One of the world's largest coal reserves is located in Mozambique, spanning 25,000 hectares and boasting an estimated 1.9 billion tons of coal. The mine produces 1 million tonnes of coal monthly and employs over 4,000 people, making it a critical asset in the global coal industry.
Goodwin Africa's Submersible Slurry Pumps to Improve Operational Efficiency at a Coal Mine in Mozambique
One of the world’s largest coal reserves is located in Mozambique, spanning 25,000 hectares and boasting an estimated 1.9 billion tons of coal. The mine produces 1 million tonnes of coal monthly and employs over 4,000 people, making it a critical asset in the global coal industry.
However, the mine faced significant operational challenges due to recurring sump flooding, primarily caused by failing vertical spindle pumps. These failures resulted in motor burnouts every 8 weeks, leading to production losses, safety hazards, and costly repairs. Seeking a long-term solution, the mine engaged Goodwin Africa to provide a robust and efficient pumping system that would resolve these ongoing issues.
Challenges in the Existing Pumping System
The mine’s two processing modules, each handling 4,000 tons per hour, included 14 underflow sumps equipped with vertical spindle pumps for transferring coarse slurry. However, the existing pumps faced the following issues:
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High motor failure rates – Burnouts occurred every 8 weeks, causing excessive downtime and increased maintenance costs.
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Frequent flooding – Inefficient sump management resulted in water accumulation, affecting production efficiency and worker mobility.
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Unsafe working conditions – Due to constant flooding, plant personnel were forced to wear rubber Wellington boots to navigate the facility safely.
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Significant production losses – With each pump failure, coal processing was delayed, impacting output targets and overall profitability.
Goodwin’s Tailored Solution: ANZE 100 Submersible Slurry Pump
Recognizing the urgency of the issue, the mine’s operations manager engaged Goodwin Africa’s technical team to conduct a comprehensive site assessment. After a detailed plant audit, Goodwin proposed replacing the existing vertical spindle pumps with ANZE 100mm submersible slurry pumps.
Initially skeptical, the mine agreed to a 12-week trial, installing two 100ANZE submersible pumps in the cyclone underflow sumps. These pumps featured:
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100mm discharge for high-efficiency slurry transport.
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30kW motor power, ensuring consistent performance under high-density slurry conditions.
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Heavy-duty design, built to withstand abrasive materials and prolong pump lifespan.
Instant Operational Improvements
Following the successful trial, the mine experienced immediate and measurable improvements in operational efficiency:
1. Elimination of Sump Flooding
The 100ANZE submersible pumps provided continuous, reliable sump dewatering, eliminating excess water buildup. As a result:
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Personnel mobility significantly improved, with no further need for rubber boots.
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Workplace safety conditions were enhanced, reducing slips, falls, and equipment damage.
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The plant floor remained dry, allowing for a more organized and hazard-free environment.
2. Significant Reduction in Maintenance Costs
With no unexpected pump failures, Goodwin 100ANZE pumps drastically reduced maintenance expenses. The benefits included:
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Elimination of costly motor burnouts, which previously occurred every 8 weeks.
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Lower spare parts usage, reducing inventory costs for pump components and motors.
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Longer pump lifespan, minimizing the need for frequent replacements.
3. Increased Production Efficiency
By ensuring uninterrupted coal processing, the new Goodwin pumps played a key role in:
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Minimizing downtime, allowing the plant to achieve consistent production targets.
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Optimizing slurry transfer, improving material flow rates and plant throughput.
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Reducing energy waste, as the efficient pumps required less power to operate effectively.
4. Higher Productivity and Reduced Downtime
The robust performance of the Goodwin pumps enabled the facility to operate continuously without interruptions, resulting in a higher production yield and reduced operational costs.
"The frequent failure of the vertical spindle pumps has led to output production loss and the flooding has compromised the safety of the production personnel"
Scaling Up: Replacing All Vertical Spindle Pumps with Goodwin ANZE Models
After witnessing the reliability and performance of the trial pumps, the mine decided to replace all 14 vertical spindle pumps with Goodwin 100ANZE submersible slurry pumps. This strategic upgrade provided long-term benefits:
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Standardization of pumping systems, simplifying spare parts management and maintenance routines.
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Uniform efficiency improvements across all sumps, ensuring consistent dewatering and slurry handling.
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Reduced operational costs through energy savings, minimized downtime, and lower repair expenses.
Goodwin Africa’s On-Site Technical Support
A critical component of the project’s success was Goodwin Africa’s dedicated technical support. Their engineering team was present throughout the installation, commissioning, and post-implementation phases, ensuring the following:
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Comprehensive operator training, equipping plant personnel with pump operation and maintenance knowledge.
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Real-time performance monitoring, making adjustments to maximize pump efficiency.
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Regular maintenance check-ups, ensuring long-term reliability and optimal system performance.
Company-Wide Impact: Sharing Best Practices Across Mining Sites
Encouraged by the success of the Goodwin ANZE pumps, the mine initiated internal workshops to share the best practices with other operations within their mining group. These workshops focused on:
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How to optimize sump dewatering strategies for improved efficiency.
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Maximizing equipment lifespan through proper maintenance routines.
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Evaluating energy savings and cost reductions achieved through Goodwin pumps.
What Were The Key Benefits Realized by the Mine?
The successful implementation of Goodwin 100ANZE submersible slurry pumps resulted in transformational improvements in efficiency, cost savings, and safety.
The top benefits included:
1. Cost Reductions
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Eliminated frequent pump failures, reducing maintenance expenses.
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Lower energy consumption, optimizing operational expenditure.
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Reduced need for spare parts, streamlining inventory management.
2. Operational Efficiency
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Eliminated plant flooding, preventing disruptions in coal processing.
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Enhanced slurry handling, optimizing material flow and reducing bottlenecks.
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Consistently achieved production targets, maximizing coal output.
3. Improved Workplace Safety
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Reduced risk of slip-and-fall accidents, improving employee well-being.
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No more reliance on Wellington boots, creating a cleaner and more comfortable work environment.
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Lower exposure to hazardous conditions, fostering a safer workplace culture.
Goodwin Africa's ANZE Pumps - A Game-Changer for Mozambique's Coal Industry
The integration of Goodwin Africa’s submersible slurry pump solutions at the coal mine in Mozambique has redefined operational excellence, cost efficiency, and workplace safety. By replacing inefficient vertical spindle pumps with Goodwin 100ANZE submersible pumps, the mine has successfully:
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Eliminated flooding and improved plant conditions.
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Reduced maintenance costs by extending pump lifespan.
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Increased production efficiency, ensuring optimal coal processing.
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Enhanced worker safety, minimizing hazards associated with sump overflow.
With Goodwin Africa’s technical support and proven pump reliability, the mine has set a new industry standard for efficient coal processing operations. This strategic investment has established Goodwin ANZE pumps as the preferred choice for challenging mining applications in Mozambique and beyond.
