Hindustan Zinc Limited

Hindustan Zinc Limited (HZL), one of the world’s leading producers of zinc and lead, operates extensive underground mining facilities at its Dariba complex. Efficient dewatering systems are critical for maintaining safe mining conditions and ensuring uninterrupted production. Any failure in the pumping system can directly impact operational safety and productivity.

The existing Chinese make pumps were facing frequent breakdowns, poor performance, and lack of service support. Additionally, spare parts were not readily available, resulting in increased downtime and operational inefficiencies. The mine required a high-head pumping solution capable of handling extreme conditions while delivering consistent and reliable performance.

Wilo was approached to develop a technically advanced solution tailored to these demanding requirements. Since such high-head pumps were not available in the standard product range, this project required innovation and custom engineering. The objective was to deliver a reliable, energy-efficient solution that could improve system performance while ensuring long-term durability in harsh mining conditions.

Wilo developed a customized high-head ring section pump capable of operating up to 1100 meters head, achieved through reverse engineering and advanced hydraulic design. This solution ensured efficient removal of groundwater from deep mining levels, maintaining safe and dry working conditions.

The new system significantly improved reliability, reducing failure rates and ensuring continuous operation under extreme pressure conditions. The pumps were engineered for durability, capable of withstanding abrasive and high-pressure environments typical in mining operations.

Additionally, the upgraded system delivered energy savings of approximately 26 kW per pump, reducing operational costs while improving efficiency. The solution also enhanced serviceability, ensuring easy maintenance and availability of spare parts. This project established Wilo’s expertise in delivering high-head customized pumping solutions for critical mining applications.