Procon awarded water treatment contract at $2-billion project
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Leading environmental management expert, Procon Environmental Technologies, has been commissioned by international mining giant Vale, to install and commission a water separation system at the company’s US $2-billion Moatize Coal Mining Project in Tete, Mozambique.
Moatize is the largest Vale operation to date, and the mine is expected to yield a nominal annual production capacity of 11-million tons of metallurgical and thermal coal. Brazil-based Vale officially began mining activities at Moatize in May 2011, before commissioning the processing plant in July.
Procon’s scope on the project involves the installation of the ES 100 Ultraspin water separation system, designed to handle more than 110 m3 of water per hour, which is first received from the wash bay in two separate spill basins, which each containing one skimmer.
Procon managing director Andy Miller explains: “Water runs down into the spill basins, and from there the oil is separated from the water. Procon has also installed a TD-4100C oil in water monitor, which is designed to test for hydrocarbon presence in water on an ongoing basis. The monitor can provide up to 600-readings-per-minute, and is built into the PLC Logic that is integrated into the overall control system; thereby, ensuring that effluent levels are minimised on a constant basis.”
Miller points out that the Ultraspin separator works on a simple principle, whereby the oily water is pumped tangentially into the large diameter end of the separator, which initiates a spinning vortex. “This spinning vortex is accelerated as it moves down the tapered separation tube, transporting the heavier water to the outside walls, while the lighter oil moves to the centre,” he continues. “The separated oil is then removed via the separator end face, and the treated water is discharged out the other end of the tube.”
Unlike plate pack style separators, Miller notes that the Ultraspin separator does not rely on weak gravity forces for separation. “The centrifugal force generated inside the vortex of the Ultraspin separator is around 1 000 times the force of gravity. With such force, even emulsified oil droplets can be separated. The hydro cyclone technology is able to remove 95% of 10-15 micron oil droplets from the water, ultimately resulting in an 85% water saving strategy, which eliminates the potential hydrocarbon pollution that can occur downstream without such a system.”
Miller continues, “The Ultraspin system had to fit in perfectly with civil design, and we worked closely with VALE engineers to clarify any anomalies. we were able to swiftly overcome them, thanks to a good working relationship between the two companies.”
This is an exciting project from a Procon point of view, as we have the opportunity to gain an in-depth understanding of one of the largest coal mines in the world. What’s more, it also serves as a platform for the company to showcase its products and capabilities on an international scale.”
Miller does; however, admit that planning and logistics will remain a challenge throughout the contract. “Moatize is situated in a remote location, and it is a difficult site to gain access to. As a result, a large amount of logistical preparation and planning needs to be undertaken to ensure that there are no unnecessary delays.”
Miller adds that Procon will be providing comprehensive onsite training on the Ultraspin system, in addition to theoretical classroom training. “Procon will ensure that a qualified technician is available onsite site for 30 days, in order to ensure that all relevant mine workers are provided with the necessary skills and expertise to operate the system at maximum efficiency.”
More than 9 000 people have been involved in the implementation of the Moatize project, since work first began in 2008. During this time, Moatize Coal Mine has boosted the Mozambican economy, by ensuring that 90% of the mine’s workforce are Mozambicans.
In addition to its commitment to job creation, Vale also strives to create sustainable development nationwide in Mozambique, by working closely with the government and local civil societies. This is evident in the fact that Mozambique is the first location outside Brazil to have established a local Vale Foundation, which aims to contribute to the integrated development of the regions where Vale is present.
Vale has to date invested more than US$90-million in social programmes which include, resettling over 1 300 families; the refurbishment of Tete Provincial Hospital, Moatize Health Centre and the Moatize Intermediate Institute of Geology and Mines; the development of local agriculture and the construction of schools and health centres.
Through the Moatize project, Vale holds the concession for one of the biggest coal reserves in the world. The first shipment of 35 000 tons of thermal coal left Mozambique on September 14, 2011, after being transported for 575 km along the Sena-Beira Railroad. This was the first operation of its kind along the railroad in 28 years.
Moatize Coal Mine forms an essential part of the company’s strategy of becoming a major global player in the coal mining sector. In addition to its project in Mozambique, Vale also has coal operations and a portfolio of exploration projects in Australia and Colombia, as well as minority stakes in two joint ventures in China.
Looking to the future, Miller is confident that Procon will sustain measurable growth, as an increasing number of industries opt for cleaner processing technologies. “Procon’s superior product offering has seen the company grow from strength to strength over the years. As industries and governments become more environmentally conscious, Procon will endeavour to be at the forefront of providing the most sustainable solutions to these environmental challenges throughout Southern Africa and beyond,” he concludes.
Ends
Notes to the Editor
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About Procon Environmental Technologies
Today more than ever before it is the responsibility of companies and their employees to be aware of pollution and its environmental consequences. While the first principle of environmental management is that prevention is better than cure, accidents and spills do happen. It is for this reason that Procon Environmental Technologies was established in 1993. We offer a full scope of Environmental Products & Technologies, specializing in systems that minimize the impact of contamination on the environment and surrounding areas. The company has secured exclusive partnerships with international companies that are world leaders in their field of expertise.
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