Increasing Plant Efficiency in Chromite Mining

A large Platinum Group Metal (PGM) mine in South Africa operates a surface processing plant to produce high-purity chromite for ferrochrome production. The facility, located in the Steelpoort area, plays a crucial role in processing chromite ore from multiple mining sites. With a workforce of 600, the plant’s operations depend heavily on water recirculation systems. However, the presence of solid materials in the processed water created challenges for sump cleaning and overall plant efficiency.

Using a Goodwin ANZE 100mm Submersible Slurry Pump at a Chromite Mining Facility in South Africa

To overcome these challenges, the site sought the expertise of Goodwin Submersible Pumps Australia to provide a high-performance, heavy-duty slurry pump solution. The Goodwin ANZE 100mm Submersible Slurry Pump was selected as the ideal solution to improve reliability, reduce downtime, and increase operational efficiency. This article outlines the key benefits of the 100ANZE model for mine site managers responsible for optimizing copper processing operations.

Challenges in Chromite Mine Sump Cleaning and Plant Efficiency

The processing plant utilized sequential settling sumps for solid sedimentation by gravity. These sumps were essential in managing solid-laden water, but they posed several operational difficulties:

The sumps are filled with solids every two weeks, necessitating frequent cleaning.
Cleaning required eight workers to perform manual sump clearing, leading to high labor costs.
Each cleaning session caused a 12-hour plant shutdown, disrupting production.
Only one-third of the sump system could be addressed per cleaning session.
The abrasive and dense chromite slurry made manual removal highly challenging.

Faced with these challenges, the plant sought a more efficient and cost-effective solution that would reduce manual labor while minimizing downtime.

Goodwin Africa'sTailored Solution: The ANZE 100mm Submersible Slurry Pump

To address the sump cleaning inefficiencies, the plant consulted Goodwin Submersible Pumps South Africa. Following a detailed site assessment, the Goodwin 100 ANZE submersible slurry pump was recommended for its superior ability to handle dense, abrasive slurries.

Key Features of the Goodwin 100 ANZE Submersible Pump

100mm discharge with a high-capacity flow rate.
30kW motor capable of handling heavy-duty pumping requirements.
Designed for continuous operation in aggressive slurry environments.
Requires modest water addition to facilitate efficient solid removal.

To optimize pump performance, the plant introduced a small volume of water into the sumps to thin the settled solids. This ensured smooth suction and enabled the Goodwin pump to clear the sumps quickly and effectively.

Significant Improvements to Chromite Plant Operations

The implementation of the Goodwin ANZE 100mm pump led to dramatic improvements in sump cleaning and overall plant efficiency.

1. Drastic Reduction in Cleaning Time

Before the Goodwin pump’s installation, the sump cleaning process required 12 hours per session. The Goodwin 100 ANZE pump reduced this time to just 4 hours, increasing operational efficiency and minimizing plant downtime.

2. Reduced Labor Requirements

Previously, eight workers were needed for manual sump cleaning. With the Goodwin pump, a single operator can now manage the entire sump cleaning process, drastically cutting labor costs and safety risks.

3. Enhanced Safety and Workplace Conditions

Manual sump cleaning involved exposure to abrasive materials, posing risks to workers.
The Goodwin pump’s automation eliminated the need for physical handling of the slurry, improving worker safety.
Less downtime meant fewer safety concerns related to process disruptions.

4. Significant Cost Savings

The reduction in labor needs, plant shutdowns, and maintenance costs resulted in major financial savings.

Fewer spare parts were needed due to the pump’s high durability.
Lower labor and downtime costs meant a strong return on investment within a short period.

5. Environmental Compliance and Reduced Risk of Spillage

By preventing sump overflows, the Goodwin 100ANZE pump helped the mine meet environmental regulations and reduce the risk of environmental incidents. This ensured compliance with government policies while also improving the overall sustainability of operations.

"This is pumping like I've never seen before!"

Senior Engineering Supervisor - Chromite Mine

Adoption of Goodwin Technology in Nearby Facilities

The success of the Goodwin 100 ANZE pump in sump management prompted a nearby chromite concentrator to adopt the same solution. The results mirrored those of the original site:

Streamlined sump cleaning operations.
Reduced maintenance requirements.
Optimized plant uptime and efficiency.

Additionally, the low usage and minimal maintenance requirements of the pump meant that in three years of operation, only one wet-end replacement was necessary, further reinforcing its cost-effectiveness and reliability.

A Smart Investment for Engineering Supervisors in Africa

For engineering supervisors overseeing chromite processing operations, the Goodwin ANZE 100mm submersible slurry pump has proven to be a game-changing investment. The pump’s ability to efficiently clear settled solids, reduce labor demands, and increase plant uptime makes it an ideal solution for sump management challenges in the mining industry.

By implementing Goodwin’s heavy-duty submersible pumps, mining operations can achieve:

More efficient sump cleaning with minimal downtime.
Lower operational costs due to reduced labor and maintenance requirements.
A safer working environment by eliminating the need for manual solid removal.
Extended equipment lifespan with minimal spare part replacements.

With the proven success of the Goodwin 100 ANZE pump, more mining facilities are recognizing the benefits of upgrading their sump management systems, ensuring greater efficiency and reliability in the chromite processing industry.