Ambatovy – 250 ft Dia Tailings Thickener Retrofit
ClearStream Engineering Delivers Increased Water Recovery and System Efficiency
Industry: Mining & Industrial Water Recovery
Location: Madagascar
Client: Ambatovy
Partners: Pocock Industrial, Inc.
Provided by: ClearStream Engineering
Challenge
Ambatovy is one of the largest industrial undertakings in Madagascar, operating integrated mining and refining facilities for nickel and cobalt production. During processing, tailings ponds are used to store solids generated from refining. To maximize water reuse and minimize wastewater discharge, Ambatovy required a more efficient method to reduce water content in tailings.
However, the gravity dilution system supplied by the original equipment manufacturer (OEM) was underperforming. It failed to achieve the proper dilution percentage for optimal thickener operation. As a result, underflow solids concentration remained below target, and significant volumes of process water were being lost to the tailings pond.
Solution
To address the issue, Pocock Industrial, Inc. partnered with ClearStream Engineering to analyze and resolve the problem. The team conducted comprehensive lab testing to determine the ideal dilution percentage for varying influent conditions.
Using computational fluid dynamics (CFD) modeling, ClearStream designed a new dilution capture and re-injection structure. This custom-engineered solution recirculated clarified water for controlled dilution and featured a removable pump system for easy maintenance.
Structural modeling of the existing bridge was also required to ensure safe load-bearing capacity. ClearStream engineers developed and implemented reinforcement and bracing modifications to accommodate the added weight of the new dilution water structure—ensuring both safety and long-term reliability.
Results
The retrofit achieved the desired solids concentration in the underflow, significantly improving water recovery and reducing wastewater discharge. The optimized system also lowered chemical consumption and operational costs.
Due to the success of the project, Ambatovy commissioned ClearStream to modify five additional thickener units using the same engineered solution.
Outcome Highlight
The massive structure was assembled in two floating sections—earning it the nickname “The Yellow Submarine.”
Resources and Related Links
Madagascar – Retrofit of 250 ft Dia Tailings Thickener
Equipment in this Case Study
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