction (2018 to 2022)

Bridge and access road construction. Merchantable timber salvage. Clearing and grubbing. Surface drainage.

Reclamation material salvage. Facilities construction. Opening cut overburden removal and disposal

into ODA-S. Haul road construction.

2023 First ore to OPP. 2024 Clean water diversion channel extension. 2025 Overburden placement ends at ODA-S.

Overburden placement begins at ODA-N. Construction of Cake Berm 1 begins.

2026 – 2027 – 2028 – 2029 – 2030 – 2031 Overburden placement ends at ODA-N.

Construction of Cake Berm 1 is complete. Construction of Cake Berm 2 begins.

2032 – 2033 – 2034 Construction of Cake Berm 2 is complete. 2035 – 2036 Oil sand mining is complete at MLX–W.

Note: – = No significant milestone.


Page 5-19

5.6 MLX–E Mine Plan

Development of the MLX–E resource will require progressive excavation of a mine pit, permanent construction of one out-of-pit ODA and interim construction of one reclamation material stockpile (see Figure 5.1-2). Excavation of the mine pit will be followed by infill and reclamation activities.

5.6.1 Preproduction Activities

Site development (preproduction) activities are scheduled to begin in 2022 (five years before start of bitumen production). Site development includes the following sequence of activities:

access road construction including Highway 63 underpass;

merchantable timber salvage;

clearing and grubbing;

surface drainage;

reclamation material salvage;

overburden removal from opening cut; and

haul road construction. Access construction is expected to occur concurrently with early reclamation salvage activities, as access to the MLX–E pit is readily available through existing developments. Haul road access to the MLX–E development includes construction of an underpass to cross Highway 63 (see Figure 5.1-2).

5.6.2 Timber and Reclamation Material Salvage

During steady-state operation, merchantable timber salvage and clearing and grubbing will take place during the winter months, two years ahead of mining. Similarly, reclamation material salvage activities precede overburden stripping activities by one year. For details on timber salvage, clearing and grubbing, and reclamation material salvage, see Volume 1, Section 9.3.

5.6.3 Ore Production

The proposed MLX–E pit is defined by economic limits at the northern and southern extremities. Other constraints include a 100 m setback along the Athabasca River escarpment to the east, and geotechnical offsets of 200 m from both the Mildred Lake Settling Basin and the Mildred Lake Reservoir to the west. For the proposed MLX–E pit limit, see Figure 5.1-2. For a summary of mineable resources, see Table 5.6-1.


Page 5-20

Table 5.6-1: MLX–E Mineable Resource Summary

Year Ore Grade

Water Content

Solids Fines Recovered Bitumen

Tonnage (Mt)

Volume (Mm3)

wt% wt% wt% wt%

of solids Mbbls

2027 26 12 9.0 4.6 86.4 28.3 12

2028 60 29 10.3 4.6 85.1 24.2 35

2029 60 29 9.6 4.6 85.8 24.6 31

2030 60 29 9.8 4.6 85.6 29.5 32

2031 44 21 10.0 4.6 85.4 24.6 24

2032 0 0 0.0 0.0 0.0 0.0 0

2033 18 9 9.6 4.6 85.8 27.1 9

2034 60 29 10.2 4.6 85.2 25.0 34

2035 21 10 10.6 4.6 84.8 23.1 12

2036 0 0 0.0 0.0 0.0 0.0 0

Total 349 168 9.9 4.6 85.5 25.8 189

The mining sequence initially proceeds from north to south, mining the eastern portion of the ore body and exposing the footprint of a highway berm to be constructed against the pit wall on the east side of the pit. Once the eastern panel reaches the southern pit boundary, the western panel will be mined from south to north. For an illustration of the mining sequence based on overburden advances, see Figure 5.6-1. There will be limited mining activity at MLX–E during highway relocation activities, estimated to occur in 2032.

5.6.4 Overburden and Interburden

For a summary of annual overburden and interburden volumes mined at MLX–E, see Table 5.6-2. For the MLX–E construction material schedule, see Table 5.6-3, and for the material placement schedule, see Table 5.6-4.

Table 5.6-2: MLX–E Overburden/Interburden Volumes

Year Overburden Interburden Total Plant Rejects

Mbcm Mbcm Mbcm Mbcm

2026 14.3 6.2 20.5 0.0

2027 7.1 6.1 13.2 0.3

2028 1.6 11.5 13.1 0.7

2029 9.2 19.9 29.1 0.7

2030 4.5 20.6 25.1 0.7

2031 5.0 14.4 19.4 0.5

2032 0.0 0.0 0.0 0.0

2033 9.8 5.4 15.2 0.2

2034 3.0 19.2 22.1 0.7

2035 0.0 1.7 1.7 0.2

2036 0.0 0.0 0.0 0.0

Total 54.5 105.0 159.4 4.0

RGE 11 RGE 10 W4

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TWP 93

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Year 2026

Year 2028

Year 2033

Year 2030

Year 2027

Year 2031Year 2034

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East Athabasca

Highway

La SalineNatural

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Project Footprint


Mine Advance

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Fig05.06-01 E Annual Mine Advance14-11-03

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Page 5-22

Table 5.6-3: MLX–E Construction Material Schedule

Year

Kcw/Marine Oil Sands and Interburden

Mbcm

High Spec Low Spec

Available Planned Available Planned

2026 1.4 0.0 5.0 0.0

2027 1.4 0.0 4.9 0.0

2028 2.7 0.0 9.2 0.0

2029 4.6 4.6 11.3 11.3

2030 4.7 4.7 11.7 11.7

2031 3.3 3.3 8.2 4.9

2032 rehandle 3.4 rehandle 6.1

2033 1.2 0.0 4.3 0.0

2034 4.4 0.0 15.3 0.0

2035 0.4 0.0 1.3 0.0

Notes: Operational and environmental capture rates are applied to total material from the shovel face. Unused high-spec material becomes available for placement in low-spec zones. Material not used for structures is placed in in-pit or out-of-pit disposal areas.

Table 5.6-4: MLX–E Overburden/Interburden Placement Schedule

Year Highway Berm ODA-E In-Pit Dump Misc.

Mbcm Mbcm Mbcm Mbcm

2026 0.0 20.5 0.0 0.0

2027 0.0 13.1 0.0 0.2

2028 0.0 13.0 0.0 0.2

2029 15.9 13.0 0.0 0.2

2030 16.5 2.3 6.2 0.2

2031 8.3 0.0 11.0 0.2

2032 9.4 -9.61 0.0 0.2

2033 0.0 0.0 15.1 0.2

2034 0.0 0.0 22.0 0.2

2035 0.0 0.0 1.5 0.2

2036 0.0 0.0 0.0 0.0

Notes: 1 Volume rehandled from ODA-E, placed into highway berm.


Page 5-23

5.6.5 Mine Status

For MLX–E development milestones, see Table 5.6-5. For status maps showing the MLX–E development, from preproduction through to closure, see Volume 1, Section 7.2.

Table 5.6-5: MLX–E Development Milestones

Year Development Milestones

Preproduction (2022 to 2026)

Access road construction including Highway 63 underpass. Merchantable timber salvage. Clearing and grubbing. Surface drainage. Reclamation material salvage. Opening cut overburden removal and disposal into ODA-E. Haul road construction.

2027 First ore to OPP.

2028 Addition of clean water diversion system to the south (Horseshoe Lake).

2029 Overburden placement begins in-pit with construction of the Highway Berm.

2030 Overburden placement ends at ODA-E.

2031 –

2032 Construction of Highway Berm is complete; Highway is relocated onto Highway Berm.

2033 –

2034 –

2035 –

2036 Oil sands mining is complete at MLX–E.

Note: – = No significant milestone.

Documents

Vol 1 Sec 5 Mine Design - Alberta...Syncrude Canada Ltd. Mildred Lake Extension Project Volume 1 – Project Description December 2014 Page 5-1 5.0 MINE DESIGN 5.1 Introduction This