Pump and dredging technology leader, IPR, has taken a pivotal role in enhancing the efficiency of acid mine drainage (AMD) treatment at historic mining sites in Gauteng. By customizing its innovative SlurrySucker dredging unit, IPR has contributed to better operational performance for two AMD treatment plants near Johannesburg.
Understanding the Acid Mine Drainage Challenge in Gauteng
AMD is a significant environmental issue, particularly in mining regions around Johannesburg. Here, water within abandoned underground mines becomes contaminated when it contacts sulphur-bearing rocks. Once this polluted water reaches the surface, it poses health risks and impacts other water resources.
The AMD Treatment Process: Challenges and Downtime
In AMD treatment plants, contaminated water is treated with lime to neutralize acidity before flowing through reactors where sediment settles. Over time, this sediment clogs the concrete channels, which necessitates frequent reactor downtime for cleaning.
Downtime Impact on Plant Operations
According to Ruaan Venter, Business Development Manager at IPR, the downtime involved in cleaning out sediment from the reactors significantly disrupts plant operations.
“To clean one reactor, it had to be taken offline, which cut into plant throughput and put additional strain on the second reactor,” explained Venter. “Our client needed a solution that would minimize disruptions and boost overall plant uptime.”
Introducing IPR’s Customized SlurrySucker for AMD Treatment
IPR’s SlurrySucker dredging system offers a reliable solution, allowing for continuous dredging with minimal manual supervision. The system includes a heavy-duty submersible slurry pump mounted on a specially designed flotation raft, which can operate seamlessly within the treatment process.
Customizing the Mini SlurrySucker for Reactor Constraints
Due to the unique structural layout of the plant’s reactors, IPR initially provided a rental version of the Mini SlurrySucker to demonstrate its efficiency. After proving its effectiveness, the plant invested in a custom-built version tailored to their specific needs. This customized design enhances the unit’s mobility and adaptability.
“Leveraging our in-house engineering expertise, we developed a custom version of the Mini SlurrySucker,” Venter said. “One of the key requirements was that the unit should not need an on-site crane for repositioning within the reactor.”
Key Features of the Custom-Engineered Mini SlurrySucker
The custom Mini SlurrySucker model has several features that make it ideal for AMD treatment operations:
Corrosion-Resistant Stainless Steel Frame
Constructed with stainless steel, the Mini SlurrySucker withstands the corrosive effects of acidic water, ensuring longevity and reliability.
Enhanced Mobility for Confined Reactor Spaces
Designed to pass under reactor walkways, the unit maneuvers easily through the narrow channels, eliminating the need for cranes or additional lifting equipment.
High-Performance Pumping Power with the Toyo GR20
To handle the high solid content in the slurry, the custom Mini SlurrySucker is equipped with a Toyo heavy-duty GR20 submersible slurry pump, distributed exclusively by IPR in Southern Africa.
Solids Handling Capability for Efficient AMD Treatment
The GR20 pump can handle particles up to 30 mm, making it suitable for the plant’s demanding conditions, where the slurry mixture consists of 60% water and 40% solids.
Impressive Pump Performance Metrics
Powered by a 15 kW motor, the GR20 delivers up to 190 m³ per hour with a head of 30 meters, providing high-capacity output with minimal maintenance needs. This model was selected for its robust design, low total ownership cost, and suitability for the rigorous demands of AMD treatment.
Advantages of IPR’s SlurrySucker in AMD Treatment Applications
The custom-engineered SlurrySucker offers the AMD plant several advantages:
- Increased Plant Uptime: Continuous dredging prevents sediment build-up, reducing the need for reactor downtime.
- Lower Maintenance Requirements: With fewer maintenance needs, the SlurrySucker delivers a low total cost of ownership.
- Enhanced Efficiency: The high-performance pump and durable design ensure efficient sediment removal, supporting seamless AMD treatment.
Conclusion: A Tailored Solution for Complex AMD Challenges
IPR’s customization of the SlurrySucker has successfully addressed the unique requirements of the AMD treatment plants near Johannesburg. By optimizing the Mini SlurrySucker for corrosion resistance, mobility, and high-performance pumping, IPR has provided a sustainable, efficient solution for the treatment of acid mine drainage. This innovative approach highlights the potential for advanced dredging technology to tackle environmental challenges in the mining industry.