In what is probably the most exciting development in the dewatering pump industry is the news that IPR (Integrated Pump Rental) has become part of Atlas Copco’s Specialty Rental Division within the Power Technique Business Area. Announced just ahead of Electra Mining Africa, this acquisition is expected to bring significant benefits to the mining sector. 

Lee Vine, Managing Director of IPR, says the mining industry, known for its complex and demanding operations, relies heavily on effective water management solutions to ensure operational efficiency and safety. 

“We have seen a shift where dewatering pumps, essential for managing water ingress and maintaining dry working conditions, are increasingly being rented with appropriate accessories,” he says. “This trend is driven by several factors that reflect the evolving needs and challenges of the mining sector and our recent acquisition by Atlas Copco will allow us to continue to grow both our geographic footprint in Africa while increasing our already comprehensive dewatering pump rental fleet.” 

The company’s recent participation at Electra Mining Africa highlighted some of the pumps within its extensive range. This included Atlas Copco diesel self-priming pumps and submersible units as well as the range of Toyo heavy duty slurry pumps and IPR’s in-house designed SlurrySucker dredging unit.

“It is a fact that renting dewatering pumps offers mining companies a significant degree of flexibility,” Vine explains. “Instead of committing substantial capital to purchase equipment, companies can allocate resources more efficiently by renting dewatering pumps as needed. This approach allows for better financial planning and reduces the burden of maintenance and storage costs associated with owning dewatering equipment.”

Vine says the rental market for dewatering pumps is highly competitive, and IPR has stayed ahead of the curve by continuously updating its rental fleet to include the latest technological advancements. This, he says, means end-users benefit from access to state-of-the-art pumps that offer improved efficiency, reliability and environmental performance. 

“Feedback from our customers underscores the major advantage that renting offers in terms of being able to leverage the newest technology without the need for frequent capital expenditures,” he says. 

Another important advantage when renting dewatering and other pump solutions is that the mining operations can choose pumps that are tailored to the specific requirements of their projects. Whether the need is for high volume water removal, handling abrasive materials or operating in challenging conditions, IPR offers a diverse range of pump types and configurations which ensures that the most suitable equipment is selected for specific application needs.

IPR offers the market the advantage of comprehensive maintenance and support services, ensuring rented pumps and ancillary equipment remain in optimal working condition. “This reduces downtime and the risk of operational disruptions due to equipment failure,” Vine says. “Additionally, our experienced and skills team can provide valuable insights and assistance, further enhancing the efficiency of dewatering operations.” 

“The ability to scale dewatering solutions up or down based on project demands is another significant advantage when renting pumps. This is important for both underground and surface mining operations, which often face fluctuating water management needs, as they can quickly adjust their dewatering capacity by renting additional pumps or returning underutilised equipment,” he continues. This scalability ensures that mining companies can respond rapidly to changing conditions without the delays associated with procuring new equipment.

The IPR rental fleet comprises modern dewatering pumps designed to meet stringent environmental and regulatory standards. By renting newer models, mining companies can ensure compliance with environmental regulations, reducing the risk of penalties and contributing to sustainable mining practices. Advanced features such as energy-efficient motors and reduced emissions are increasingly called for, and the company can accommodate these requirements. 

In the challenging environment of open pit mining, efficient water management is crucial to maintaining operations and ensuring the safety and productivity of the site. IPR (Integrated Pump Rental) stands out as a key partner for surface mines, offering customised dewatering solutions designed to meet the specific needs of each site.

Managing director, Lee Vine says by conducting thorough assessments and providing correctly specified equipment, IPR ensures that mines can rely on effective and dependable dewatering systems.

“IPR’s approach begins with a detailed assessment of each individual application. This involves understanding the unique conditions and requirements of the mine such as water volume, pit dimensions and site-specific challenges,” Vine says By doing so, this leading dewatering pump solutions provider can recommend the most appropriate equipment and strategies for dewatering, ensuring optimal performance and cost efficiency.

The backbone of IPR’s dewatering solutions is its extensive range of high-quality dewatering pumps and accessories. This includes the well-known Atlas Copco range of diesel driven and submersible pumps with the company being the Master Distributor across southern Africa for this dependable brand. The company also represents the Toyo range of heavy-duty slurry pumps.

Vine says both pump brands are engineered to handle the demanding conditions of open pit mining, providing robust and reliable performance.

The solution chosen for a specific dewatering project would be dependent on the on-site requirements. As an example, he says that one option would be pontoon-mounted pumps which . allow the pumps to remain operational even as water levels fluctuate. This eliminates the need to frequently relocate the installation as the water level drops, reducing downtime and labour costs.

On the other hand, for mines that require flexibility and mobility, IPR offers skid or trailer mounted dewatering pump sets. These systems can be easily installed at the side of open pits and moved as needed within the mining operation. This mobility ensures that dewatering can be efficiently managed across different areas of the mine, adapting to changing conditions and requirements.

Understanding the financial considerations of mining operations, IPR provides both rental and outright purchase options for its dewatering solutions. Renting dewatering equipment can be an attractive option for mines looking to manage capital expenditure or requiring temporary solutions.

“IPR’s rental services offer mines the flexibility to access the latest technology and equipment without the long term commitment of ownership. However, for mines with ongoing dewatering needs, purchasing equipment outright may be more cost effective in the long run,” Vine says. IPR offers competitive pricing and comprehensive support for purchased equipment, ensuring mines receive the best value for their investment.

IPR’s commitment to its customers extends beyond providing equipment. The company offers comprehensive support services including installation, maintenance and troubleshooting. This ensures that dewatering systems remain operational and effective, minimising downtime and maximising productivity.

“Our expertise in dewatering solutions, combined with our team’s tailored approach to each mining site, makes IPR an invaluable partner for surface mine dewatering projects. By offering a range of reliable equipment, innovative solutions like pontoon mounted pumps and flexible acquisition options, we help mines manage water effectively, ensuring smooth and efficient operations,” Vine concludes.

Cost effective and agile rental solutions for dewatering will take centre stage at IPR’s (Integrated Pump Rental) exhibition stand at Electra Mining Africa this year, as well as its quality range of slurry and sludge pumping equipment.

“Showcasing our growing range of rental pump dewatering options, we will also be celebrating our partnerships with world leading pump OEMs Atlas Copco and Toyo,” says Lee Vine, Managing Director at IPR. “The past year has seen us grow our formal collaboration with Atlas Copco and the great results are there for all to see.”

Featuring strongly at IPR’s stand will be the range of Atlas Copco diesel self-priming pumps and submersible units, says Vine, which the local market has embraced for its quality and performance. Also on show will be the range of Toyo heavy duty slurry pumps, and IPR’s in-house designed SlurrySucker dredging unit.

“There has never been a better time for mines, industry and other sectors to rent their pumping solutions from IPR,” he explains. “Pump rental allows companies to conserve their capital, and avoid high interest rates when borrowing for equipment purchases. Other key advantages are that customers incur no overhead costs with rental, and can rely on us to keep everything running smoothly.”

Vine emphasises that IPR has continued to grow its fleet in partnership with its OEM partners – whose own experts will be joining IPR’s technical and sales team at the Electra Mining Africa exhibition stand. 

Steve du Toit, Sales Manager at IPR, points out that the event remains an important forum to engage with the market face to face – and to share insights and experience to improve customers’ business efficiency. 

“Having a selection of our exciting products on the stand, combined with our depth of expertise, helps to facilitate valuable discussions and problem-solving with visitors,” says du Toit. “The presence of our OEM partners reinforces the strength of our partnerships – which benefit the customer through quality, performance and rapid support.”

He also highlights IPR’s in-house design and engineering capability, which underpins its customised solutions for specific challenges that mines face. This capacity is well proven through its pioneering SlurrySucker dredging unit; equipped with a Toyo heavy duty submersible pump, IRP recently upgraded its SlurrySucker to a Mk III model.

“We expect high levels of interest in water management challenges among Electra Mining Africa visitors, as we have seen how regulations are becoming more stringent,” he continues. “As retention ponds silt up over time, for example, mines face a growing risk of spillage which can cause environmental damage. There are similar problems facing wastewater treatment plants and other industrial sectors.”

Vine says that visitors to the exhibition will be impressed by IPR’s range of pumping solutions – with diesel units mainly for remote and opencast sites with no power supply and submersible electrically-powered units for underground and plant applications. 

“We welcome visitors bringing their on-site challenges to us,” he says. “With our world class products and OEM partnerships, we have the hardware and experience to know what will work best for them.”

Visit IPR (Integrated Pump Rental) at stand number – YE13 

Developed by local pump and dredging expert IPR, the SlurrySucker dredging system recently provided the ideal solution for getting the emergency water dams at a Gauteng wastewater treatment plant back to optimal condition.

Warren Spann, Business Development Manager at IPR, explains that the emergency dams had filled with sludge over time, and were presenting an operational risk to the plant. Dredging the dams with hydraulic excavators was not effective for a number of reasons, and the manual removal of sludge in trucks caused environmental challenges. The dams are vital sources of additional water for the treatment plant during times when insufficient volumes are flowing into the facility.

“IPR was contracted to conduct the dredging of these emergency water dams, and we put our new generation SlurrySucker Maxi onto the job,” says Spann. “This powerful dredging system is equipped with three Toyo K30 heavy-duty submersible slurry pumps, and was able to remove 50 dry tonnes per hour.”

Importantly, these specialised heavy duty 22kW Toyo pumps are capable of dealing with the wide variety of solids that accompany the wastewater to the plant including rags, nappies and even pillows. The pumps’ capacity allowed them to pump the sludge through 450 metres of pipeline on this contract, without the need for inline boosting.

Mounted on a purpose-designed pontoon, the SlurrySucker Maxi was drawn from across the 250 m long dams using ropes and a winching system. The operation was managed through remote controls in the hands of a trained and experienced technician, ensuring optimum safety.

“There were also two Atlas Copco WEDA D70H jetting pumps on the pontoon, to help stir up the sediment in the dams,” he says. “The first pump jets water down to the dredge head to agitate compacted sludge on the bottom of the dam, while the second pump jets water into sludge that is near – or even protruding from – the surface of the water. The latter is necessary as the pontoon needs 350 to 400 mm of water on which to float.”

To ensure that the discharge from the dredging activity complied with environmental standards, the dredged material was pumped into large dewatering bags. Each bag held 25,000 tonnes of material, and measured 30 m in circumference and was 60 m long.

These bags allowed water to weep out into a catchment pond, and IPR added a flocculant to the pipeline to help the solid materials to settle out. This strategy helped the wastewater plant to conserve water, as the filtrate was pumped back to the plant for re-use. The added flocculant in the filtrate assisted the plant further by contributing to the levels of flocculant that the plant would be adding as part of its normal process.

Lime was used to reduce the odour from the dewatering bags, giving the customer various options related to removing the material later including the provision of activated sludge to the agricultural sector.

“An added advantage of our dredging technique is that all our equipment is electrically powered, so it operates with hardly any noise,” says Spann. “This is in stark contrast to heavy mechanical equipment, and meant that we did not disturb the neighbouring residential estate.”

He adds that IPR’s advanced control panels on the SlurrySucker ensured that the power would trip if any oversize material threatened to damage the pumps. The panels convey an error message to the operators, so they can resolve the issue and return the system to work without risking any further harm to the equipment.

In the current economic climate, where reducing operating costs is paramount, IPR’s advanced pump servicing, repair, rebuild and refurbishment capabilities emerge as a critical solution for businesses seeking to enhance efficiency and reliability without the need for substantial new investments. 

This is according to Henru Strydom, Operations Manager at IPR, who says that the company’s pump rebuild facility plays a pivotal role in the lifecycle management of pumping equipment, offering a cost effective alternative to the outright purchase of new equipment. 

“The significant investment in our facility underscores our commitment to supporting industries like mining, quarrying, water and wastewater management, oil and gas, and manufacturing through the repair and refurbishment of various types of pumps,” Strydom says. 

Refurbishing pumps, Strydom says, offers an opportunity to extend equipment lifespan significantly, and at a far lower cost. “Through expert repair and refurbishment, pumps that might otherwise be decommissioned can continue to operate effectively, delivering value well beyond their expected service life. This not only maximises the return on the original investment but also contributes to operational continuity and reliability.”

The process of rebuilding a pump involves disassembling it, cleaning all components and then inspecting each part for wear and damage. Worn or defective parts are repaired or replaced, where deemed necessary, and significant upgrades can be made to improve the pump’s performance. This meticulous process ensures that the rebuilt pump is not just restored to its original condition but is often enhanced to offer better efficiency and reliability.

“During the rebuild process, pumps can be tailored to meet specific operational requirements or upgraded with the latest technologies to improve performance and efficiency. This level of customisation allows businesses to adapt their pumping equipment to changing needs or advancements in technology without the need for entirely new purchases,” he explains. 

Before a rebuilt pump is deemed ready for return to service, it undergoes rigorous performance testing ensuring adherence to original specifications. The company’s facility boasts a test tank designed to simulate operational conditions, and this allows the evaluation of key performance parameters such as flow rate, pressure, power consumption, efficiency and overall reliability of the pump.

Having built its reputation as a responsive and reliable partner in the field of dewatering, heavy duty slurry pump and dredging, IPR is now well positioned to provide customers with all they need.

Managing Director Lee Vine says that the company’s success is a combination of quality global brands and solid home-grown expertise. This allows IPR not only to represent and market the highest quality of equipment, but also to specify optimal solutions and design customised products that support customers’ efficient operation.

“Our professionalism over the years has led us into partnerships with the world’s leading pump manufacturers,” says Vine. “Among these collaborations is our role as master distributor for Atlas Copco dewatering pumps in southern Africa, as well as our agency across sub-Saharan Africa for the Toyo range of specialised heavy duty submersible slurry pumps.”

These brands, he explains, are today the core of a comprehensive rental fleet that drives IPR’s vision of becoming the leading player in dewatering and heavy duty slurry pumping. The IPR fleet has everything a customer needs – from electrical submersible pumps to diesel-driven pump sets – for a quick and sustainable response. Its success to date has also been underpinned by its design expertise and modern workshop facilities.

“Our understanding of our customers’ challenges, combined with our technical prowess, has allowed us to locally develop and manufacture the innovative SlurrySucker dredging system, for instance,” he says. Designed to safely and efficiently cleaning settlement dams or process ponds, the SlurrySucker can remove up to 60 dry tonnes per hour – without the risk of damaging pond liners with heavy excavating equipment.

IPR Sales Manager Steve du Toit highlights that IPR’s offering of both rental units and capital purchases has a hidden benefit for customers, as they seek to improve their uptime while balancing capital with operating expenditure.

“A rental pump solution – which we provide after a detailed assessment of its planned duty – can often act as a technical trial for a customer,” says Du Toit. “They can demonstrate the pump’s performance during a rental, and purchase their own as and when capital is available. On the other hand, they may prefer contracting out this function, ensuring reliability and uptime.”

The company recently added Olikara’s range of QubePower lighting towers to its offering, which has three different sizes and can be powered by diesel, petrol, solar, battery or mains electricity.

Not only does IPR’s SlurrySucker dredging system effectively clean process water ponds, return water dams or other water storage areas, it has become recognised as an ideal solution for cleaning water capture areas where silt is an issue, or where water retention and water holding capacity is being threatened. Some of these areas are environmentally sensitive and must be protected from causing any pollution.

Taking this innovative locally manufactured product to the next step, IPR recently launched its new generation unit – the SlurrySucker MK III. This powerful dredging system now incorporates the world renowned Toyo heavy duty slurry pump, making it the most efficient and cost effective electrically powered floating dredging system available on the market.

This is according to IPR Managing Director, Lee Vine, who says that the benefits of the SlurrySucker extend well beyond improving mines’ environmental footprints. “Bodies of water such as ponds, lagoons, dams and canals should be considered valuable plant assets and must be maintained to maximise their operational efficiency and contribution to optimised operational performance,” he explains.

“This is where the SlurrySucker has continued to deliver without fail, assisting our customers with some of their pressing issues including the need to increase water storage capacities, the recovery of minerals and improving process water quality,” he continues.

Equipped with Toyo heavy duty slurry pumps, the SlurrySucker MK III boasts enhanced solids handling capabilities. The pumps are fitted with robust cutter fans or agitators, facilitating the management of larger particles. Moreover, they can effectively handle slurries with a high specific gravity (SG).

Commenting on the effectiveness of the SlurrySucker MK III, Vine says the unit can be sized to meet an individual plant’s slurry removal requirements in terms of particle size, aggregation, distribution, cohesiveness, flow characteristics, sedimentation rates and specific gravity.

He is quick, however, to point out that while desilting or cleaning of settlement ponds may seem like a simple task, it is not always as straightforward as it would initially appear. Cleaning these facilities can become an onerous task, as it involves the pumping of high solids materials from the facility being desilted and should an incorrect system or equipment that is not fit for the task be specified this could cause issues including environmental harm.

“Historically many operations have used manual excavation methods for desilting and cleaning, but our established track record has proved that this is not only inefficient, but it often fails to remove the required volume of sediment,” Vine says.

There are several ways to accomplish effective desilting, but it has to be done effectively and cost efficiently, and this is where IPR’s skilled and experienced team comes into play. The best option, according to Vine, is a site visit to assess the application requirements and conditions.

“In some instances, it is possible to pump the high solids material to another nearby dam or reservoir. However, this is sometimes not possible and in this type of scenario we implement an alternate solution such as capturing and storing the content in specialised geotextile bags while the water is separated from the solid material,” he explains.

Once the actual condition of the dam or pond has been assessed the decision can be made as to how to proceed. The SlurrySucker itself needs sufficient volume of water on which it can be floated, and should there be areas where this is not possible, then a hydro-mining solution is applied to these drier areas.

“What is also important is that we can effectively ensure mine and industrial water contaminated sites do not negatively affect surrounding areas and being equipped with remote controlled height adjustment of the primary slurry pump and dredge head assembly allows the SlurrySucker to operate without causing damage to plastic liners in dams and settlement ponds.

Vine highlights two product options – the Maxi SlurrySucker which is capable of moving 250 m³ an hour at 20% to 30% by volume – equivalent of approximately 70 dry tons per hour. The Mini SlurrySucker® operates at 100 m³ an hour, again at 20% to 30% by volume for roughly 30 dry tons every hour.

The SlurrySucker comes standard with a galvanised frame structure and IPR’s flexible design provides the option for stainless steel with polyethylene and UV-stabilised pontoons.

In conclusion, Vine says that the opting for the SlurrySucker option is also far safer as the barge itself can be operated remotely from a defined distance away from the dam or pond edge. This is much safer than having equipment and personnel on the dam.

Having witnessed that customers often need robust and compact on-site lighting, IPR now offers the range of Olikara lighting towers to suit every application.

The specialist pump dewatering company can now provide lighting solutions as part of its package, according to Warren Spann, Business Development Manager at IPR. The Olikara range of QubePower lighting towers includes three different sizes, and can be powered by diesel or petrol engines, solar or battery power, or mains electricity.

“All models share the ability to withstand the rigours of mining, infrastructure and industrial environments,” says Spann. “As a leader in pumping solutions, we can offer the Olikara QubePower range with the same attention to quality, support and maintenance that our customers have become accustomed to.”

At the smaller end of the range is the QubePower Mini – an ultra-compact, petrol driven unit with a 10 foot extendable tower with 400 W LED lights. In the mid-range is the QubePower model, a medium sized lighting tower powered by an air-cooled diesel engine and with its compact footprint this model allows more towers to be carried per truckload.

“For big projects, we offer the QubePower Max, which is a large format tower light powered by a water-cooled diesel engine, ideal for use in extreme and demanding conditions,” he explains. “For customers needing higher specifications, this solution can be enhanced with larger fuel tanks and hydraulically powered towers.”

The range’s QubeSolar model is a tower that runs off green energy, with solar panels and battery storage to ensure long runtimes. The success of the QubePower solutions is demonstrated by their penetration into regions including North America, Asia and Australia. Used in climates where temperatures drop as low as minus 40 degrees C and rise up to 55 degrees C, says Spann, their quality design and manufacture ensure lower maintenance and longer working life.

He highlights that Olikara’s QubePower is the only range in the world that offers a manual tilting option for the lamp. Enhancing the safety of the equipment is the worm-winch, for a lower load when raising the tower; this is a safer alternative to the ratchet winch since the basic gear design is self-locking.

“The modular design ensures that QubePower lighting towers are future-proof, and that all new innovations fit the existing towers,” he says. “This extends the life of the light towers, while allowing customers to benefit from the latest technologies.”