Pilbara Iron Ore Mine, 2023.
Pilbara, Western Australia
The Challenge: Water Storage Solution for Dust Suppression
The Pilbara iron ore mine faced a critical need for a high-volume water storage solution to support dust suppression activities for their fleet of water trucks. They required a system capable of delivering water at extremely high flow rates to ensure efficient dust control. Traditional methods, including hard-sided tanks and turkey-nest solutions, proved to be costly, time-consuming, and environmentally intrusive.
Objectives: High-Flow Water Storage Tank with Minimal Environmental Impact
The key objective of this project was to design and deliver a water storage solution with the capability to handle flow rates of 400–600 litres per second. The client needed a reliable and efficient system that could quickly fill water trucks and support dust suppression operations while being environmentally friendly and cost-effective.
Solution Provided: Custom Water Bladder Tank System
Get Wet Solutions delivered a 2-million-litre water bladder tank, designed to meet the specific needs of the Pilbara iron ore mine. The solution included the following features:
High-Flow Water Storage System
- 2-million-litre bladder tank with 600mm valves and a manifold system capable of delivering over 400 litres per second to the truck fill standpipe.
- High-flow pump to ensure steady water delivery.
- Remotely operated level monitoring system for efficient management of water levels.
Solar-Powered & Safe Overflow Features
- Solar-powered battery system with an auto shut-off feature to prevent overfilling, ensuring the bladder remains full without risk of spillage.
- Safe overflow loop to protect the system from potential failures.
Integration with Existing Infrastructure
- The bladder tank was connected to the existing bore field, requiring the installation of several kilometers of HDPE pipe, which was welded onsite by Get Wet technicians.
Why Choose a Bladder Tank Solution?
The client chose Get Wet’s bladder system for several key reasons:
- No excavation was required, saving time and avoiding the need for permitting and approval processes.
- Rapid installation – the bladder tank was installed in less than a day, significantly reducing project timelines.
- Cost-effective and environmentally friendly solution with no need for construction work such as concrete pouring or digging.
- UV protection, wildlife-friendly, and fully recyclable, built to withstand harsh Australian conditions, with a 10-year warranty and a 20-year lifespan.
Results and Benefits: Efficient, Scalable, and Sustainable Solution
Key Outcomes
The installation of the custom water bladder system led to significant improvements in the client’s operations:
- Decreased truck fill-up times from 42 minutes to under 3.5 minutes, streamlining operations and improving fleet efficiency.
- Increased water storage capacity from 500,000 litres to 2,000,000 litres, ensuring sufficient water for ongoing dust suppression.
- Rapid installation completed in under one day, reducing downtime and allowing for quicker project completion.
- Environmentally friendly solution with no excavation or construction work, reducing the project’s environmental impact.
Measurable Results
- Reduced truck fill-up times from 42 minutes to 3.7 minutes.
- Increased storage capacity by 300%, from 500,000 litres to 2,000,000 litres.
- Decreased fuel burn for CAT-777 trucks by 4 hours per 12-hour shift, lowering operational costs.
- Increased dust suppression operational hours by improving water on roads (WOR) and extending operational time for water trucks.
- Installed and operational within a few short hours of arrival on site.
Challenges and Solutions: Overcoming Tight Deadlines and Custom Requirements
Despite tight deadlines and specific requirements, Get Wet Solutions delivered a fast, durable, and efficient water storage solution that met the client’s needs. The key challenges included the rapid installation timeline and the need for a system that could handle high water flow rates without disruption.
Challenges Addressed
- Rapid installation: The bladder tank was up and running in a matter of hours, avoiding delays in the client’s ongoing operations.
- Custom design: The system was tailored to meet specific flow rate requirements, ensuring optimal performance for dust suppression needs.
Conclusion: Efficient and Cost-Effective Water Storage Solution
Get Wet Solutions successfully delivered an efficient, environmentally friendly, and cost-effective water storage solution that supported the Pilbara iron ore mine’s dust suppression activities. The custom bladder tank system exceeded expectations by reducing fill-up times, increasing storage capacity, and providing a quick and sustainable solution for the mine.
