WATER MANAGEMENT
Sykes Group – energy efficient mine dewatering
IM caught up with Sykes Group Global Product Manager , Chris O ’ Brien , for some insight into the approach and technology that have helped it achieve sustained growth in the mining market
Q You supply some of the most energy efficient pumps in mining - how did you achieve this in terms of the design and is the energy factor an increasingly important part of mining company / contractor decisions when it comes to dewatering pump selection ? A At Sykes Group , we are proud to supply some of the most energy efficient pumps in the mining industry . Our advanced design is anchored by a unique wet end featuring removable shims and gaskets between the front adaptor plate and the casing , allowing for up to 5 mm of clearance adjustment between the impeller and the wear plate . This innovative feature not only negates the need for major overhauls but also enables quick , efficient maintenance to restore pump efficiency swiftly . By optimising the wet end , our pumps require less power to achieve more , a critical advantage in an environment of rising fuel costs and a growing emphasis on sustainability . As mining companies and contractors set ambitious environmental targets , energy efficiency has become a key criterion in dewatering pump selection . Sykes Group is up for the challenge , delivering solutions that reduce operating costs while supporting environmental goals and ensuring our clients receive the best in performance and efficiency . Furthermore , we are constantly exploring new options , including electrically driven and solar powered pump systems , to further reduce power consumption and drive sustainable innovation in the industry .
Q Predicting weather extremes has become more difficult today - are mines having to factor in more contingency when it relates to the ability to respond to extremes such as flash flooding ? A The ingress of water into mining areas due to weather extremes is difficult to predict so it is imperative to factor in contingencies to ensure the mining areas are accessible thus maintaining mining efficiency . Sykes pumps can operate over a wide range of flow rates and heads in order to maintain normal water ingress to dealing with the extreme weather conditions . It is convenient to have a standby pump available to cater for the extraordinary weather conditions . The standby pump can be situated alongside the duty pump and can be activated manually or automatically based on sump water levels by a level transducer . The standby pump can pump in tandem through a common discharge line or have its own dedicated discharge pipe depending on the static discharge head pipe size and length . For sites situated in extremely wet regions subjected to constant heavy rain events it is common to have the pumps mounted on a pontoon to ensure any sudden increase in water level ensures the pumps do not become submerged thus damaging the diesel engine or electric motor . The pump will simply go up and down with the water level . This also ensures the pumps suction capability and performance remains constant when the water level subsides .
Q A lot of mines are getting deeper as brownfield expansion is often an easier prospect than a greenfield mine - does this create extra dewatering demands and how is Sykes placed to meet this demand ? A Around the world mines are getting deeper and expanding their footprint which creates extra demand on their ability to dewater the mining area . As Sykes specialises in dewatering solutions , we are well placed to meet this demand , in terms of both ability to supply direct globally or through our distributors , as well as having an extensive product range specifically
Sykes ' Extra High Head ( XH ) pump is helping to meet the increasing demands of the mining sector as open pits go deeper
designed for these applications . Sykes have a range of High Head and Extra High Head pumps designed to cater for deep mining , where water needs to be moved over significant vertical and horizontal distances . They are designed to generate high discharge pressures , enabling them to lift water from great depths and away from the mining area . These pumps are also available in high-flow rate models which are capable of moving large volumes of water , essential in mines with substantial water ingress . They ensure a rapid response to water accumulation , maintaining safety and operational continuity . All Sykes pump models are available as skid , tow or trailer mounted options which allows pumps to be transported and moved around site quickly and with a minimum of fuss .
Q Sykes is a pumps specialist - does that specialism give you greater insight or understanding of the market needs ? A Sykes is a specialist dewatering pump design and manufacturing company , and as such all our people are experts in the challenges faced to dewater mining & construction sites around the world . We pride ourselves in being the global leaders in mine surface dewatering , and this expertise extends to our engineers , production , sales , commissioning , service and aftermarkets
process and mechanical engineers to meet the required discharge standards using a modified Ludzack-Ettinger treatment process . As such , the plant utilises an activated sludge system with nitrogen-reducing capacity .
During the process , the wastewater is pumped through an upfront screenings box and then enters a concrete buffer tank designed to contain peaks and avoid overloading of the biological reactor .
The bioreactor , specifically designed by WEC Water , is comprised of two zones – the anoxicand aerobic zones – and includes an integrated clarifier . The screened wastewater is pumped into the anoxic zone of the reactor where a submersible mixer maintains constant mixing of the anoxic mixed liquor . An air-lift pump transfers mixed liquor to the aerobic zone , which induces the A-recycle for nitrogen removal . Air diffusers , fed by blowers , drives air into the reactor to maintain the biological oxidation and continuous mixing effect . Sludge recirculation retains healthy sludge in the system and periodic wasting to drying beds ensures a consistent sludge retention within the reactor .
Aluminium sulphate is dosed during the process to enable compliance with local phosphate limits and disinfection is achieved by dosing a hypochlorite solution into the clarifier overflow before entering the chlorine contact
tank . Once disinfected , the treated effluent is stored in a lagoon for subsequent reuse as dust suppression , irrigation water or for safe environmental discharge .
Nigel Birchall , Senior Contracts and Project Manager at WEC Water , says : “ One of the major challenges of this project arose due to the mine ’ s remote location . This required considerable logistical expertise to ensure the safe delivery of the complete plant to site without damage . The packaged design of the plant simplified the process as most of the plant was built within the footprint of standard shipping containers .”
Several WEC Water personnel were on site during the construction and commissioning
82 International Mining | MARCH 2025