A significant zinc mining operation in North Queensland operates the largest tailings re-treatment facility in Australia. Ranked among the top 15 global zinc producers, the site produced 118,108 metric tonnes of zinc in FY2022. However, the site faced challenges in maintaining optimal production efficiency due to frequent pipeline blockages, slurry density inconsistencies, and pump failures.
Enhancing Dewatering Efficiency: How Goodwin Brazil's Submersible Slurry Pumps Cut Costs, Downtime, and Labour
In underground mining operations, managing water and slurry is a constant and critical challenge. Inefficient dewatering systems and clogged spillage sumps can bring production to a halt, increase equipment wear, and drive up operational costs. To address these persistent problems, a major underground mining facility implemented Goodwin Brazil’s NZE range of submersible slurry pumps—specifically the 100mm, 150mm, and 200mm models—with transformative results.
Drawing inspiration from a successful application in Brazil’s steel industry, where a Goodwin 100 ANZE submersible pump dramatically improved mill scale recovery, this mining operation leveraged similar technology to solve its own unique challenges. The result was a major improvement in operational efficiency, safety, and cost savings.
Addressing Slurry Management in Underground Mining
The facility faced recurring issues with sump cleaning. Spillage sumps, which collect dense, abrasive slurry mixtures from ongoing mining activities, were constantly overflowing or clogging due to limitations in traditional pumping systems. This led to:
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Regular and costly downtime
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High labour demand for manual cleaning
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Health and safety hazards due to spillage
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Increased wear on equipment exposed to uncontrolled slurry
Conventional methods relied heavily on manual intervention using suction hoses, mechanical dredgers, and support crews. Each sump cleaning cycle required halting nearby operations, creating inefficiencies that rippled across the site.
Learning from Brazil’s Steel Industry Success
In a similar industrial scenario, a major steel production facility in Minas Gerais, Brazil faced significant challenges with mill scale, a byproduct of the hot rolling process. Water sprayed on hot steel during production results in a mix of water and mill scale, which accumulates in a recovery tank. The facility had relied on a clamshell grab system that was inefficient, caused frequent spillages, and clashed with the continuous nature of steel production.
To address this, Goodwin Brazil installed a 100 ANZE submersible slurry pump, engineered for high-density materials in high-temperature environments. With a 100mm discharge and a 30kW motor, the pump delivered a continuous, automated removal solution. The result was the elimination of spillages, improved safety, and reduced labour requirements—creating a compelling case for adaptation in other sectors.
The Mining Operation: Implementing Goodwin NZE Submersible Pumps
Inspired by the success in Brazil, the underground mining facility adopted a combination of Goodwin NZE 100mm, 150mm, and 200mm submersible slurry pumps to modernize its dewatering and sump cleaning systems.
Following a comprehensive site assessment, Goodwin’s engineering team recommended a tailored deployment plan. Their pumps—designed with high-chrome wear components, dual mechanical seals, and robust motor assemblies—are ideal for operating in slurry-heavy environments with minimal supervision.
Results and Key Benefits
1. Continuous Operation with Reduced Downtime
With the NZE pumps, the mining facility transitioned from intermittent manual sump cleaning to a fully automated, continuous slurry removal system. This shift led to a 35% reduction in operational downtime, allowing uninterrupted production and better resource allocation.
2. Labour and Cost Efficiency
Previously, sump cleaning required teams of up to ten workers per shift, along with support vehicles and equipment. Post-implementation, these efforts were significantly reduced or eliminated entirely. The outcome:
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Lower labour costs
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Fewer equipment rentals and fuel usage
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Personnel reallocated to core mining tasks
The return on investment was apparent within the first few months.
3. Enhanced Safety and Environmental Control
The sealed, submerged operation of the Goodwin pumps eliminated the need for open handling of slurry, drastically reducing spillages and the associated health and environmental risks. Compliance with safety and environmental standards improved noticeably.
4. Flexible Sizing and Deployment
The use of different pump sizes—100mm for compact spaces, 150mm for standard operations, and 200mm for high-volume zones—allowed for optimal adaptation across the site. This ensured each sump was managed according to its specific requirements without overengineering the solution.
5. Durability and Low Maintenance
Unlike previous pumping systems that failed frequently or needed bi-weekly servicing, the NZE pumps operated for extended periods with minimal maintenance. Built to run dry for short durations and handle heavy, abrasive slurry, the pumps brought new levels of durability to the site’s infrastructure.
Operational Feedback and Endorsement
The operations team reported a dramatic improvement in sump management efficiency. According to the site’s maintenance supervisor:
“These pumps have fundamentally changed how we manage slurry underground. The shift from manual to automatic has not only saved money but made the entire environment safer and more productive. We no longer need to pause our operations for cleanup.”
The Broader Impact of Submersible Slurry Pumps
Whether in steel production or underground mining, slurry management remains a persistent industrial challenge. The successful adaptation of Goodwin Brazil’s submersible slurry pumps proves that with the right technology, even the most labour-intensive and hazardous processes can be streamlined.
The key takeaway from this case is that automation and durability are not luxuries—they are necessities in modern industrial operations. By investing in purpose-built equipment like the NZE submersible slurry pumps, operators can future-proof their processes, reduce operational risks, and improve bottom-line performance.
Conclusion
The adoption of Goodwin Brazil’s NZE 100mm, 150mm, and 200mm submersible slurry pumps stands as a model of industrial problem-solving. From cutting downtime and labour costs to enhancing safety and boosting reliability, these pumps have enabled a mining facility to meet its production goals more efficiently than ever before.
As global industries face mounting pressure to operate more sustainably and cost-effectively, Goodwin’s rugged, performance-driven solutions offer a reliable pathway forward—turning operational headaches into streamlined success stories.
