Operating in the arid Pilbara region of Australia, a major iron ore mine faced the dual challenge of reducing its environmental footprint while maintaining high production levels. Traditional horizontal belt filter systems relied on vacuum pumps and air deck support structures—both energy- and water-intensive technologies. With mounting pressure to reduce carbon emissions, lower freshwater use, and minimise maintenance downtime, the mine sought more sustainable and cost-efficient alternatives.

In 2012, the mine implemented FLSmidth’s advanced dewatering technologies. Vacuum pumps were replaced with blowers, significantly lowering energy demand. At the same time, the belt filters were upgraded from water-lubricated air deck systems to roller deck systems, further reducing power needs and maintenance requirements. Blowers also eliminated the need for sealing water, while roller decks required no water lubrication—conserving vast amounts of freshwater. 

Over a decade of continuous operation, these solutions have delivered measurable impact: 

• 29% reduction in energy consumption and CO₂ emissions—saving over 1.6 million kWh and 672 tonnes of CO₂ annually.

• 383,160 m³ of water saved per year—equivalent to 153 Olympic-sized swimming pools.

• Lower maintenance and increased uptime, enabling more reliable production and reduced operational costs. 

Over the ten years since making the change, the mine has therefore not only improved its environmental sustainability; it has also cut operating costs associated with energy, water, and maintenance, while benefitting from higher uptime to increase production.