Industrial water security specialist Talbot has successfully commissioned a phase 2 water treatment plant at Pan African Resources’ Evander Gold Mine in Mpumalanga, doubling treatment capacity while maintaining uninterrupted operations in a live mining environment.
Following the completion of phase 1 of the water treatment facility in 2023, phase 2 was initiated to address the mine’s rising water demand and increasing operational risk as a result of municipal water supply disruptions.
Treatment capacity has been expanded from 3 ML/d to 6 ML/d. This Water Treatment Plant represents an advancement in sustainable mining water management, demonstrating how focused engineering, value optimisation and disciplined execution can enhance water security at deep-level gold operations.
Scaling capacity for operational resilience
Water is a production‑critical resource in gold mining operations. At Evander Gold, ongoing and unplanned interruptions to municipal supply had created a vulnerability that threatened production continuity, accelerating the need for infrastructure capable of recovering and treating underground mine water to potable standards.
“The objective of phase 2 was not only to scale capacity, but to do so without disrupting an already critical operational asset,” explains Kieran Govender, project manager at Talbot. “From the outset, our focus was on ensuring that every engineering and execution decision supported long-term operability, reliability and ease of use for the teams who would ultimately run the plant.”
The phase 2 upgrade was delivered under a full EPC model, encompassing detailed design, fabrication, installation, integration and commissioning. A fundamental requirement was seamless tie‑in with the existing phase 1 facility while keeping the plant fully operational throughout construction and commissioning.
Compact design achieving SANS 241 water quality
A compact, bespoke design with an optimised layout was achieved, saving an estimated 65% to 70% of space compared with traditional expansion approaches. The upgraded facility incorporates a multi-stage treatment process designed to recover and treat underground mine water to SANS 241 drinking water quality standards. The system integrates ultrafiltration (UF), reverse osmosis (RO) and chemical dosing to ensure consistent water quality and process stability.
Zero‑disruption execution in a live plant
A critical aspect of the project was executing the upgrade in a live operating environment, where continuous water availability was essential. Any loss of supply would have had immediate implications for underground safety and processing continuity.
“Keeping phase 1 operational while integrating phase 2 was technically complex,” Govender notes. “Water outages simply aren’t an option in gold mining. This plant is designed to support gold production security, ensuring the Evander Gold Mine operations can meet its targets even when external water supply is unavailable.”
Talbot adopted a phased implementation strategy, carefully sequencing mechanical completion, wet commissioning and performance ramp‑up activities. The project achieved first water on schedule, validating both the installation quality and the integration methodology.
I’m incredibly proud of the way our team executed the design, installation, commissioning and handover process on this plant,” says Jutta Dedekind, Implementation Manager at Talbot. “From detailed performance and quality checks, troubleshooting during commissioning, and operator training and transfer of operational skills, this project reflects Talbot’s integrated approach. With one team delivering the new plant and another seamlessly taking over plant operation and management, it ensures long-term performance.”
To further enhance reliability and operational efficiency, the upgrade included the integration of a centralised automation and control system, enabling real‑time monitoring, process optimisation and reduced operator dependency.
Delivering operational and sustainability outcomes
“The Phase 2 upgrade has significantly strengthened our operational resilience and water security,” says Wayne Allen, Group Consulting Engineer surface operations at Pan African Resources. “Delivering increased capacity with zero disruption in a live environment reflects strong execution and partnership. The plant not only supports reliable production but also advances our sustainability objectives through improved water reuse and reduced dependence on external supply.”
The completed phase 2 plant has delivered measurable outcomes for the Evander Gold Mine operation, including:
- Improved water security, significantly reducing reliance on inconsistent municipal supply
- Enhanced production reliability, supporting uninterrupted mining operations
- Doubled treatment capacity, enabling the mine to meet growing operational demand
- Zero unplanned downtime during construction and commissioning
- SANS 241‑compliant potable water, supporting regulatory compliance and safe reuse
- Reduced environmental footprint, through increased recovery and reuse of underground water
Beyond site‑specific outcomes, the project highlights how established mining operations can transform water management challenges and improve resilience in an environment increasingly impacted by water scarcity.
“Water scarcity is becoming a critical issue not only for communities, but for industries that rely on water to operate and sustain employment,” Govender adds. “By helping clients like Evander Gold maintain consistent production, we’re also supporting broader economic stability and protecting the environment.”
Partnerships of this nature are becoming increasingly important, as mining operators take proactive steps to future-proof their operations.
Advancing water security in mining operations
The successful delivery of this Water Treatment Plant reinforces Talbot’s capability to implement high‑impact water infrastructure under complex operational constraints, positioning the company as a trusted partner for mining operations pursuing greater water independence.
For the wider mining industry, the project demonstrates that constrained sites and live operations do not need to limit sustainable water solutions. Instead, they can become drivers of innovation, efficiency and long‑term operational resilience.
Find out more about our Wastewater treatment solution – click here
Visit our LinkedIn Page – click here