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Mogale Tailings Retreatment

  • Date of Steelwork Completion
    2024-06-30
Project Type
  • Mining/Industrial
Project Team Zoom Interview Case Study
Project Summary Case Study
Steel Profiles Used
  • Date of Steelwork Completion
    2024-06-30
  • Tonnage
    1300
  • Hot Rolled Structural Sections
    IPE Sections, Equal Angles, Unequal Angles, Flat Bars
  • Plates
    High Strength and Special Structural Plates
Project Overview

Project Scope:
• Detail, Fabricate, Construct and Erect 10 Welded CIL Tanks
• Clients original tender called for tanks to be fabricated and welded on site.
• Betterect proposed an alternative solution of bolted rubber lined tanks. Betterect designed, detailed and completed a finite analysis on the design of the tanks.
• This proposal meant that most of the risk could be controlled in Betterect's factory eliminating the need for large welding teams on site.
• By suggesting a different design approach for the CIL tanks, we were able to achieve significant cost savings of 20% for our client. This accomplishment underscores our dedication to value engineering and continuous improvement, as we
leverage our expertise to identify opportunities for optimization without compromising quality or functionality.

Project Overview
• Detail, Fabricate, Construct and Erect 10 CIL Tanks
• Betterect was the main contractor and were responsible for all detailing, fabrication and site installation of structural
steel.

Project Details
The fabrication process includes precise welding techniques to create seamless joints, preventing leakage and ensuring structural integrity. Additionally, special attention is paid to the lining of the tanks with abrasion-resistant materials to withstand the abrasive nature of the slurry. Quality control measures are rigorously implemented throughout fabrication to meet industry standards and guarantee optimal performance in the gold leaching process. The erection of carbon-in-leach (CIL) tanks is a meticulously orchestrated process that demands precision and expertise. It begins with thorough site preparation, ensuring a stable foundation for the tanks. Skilled technicians then assemble the tank components according to detailed engineering drawings, employing specialized equipment such as cranes and lifting gear to manoeuvre heavy sections into place safely. Close attention is paid to alignment and levelling to guarantee the tanks' integrity and functionality. Close attention is paid to alignment and levelling to guarantee the tanks' integrity and functionality. Once erected, rigorous testing procedures are conducted to validate structural integrity and ensure leak-proof performance. Throughout the erection process, strict adherence to safety protocols and quality standards is paramount to safeguard both personnel and equipment, ultimately facilitating the seamless integration of CIL tanks into gold processing operations.
The modular, bolted design of the steel tanks allowed for seamless on-site installation. Fabricated in a controlled workshop environment, the tank sections were precisely aligned and assembled with minimal crew, eliminating the need for extensive welding. This approach significantly reduced the project's exposure to weather delays and safety risks typically associated with traditional welded tank construction. The client's specific requests were easily accommodated, showcasing the flexibility of the steel design. With exceptional attention to quality, the installation process achieved remarkable levels of accuracy, setting a new benchmark for large-scale mining infrastructure projects.
The project faced significant weather challenges, with prolonged periods of heavy rain and high winds. However, the modular, bolted steel design proved resilient, enabling uninterrupted fabrication in the controlled workshop environment. Compared to welded tanks, the reduced on-site hook time and smaller crew size of the bolted solution minimised the impact of inclement weather during installation. Betterect's innovative approach to rigging and lifting methodologies further mitigated the risks posed by high winds, ensuring a seamless and safe erection process. The inherent flexibility and durability of steel allowed the team to quickly adapt to late design changes, maintaining the project's momentum despite the challenging conditions.
Benefits of Steel in this Application

• Strength and Durability:
Steel is known for its high strength-to-weight ratio, making it a durable and robust material for constructing tanks. CIL tanks are subjected to harsh conditions, including chemical reactions and abrasion, and steel can withstand these conditions effectively.

• Corrosion Resistance:
Steel can be coated or alloyed to enhance its resistance to corrosion, which is crucial in CIL tanks where corrosive chemicals are present. Proper surface treatments and coatings can significantly prolong the lifespan of steel tanks in such environments.

• Customization and Flexibility:
Steel fabrication allows for flexibility in design and construction, enabling engineers to tailor tanks to specific project requirements. This flexibility includes variations in size, shape, and features like baffles or agitators, optimizing tank performance.

• Ease of Maintenance:
Steel tanks are relatively easy to maintain compared to other materials. Routine inspections and maintenance activities such as cleaning, repairs, and coatings can be performed efficiently, minimizing downtime and
operational disruptions.

• Cost-Effectiveness:
Despite the initial investment, steel construction can be cost-effective in the long run due to its durability and low maintenance requirements. Additionally, steel fabrication processes have become increasingly efficient, reducing production costs.

• Recyclability:
Steel is highly recyclable, making it an environmentally friendly choice for construction. At the end of a tank's lifespan, steel components can be recycled and used in new applications, reducing waste and conserving resources.

Overall, the use of steel in CIL tanks provides a reliable and efficient solution for processing facilities in the mining industry, offering longevity, customization, and cost-effectiveness.

Carbon-in leach (CIL) is a simultaneous leach and absorption process. The simultaneous leach and absorption phases of the CIL process were developed for processing gold ores that contain pre-robbing materials such as natural absorptive carbon. These reduce the gold yield by attracting gold meant for the activated carbon. Simultaneous leaching and absorption help minimise the problem. The MTR plant will produce about 50 000 oz of gold a year over an expected 20-year period.

Testimonials

Betterect is immensely proud of the innovative, cost-effective steel solution they delivered for the Mahali Tailings Retreatment Project. The successful partnership with the client, coupled with the project's on-time completion and significant savings, has solidified Betterect's reputation as a leader in steel fabrication for large-scale mining applications.

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