Increasing efficiencies with lower operating temperatures

Due to a lack of regularly scheduled maintenance, the cooling towers at a Western American gold mine were failing at a rapid rate. The environment in which the mine was situated contributed significantly to the problem, with high levels of dust and debris in the air. This build-up of particles caused the water treatment system to struggle to keep up, putting the cooling towers under increased strain as they worked overtime to maintain safe temperatures.

If the cooling towers shut down completely, a crucial part of the mining process would have to come to a halt, potentially costing the mine a minimum of $1 million per day in profit losses. Fully aware of the risks, the mining company sought an immediate and effective solution to keep operations running.

As towers struggled to regulate temperatures, blowdown and makeup water rates had to be significantly increased compounding the water conservation challenge in an area where water resources were already limited.

Recognizing the urgency of the situation, the mining company discovered that their supply chain couldn’t procure the necessary parts for repairs without significant delays. Scheduling a contractor for repairs would have further prolonged the process. With time constraints in mind, Aggreko devised an innovative solution: providing five of our 1,000-ton cooling towers to replace the failing system.

Transporting the towers to the remote mining site posed logistical challenges, especially given the extreme weather conditions in the region. However, Aggreko’s engineers rose to the occasion, ensuring seamless installation without disrupting the mining process. This enabled the mine to continue operating 24/7 without interruption.

The temporary cooling towers installed by Aggreko effectively reduced temperatures in the mine by approximately 30 degrees Fahrenheit, allowing for safer and more efficient operations. This immediate temperature drop not only enhanced productivity but also significantly reduced the strain on the mine’s water resources.

Aggreko’s solution directly contributed to water conservation efforts by optimizing cooling efficiency. With lower operating temperatures, the cooling water running through the system experienced significantly less evaporation. This reduced water loss and improved overall system efficiency, an essential factor in regions where water conservation is a priority. Overall, water use at the mine was reduced by 18-23%, further enhancing sustainability and operational efficiency.

Additionally, Aggreko’s expert engineers took the opportunity to educate and mentor younger on-site engineers, equipping them with the knowledge needed to maintain cooling systems effectively and prevent future issues.

Through this partnership, Aggreko not only ensured the mine's continuous operation but also helped establish long-term sustainability practices that balanced efficiency with responsible resource management.