From Scarcity to Sustainability: Transforming Water Management in the Mining Industry

Water conservation has become a critical focus for mining operations in South Africa, especially amid growing concerns about environmental impact and resource management. As the country grapples with severe water scarcity, companies like Mechanical Rotating Solutions (MRS) are leading the charge in implementing innovative technologies that not only save water but also reduce operational costs and enhance overall efficiency.

According to CEO Franscois Steenkamp, one of the primary areas where significant water savings can be achieved is through process water management. “AESSEAL’s water recycling and reuse systems treat and repurpose water that would typically be wasted in mining processes. For example, their systems can capture water used for dust suppression, ore processing, and equipment cooling, allowing mines to reduce their reliance on fresh water sources.”

In a notable case study from a chrome mine in Limpopo, South Africa, the installation by MRS of AESSEAL’s FGDSS-N mechanical seal on a Warman 6/4 E AH WRT Tailings Pump demonstrated substantial cost savings. By replacing traditional gland packing with this advanced mechanical seal, the mine was able to achieve a return on investment in less than three months. The mechanical seal not only enhanced the pump’s reliability but also reduced water loss drastically, contributing to significant operational and maintenance savings.

The FGDSS-N™ (Flue Gas Desulphurization Single Slurry) single mechanical seal installed by Mechanical Rotating Solutions achieved a return on investment in less than three months.

Internationally, in the quest for improved sustainability and cost-efficiency, a Canadian copper mine implemented AESSEAL’s innovative sealing technology, which led to remarkable results, including a substantial reduction in water usage.

This significant decrease translated into annual savings of approximately CAD 500,000, demonstrating how advanced engineering solutions can profoundly impact operational efficiency. The mine faced substantial challenges with water waste, which not only increased operational costs but also posed environmental compliance risks. “Traditional pumping systems, reliant on gland packing, often resulted in excessive water consumption and maintenance issues. As a solution, the mine opted to integrate AESSEAL’s mechanical seals, known for their ability to minimise leakage and enhance overall equipment reliability. The impact of these changes was substantial. The mine reported a 70% reduction in overall water usage, which directly correlated with a significant decrease in costs associated with water procurement and treatment. Furthermore, the reduction in water usage not only helped the mine comply with stringent environmental regulations but also enhanced its operational efficiency.”

According to Steenkamp, another key area of focus all South African mining operations should pay special attention to is efficient pumping systems. “By upgrading to high-efficiency pumps and implementing mechanical seals, mining operations can minimise water loss and leakage. Traditional pumping systems often rely on gland water, which can waste millions of litres annually. For instance, a typical pump using gland packing may consume around 6.3 million litres of water each year​. In contrast, AESSEAL’s solutions can reduce this consumption to less than 1 litre per month, leading to enormous savings over time.”

A recent collaboration between AESSEAL and various mining companies has underscored the effectiveness of these technologies. With over 15,000 water management systems currently in operation globally, AESSEAL is contributing to the conservation of more than 95 billion litres of water each year.

The AESSEAL SW Range consists of the SW2 and SW3 Water Management Systems. The environmentally-friendly SW Range Systems connect directly to the plant water line using it as its fluid and pressure source.

The adoption of these innovative solutions has allowed mines to achieve not only substantial water savings but also enhanced operational efficiency, enabling them to thrive even in the face of resource constraints.

“Encouraging sustainable practices, such as zero-liquid discharge (ZLD) systems, can also help curb water wastage. These systems recycle all wastewater generated in the mining process, effectively eliminating the discharge of contaminated water into the environment.” Says Steenkamp.

As water scarcity becomes an increasingly pressing issue, the adoption of ZLD technologies will be vital for mining operations to ensure sustainable practices while meeting regulatory requirements and maintaining productivity. AESSEAL’s solutions as implemented by MRS throughout Mpumalanga, such as their water management systems and mechanical seals, can integrate seamlessly with ZLD systems. By minimising water loss through efficient sealing technologies, MRS helps ensure that more water can be recovered and reused, aligning with the goals of ZLD systems. “This combination supports mining companies in meeting their sustainability targets while reducing operational costs associated with water procurement and treatment.”

As the South African mining sector continues to evolve, the need for responsible water management practices has never been more urgent. By embracing cutting-edge technologies, companies like Mechanical Rotating Solutions in partnership with AESSEAL, are helping the industry meet its sustainability goals while simultaneously ensuring that operations remain economically viable. The intersection of water conservation and cost savings represents a vital opportunity for mining operations to improve their bottom line and safeguard precious resources for future generations.

In conclusion, the integration of innovative water management solutions is essential for the sustainability and competitiveness of the mining industry in South Africa. By focusing on these advancements, mining companies can not only mitigate their environmental impact but also unlock new avenues for growth and efficiency.