Project Snapshot
Engineering Safe Chemical Containment Solutions for Gold Processing Operations
Project Overview
Robust Consulting Engineers was appointed by Evander Gold Mine to provide Civil and Structural Engineering services for the design of a new flocculant mixing facility as part of the mine’s mineral processing operations. The project involved the structural design of an elevated flocculation tank support system together with a reinforced concrete containment bund designed to safely contain chemical spills and protect the surrounding environment.
The development formed part of the mine’s process optimisation programme, where an existing emergency water storage tank was repurposed into a flocculant mixing tank to improve operational efficiency while maximising the use of existing infrastructure.
The Challenge
The client sought to repurpose an existing steel storage tank that had previously served as an emergency water reservoir into a dedicated flocculant mixing tank used during mineral processing. While this approach offered significant cost savings compared to installing a completely new system, it introduced several engineering challenges.
The existing tank had not originally been designed to support a mixing system, elevated maintenance platforms or the additional dynamic loads generated by the mechanical agitator. Furthermore, the installation required secondary containment infrastructure capable of safely containing chemical spills in accordance with environmental and mining industry requirements.
The engineering solution therefore needed to safely integrate new structural elements with the existing tank while ensuring operational safety, ease of maintenance and long-term durability within a highly corrosive mining environment.
Our Engineering Solution
Robust Engineers developed a fully integrated Civil and Structural Engineering solution that transformed the existing storage tank into a purpose-built flocculant mixing facility.
The project included the design of reinforced concrete foundations and plinths to support the agitator structure, together with a structural steel support system carrying the mixing equipment and elevated maintenance platform. Safe access to the equipment was provided through the design of permanent staircases, access platforms and handrail systems that complied with industrial safety requirements.
To protect the surrounding environment, Robust Engineers also designed a reinforced concrete chemical containment bund surrounding the installation. The bund was engineered to safely contain accidental spillages while protecting nearby infrastructure and preventing contaminated runoff from entering the environment.
Throughout construction, Robust Engineers provided engineering support and quality control services to ensure that all structural works were completed in accordance with the approved engineering designs and the mine’s operational requirements.
Value Delivered
TBy repurposing an existing storage tank rather than replacing it, Robust Engineers helped the client achieve a cost-effective engineering solution while significantly reducing construction time and capital expenditure.
The integrated design improved operational safety by providing permanent access platforms, compliant fall protection systems and a structurally sound support system for the agitator equipment. At the same time, the reinforced concrete containment bund strengthened environmental protection by ensuring that any accidental chemical releases could be safely contained and managed.
The project demonstrates our ability to combine structural engineering, industrial process requirements and environmental protection into practical engineering solutions that maximise the value of existing mining infrastructure.
Project Outcome
The completed facility provides Evander Gold Mine with a safe, reliable and environmentally responsible flocculant mixing system that supports efficient mineral processing while making effective use of existing assets. Through innovative engineering and practical design, Robust Engineers successfully extended the functionality of existing infrastructure while improving operational performance, safety and environmental compliance.
This project highlights our expertise in industrial structural engineering, mining infrastructure and the adaptive reuse of existing facilities to deliver sustainable, cost-effective engineering solutions.