WATER MANAGEMENT
Hydraulic Dewatered Stacking combines and co-disposes sand generated by coarse particle recovery with the mine’ s tailings, filtering and dewatering the tailings in the process, to produce a stable, wellconsolidated tailings stack with a low degree of saturation( photo: Anglo American)
H2 flow
Whether it is reducing, or reusing, water use remains a major consideration for the mining sector, Dan Gleeson says
Across the global mining landscape, few operational challenges are as persistent – or as potentially disruptive – as water management, when uncontrolled water can halt production, damage equipment and compromise worker safety, Ian Ross, Global Product Manager of Dewatering Solutions for Weir, says.
Two major mining operations – Hindustan Zinc Limited( HZL)’ s Rampura Agucha mine, in India, and KAZ Minerals’ Aktogay copper mine in Kazakhstan – faced significant environmental and weatherrelated challenges, with Weir working with
Weir’ s new Multiflo GMS skid-mounted pump range represents the next evolution of dewatering solutions, according to the OEM both operations to design, develop and implement mine dewatering systems to ensure production could continue, despite the extreme conditions.
Ross said:“ Together, these success stories demonstrate how robust engineering, bespoke design and on-site partnership can transform water management from a vulnerability into a competitive advantage.”
Rampura Agucha is a 300-m-deep openpit operation in Rajasthan. During India’ s intense monsoon season, the pit routinely flooded, creating hazardous conditions and forcing production shutdowns.
HZL’ s previous bore-well pump system proved unreliable, with electric cables repeatedly damaged by heavy haul trucks. Voltage drops also caused frequent pump failures. Seeking a dependable alternative, HZL turned to Weir, which proposed a skid-mounted
Multiflo ® 210MV diesel-driven dewatering unit equipped with a self-priming vacuum system. This eliminated the need for electrical power and ensured continuous operation even at low water levels. The system was deployed in a three-stage configuration – one primary pump at the pit bottom and two booster units at higher elevations – to rapidly clear floodwater.
“ The results were transformative,” Ross said.“ HZL experienced seven consecutive years without a single monsoon-related shutdown. As a result, HZL installed an additional 14 Multiflo units, achieving a combined pumping capacity of 1 million cu. m / mth during peak monsoon.”
Over 3,000 km away, Aktogay faced a different but equally demanding challenge. Located in Kazakhstan’ s Abai region, the site experiences extreme temperature swings – from-20 ° C winters to + 30 ° C summers – making water management particularly difficult.
The mine required a portable, dieselpowered dewatering system capable of handling large volumes of return water while operating reliably in sub-zero conditions. Weir responded with a custom-engineered Multiflo RF-90HV unit, designed specifically for the site’ s environmental and operational constraints.
The solution included a diesel-driven vacuum self-priming pump mounted on a heavy-duty skid, which enabled the operator to move it along the tailings dam.
Weir also designed an external enclose to house the pump and skid, which was portable and provided the insulation needed to keep the pumping system warm during the coldest winter months and cool during the warmest summer months, Ross explained.
Additionally, the pump can handle solids with high and varying flow rates at medium pressure heads. A specially designed suction strainer was provided to eliminate clogging and reduce suction losses. A suction boom was also provided to support and adjust the suction pipe appropriately. Ross said:“ This solution ensured continuous operation throughout the year, even during the harshest winter conditions.”
The Multiflo RF-90HV delivered reliable performance, easy maintenance and the flexibility to relocate the unit as tailings dam conditions changed, according to Weir, being key advantages for a remote, climatechallenged operation.
Ross said:“ Though separated by geography and climate, both mines share a common challenge: water management was a critical operational risk until Weir’ s Multiflo technology and solutions reshaped their approach.
International Mining | MAY 2026