1. Overview Chilean mining company

Strategic

importance

The company’s activities are essential for Chile’s economy and the global copper market. Its production supports national export earnings and the supply of copper for major industrial and clean-energy applications worldwide. The company is also investing in mine extensions and infrastructure to sustain and grow future outputs.

Challenges

Despite its scale, production volatility and operational disruptions have been faced in recent years, including lower output periods and accidents that have impacted performance at major assets points.

2. Problem

2.1 Unpredictable water quality

During mining operations, the company generates acid mine drainage (AMD) that must be treated to meet increasingly strict environmental regulations. The composition of this water, especially pollutants such as sulphates, can vary significantly (e.g. from 2 mg/l to 50 mg/l).

Fig.  The Process Flow Diagram of a HDS Treatment Process.

2.2 Sulphate Control 

Sulphate control has become a greater concern in recent years because it has been added as a regulated parameter in many jurisdictions, with limits varying  from approximately 2,000 mg/L (as sulphate, SO4 2-) in the high end to as low as 10 mg/L in the receiver.

2.3 Inefficient plant operation

Scaling issues lead to :

• Energy costs and staffing increase to maintain stable flow rates 

• Treatment efficiency is significantly reduced

2.4 Environmental and operational consequences

Additional risks deriving from inefficient treatment operations:

• Overfilled tailings ponds

• Increased pressure on tailings dams

• Higher risk of untreated water discharge or, in extreme cases, dam failure

2.5 Regulatory and business risk

Environmental incidents or non-compliance can trigger:

• Environmental penalties

• Delays or denial of permit renewals

• In the worst case, temporary or permanent shutdown of operations

3. Solution

3.1 How do we solve the issue of inefficient water treatment?

Our use-case is AMD monitoring for HDS plants monitoring & aquifer protection. We detect pollutants such as Sulphate and Carbonate and quantify their concentrations by collecting data in near real-time (every 15 minutes).

Our advantages are:

1. Optimization dosing of Protective Lime (CaO).

2. Preventing scaling issues  in pipelines, pumps, valves and membranes, reducing backflows and CapEx.

3. Reducing unplanned downtimes and energy costs.

Additionally, we analyse the data to offer direct insights to the customers. 

3.2 What is the business case and the ROI?

3.2.1 Reagent Efficiency & OPEX Reduction

The shift from manual safe-side over-dosing to sensor-driven automation directly impacts the bottom line.

• Precision CaO Dosing: Real-time monitoring enables the automated injection of Protective Lime (CaO) at exact stoichiometric requirements.

• Financial Impact: Eliminating the 10% waste inherent in manual dosing results in €285,600 in annual chemical savings.

3.2.2 Water Stewardship & Environmental Impact

In high-water-stress regions, water recovery is both a cost-saving measure and a social license requirement.

• Improved Sludge Density: Optimized chemical management enhances the physical properties of process sludge, driving a 2% increase in water recovery.

• Resource Savings: This prevents the loss of 52,200 m³/year, reducing water intensity by 0.29m3 per tonne.

• Strategic Value: While currently saving €43,680 annually at historical prices, the solution acts as a hedge against rising desalination costs and supports the corporate pledge for Net Zero Continental Water by 2045.

3.2.3 Transition & Regulatory Risk Mitigation

Real-time data serves as an insurance policy against volatile regulatory environments and operational accidents.

• Insurance & Fines: Enhanced monitoring and lower risk profiles can reduce insurance premiums by 5% to 10%, potentially saving between €840k and €4.2m.

• Non-Compliance Prevention: The system offers a 60% probability of preventing regulatory non-compliance events, mitigating potential fines that can reach €6.7m or more.

Gross Annual Savings: €329,726-p.a

Price Watergenics €43,680,- p.a. 

Annual ROI 6.5  X