ArcelorMittal cuts water use on haul roads by 75% with biological dust control

Written by Janet Reznicek on 13. March 2025. Posted in Case study. No Comments on ArcelorMittal cuts water use on haul roads by 75% with biological dust control

Content

Problem: Dust control with traditional methods

A biological dust control approach

Dust control trial implementation

Results: 75% less water usage

A new standard for sustainable mining

Client:
ArcelorMittal Iron Ore Mine

Location:
Liberia

Challenge:
Water scarcity & dust control to protect nearby communities

Use-Case:
Dust Control on haul roads

The cost, labour, and environmental impact of this approach added up, and with the operation situated near a local community, the need to control dust without wasting water was a key priority.

After reviewing all their options, the mine trialled a biological dust control method. The results were striking: water usage fell by 75%, dust fallout was significantly reduced, and truck cycle time improved.

Problem: Dust control with traditional methods

ArcelorMittal’s Liberian site is a high-production iron ore operation with dump trucks and light vehicles cycling through every minute on 12m-wide haul roads.

Controlling dust is essential to protect nearby communities and maintain safe driving conditions. However, the traditional approach relied entirely on water, applied several times a day with a fleet of water trucks.

The daily water requirements for dust suppression were high – sometimes reaching up to 300,000 litres per day – and it still wasn’t enough to keep dust levels under control.

“Like so many mining operations that use only water to control dust, they were stuck in a cycle where they had to keep applying water, but that water would destabilise the road, forcing them to rework the surface more often,” explains Alexander McHaffie, General Manager at Bind-X.

In addition to the strain on water resources, the repeated watering cycles caused road deterioration, increasing maintenance costs and reducing vehicle cycle times.

“The type of iron ore dust there is extremely fine and when it plumes you can’t see five metres in front of you,” says McHaffie. “Dust fallout significantly reduced visibility during material hauling, occasionally causing delays and lowering cycle times.”

A biological dust control approach

Seeking a more sustainable and efficient way, the Operations Manager tested a biological dust control method developed by Bind-X. The product called Terrabind, uses biological technology to bind the upper wearing course layer with bio-cementation, forming a stable surface that reduces dust and makes the road more durable.

Unlike bitumen-based solutions, which are costly and pose environmental risks, biological dust control is a process that already occurs in nature, and is safe for waterways and ecosystems. The solid, cement-like layer that it forms reduces the need for water as dust particles in the soil are bound tight.

The mining services team were intrigued by the concept of using clean technology to control dust so they decided to trial it.

Dust control trial implementation

The team conducted a three-month trial on two sections of road: a primary haul road with heavy traffic and a secondary road with less frequent use. They applied the product in two ways: as an additive to the road surface during construction and as a surface treatment for existing roads.

Could a biological dust control approach deliver the same results as traditional methods?

“Once the trial began, the roads started holding up better almost immediately,” said McHaffie. “The product formed a hard, stable layer that didn’t require constant watering or reapplication.”

Results: 75% less water usage

The trial delivered dramatic improvements. Water usage dropped by 75%, a drop in daily consumption from 300,000 litres to just 75,000 litres. The dust-free roads improved air quality for workers and nearby communities.

In addition to water savings, the operation experienced other cascading benefits. The roads required far less maintenance, freeing up equipment and labour for other tasks. Truck cycle times improved as drivers encountered less dust plumes blocking vision, and smoother, more stable surfaces.

Mining service manager
ArcelorMittal iron ore mine, Liberia

“Reducing water trips from three or four times a day to just once every few days made a huge difference. We’re seeing better road durability, less equipment wear, and fewer operational interruptions.”

A new standard for sustainable mining

After the trial report was signed off, ArcelorMittal decided to fully adopt the biological dust control solution across its Liberian site. The move has not only helped conserve water but also improved the mine’s overall environmental footprint and they are now preparing to roll it out at other locations.

“This approach aligns perfectly with our sustainability goals,” said the Mining Services Manager. “It’s allowed us to cut water use dramatically while improving operational efficiency and reducing our impact on the community.”

The transition has also simplified logistics. Unlike traditional chemical suppressants, the biological product is easy to store, transport, and apply, further reducing costs and environmental risks.

“Our experience shows that you don’t have to choose between sustainability and performance,” said McHaffie. “With the right approach, you can achieve both.”

By embracing biological dust control, ArcelorMittal has set a new benchmark for responsible mining practices, demonstrating how modern technology can drive operational excellence while protecting vital resources.

Topic

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Dangote Cement reduces water consumption by 70% with biological dust control

Written by Janet Reznicek on 5. March 2025. Posted in Case study. No Comments on Dangote Cement reduces water consumption by 70% with biological dust control

article

Client:
Dangote Cement

Location:
Senegal

Challenge:
Excessive dust and water usage

Use-Case:
Dust control and road maintenance

Content

The problem: High water usage and constant maintenance

Trialling biological dust control

The result with biological dust control

Long-term impact

One of Africa’s leading cement manufacturers, Dangote has not only reduced their water use for dust suppression by 70% but also dramatically decreased road maintenance costs — just by using a biological dust control approach.

The problem: High water usage and constant maintenance

Only one year earlier, Dangote was experiencing several operational challenges:

Excessive dust reduced visibility across the site, creating safety concerns
Water trucks were constantly running at maximum capacity
Significant resources were dedicated to road maintenance and grading
Vehicles and equipment required frequent cleaning and maintenance
Environmental impact was a growing concern

“That place was extremely dusty. Even outside the plant, there was a dust cloud hanging everywhere. Visibility was poor,” recalls JC Le Roux, Head of Business Development Africa, Bind-X, who visited the site.

While the plant management had previously explored bitumen-based dust control options, they found these solutions too expensive. This left them continuing to rely on water alone, despite its clear limitations and resource intensity.

Trialling biological dust control

The mine’s Operational Sustainability Manager at Dangote was looking for a better way to cut water usage and manage dust, while also keeping cost in mind.

When he heard about a new and proven biological dust control product, and looked at the cost analysis, he was keen to run a trial on site.

They began a trial of Terrabind Max on a stretch of road at the facility a few kilometers long. As a spray-on application, it was ideal for their well-established roads and didn’t need to be built in with a grader.

The implementation process was straightforward:

The team received on-site technical assistance and training on product mixing and application
An initial higher dose was applied to establish the road treatment over 2-3 days
After the initial application, the team transitioned to a lower maintenance dose applied once daily

The result with biological dust control

The trial demonstrated immediate and substantial benefits — a 70% reduction in water usage for dust control — leading Dangote to continue using the method, and now expanding it across their operations.

The most significant outcomes included:

Dramatically improved visibility and safety across the site
Reduced frequency of road grading and maintenance
Lower fuel consumption for both water trucks and graders
Decreased wear on vehicles and equipment
Recognition from environmental authorities

“Suddenly, buses, trucks, and other vehicles could drive over the road without kicking up dust. That was a game-changer for the operation,” JC noted.

Perhaps most unexpectedly, the Ministry of Environmental Affairs witnessed the results during a site visit. “When they drove on that road, they were surprised at the lack of dust. They stopped and asked what was being used. They were impressed when they learned it was a biological dust suppression method, which is 100% environmentally safe, and they praised the initiative.”

Long-term impact

Based on the success of the initial results, Dangote now:

Continues to use biological dust control at their current site
Expanded the approach to additional roads within their operation
Implemented the same solution at another facility

“The two biggest benefits for Dangote were water savings and reduced road maintenance,” JC explained. “The team should be commended for their competence and excellent teamwork in executing the project.”

The combined benefits of water conservation, improved safety, reduced maintenance, and environmental recognition have made biological dust control an essential part of Dangote’s operational strategy going forward.

By implementing Bind-X’s biological dust control method, Dangote has addressed critical dust control challenges while significantly reducing their environmental footprint and operational costs.

Topic

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Jubilee Metals: Clearing the air with responsible mining

Written by Janet Reznicek on 10. February 2025. Posted in Case study. No Comments on Jubilee Metals: Clearing the air with responsible mining

Client:
Jubilee Metals

Location:
Zambia

Challange:
Excessive dust and potential disruption of local environment

Use-Case:
Access road stabilisation and dust control

Content

The problem

Considering their options

Biological dust control

Going above and beyond

Responsible mining

They took proactive steps to not only treat the road in a clean, non-toxic way but to also restore the school’s soccer pitch. An approach that went far beyond compliance to create lasting benefits for the community.

Here’s how their initiative came together and what we can learn from their commitment to responsible mining.

The problem

“Jubilee Metals were looking for a brand new way of controlling dust on the mine that would be cleaner for the environment,” says JC Le Roux, Head of Business Development – Africa at Bind-X. “The company likes sustainable approaches and they are genuinely committed to responsible mining practices.”

Their environmental stewardship and investment in community well-being has guided their approach to every project, including their latest initiative during the exploration stage of the greenfield Munkoyo Project in Zambia.

The project team knew they had to take particular care of this section of road to keep the dust down long term and stabilise the road year-round.

They also noticed that the school’s soccer pitch, a central space for the students’ recreation, was overgrown with weeds and thorns and nearly unusable.

Considering their options

Jubilee Metals had tried various dust control options before on their other mine sites but sought a better approach that aligned with their sustainable vision, while also keeping operational costs down.

“There’s some light vehicle traffic currently, but there’s going to be a steady stream of vehicles travelling past once the site is operational which could generate a lot of dust, so it wouldn’t be good near the local school,” says JC.

Plain water was not a good option as it would have yielded poor results. Dust suppression from water would only last temporarily, and need constant reapplication. Further, they knew that plain water sprayed on the road would reduce road stability and worsen the problem over time.

They had considered traditional dust control products like bitumen emulsion and polymers. While they would have kept dust down, neither were particularly clean for the environment, with the potential for run-off to local waterways.

Their next step was to consider new technologies that would be safe for people, plants and surrounding streams. They had already used Terrabind biological dust control by Bind-X at their operating mines and had seen great results, so realised it could be ideal for this new project.

Biological dust control

Jubilee Metals chose to use a 100% natural biological binder called Terrabind. It works using a natural biocementation process in the soil. Naturally occurring bacteria devour the nutrients in soil and convert it to a mineral.

“That mineral becomes a glue that binds soil particles together. You end up with solidified soil, which you’ll see in natural structures like termite mounds and coral,” explains JC.

The project team decided to apply this clean binding agent to the feed roads in front of the school to lock the soil particles together and prevent fugitive dust. By treating the 1 km stretch of road in front of the school with Terrabind, the company significantly reduced dust levels, ensuring cleaner air for the children and the surrounding community.

The application process was easily integrated into their existing operations, using regular water trucks for weekly reapplications. As traffic increases with the project’s progression, the frequency of application will be adjusted to maintain air quality, potentially as often as once daily.

Going above and beyond

Beyond dust reduction, Jubilee Metals extended their efforts to improve the school’s soccer field. The team graded the field, removed weeds and thorns, and treated it with a lighter application of Terrabind to create a safe, even surface for play. Care was taken to ensure the field remained soft enough for sports activities.

When we heard about the school, “We thought, how about we do something as well?” says JC.

“Before there was more or less a soccer field, but I mean, it wasn’t great. So we decided to grade it to make it more of a formal soccer field, to formalise it a bit.”

“Now it’s neat and you can see where the soccer field actually is, where the lines should be. We just wanted the kids to have a neat field that they can run on and play soccer and other sports. We also gave them some sports equipment to play with,” says JC.

The impact?

Health and environment benefits

The use of biological dust control has significantly improved air quality by reducing dust along the road, creating a cleaner and safer environment for the school and its surrounding community.

Community well-being

The upgraded soccer field and provision of sports equipment have revitalized a key recreational space, promoting physical activity and community engagement.

Operational efficiency

Unlike plain water, Terrabind improves road stability, reducing long-term wear and ensures sustainable dust control.

Responsible mining

Jubilee Metal’s approach reflects their dedication to building strong relationships with local communities. When the company learned of the school’s challenges, they didn’t hesitate to act.

“It’s been really nice to hear the stories and it’s quite heartwarming. It was really great to see a small gesture like a soccer ball and what it does to that child and the smile on their face,” explains JC.

For Jubilee Metals, responsible mining is about operational excellence combined with leaving a positive, lasting legacy. By prioritising the health and well-being of the communities they operate in, the company has demonstrated how clean technologies can have a positive impact on the environment, and the surrounding community.

Topic

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Enquire now

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African iron ore mine achieves 30% less water truck trips on haul roads

Written by Janet Reznicek on 30. January 2025. Posted in Case study. No Comments on African iron ore mine achieves 30% less water truck trips on haul roads

Content

Researching alternative dust control methods

Soil testing and compatibility

30% less water truck trips

Client:
An Iron ore mine

Location:
South Africa

Challenge:
Water scarcity

Use-Case:
Haul road stabilisation and dust control

Each day, this inefficient method strained the mine’s water resources, increased equipment wear, and put pressure on production costs.
The regulatory environment intensified the need to look for alternative options as the site faced warnings from South Africa’s Department of Mineral Resources and Energy (DMRE) due to excessive dust levels.

They knew that if they continued exceeding dust fallout limits, the DMRE could halt operations entirely. Faced with these challenges, the Mining Manager began to look into a more sustainable, cost-effective alternative that could control dust and reduce water use.

Researching alternative dust control methods

The mine operates in an arid region and access to water is limited. Anything that could reduce the amount of water on the roads was something the Iron Ore mine seriously considered.

“It’s a very water-scarce area. They’ve got a set amount of potable water that they can utilise across the whole mine. So anything that can reduce the amount that’s being sprayed onto the roads is worth considering because that’s put to better use in the process plant,” says Alexander McHaffie, General Manager, Bind-X.

Initially, the mine considered continuing with their existing options: lignosulfonates and bitumen blends. While these methods offered decent performance, they brought several limitations. Bitumen emulsions stained the water trucks, added wear and tear to equipment, and became cumbersome to apply.

Costs also posed a challenge: bitumen, being a crude-oil-based product, is deeply connected to the oil price which continued to rise, adding budget strain to an already cost-sensitive operation.

Although lignosulfonates helped stabilise roads, they required frequent reapplication and high volumes of water, both of which clashed with the mine’s commitment to conserving water in their community.

The Mining Manager explored newer technologies and found a biological dust control method by Bind-X which addressed each of these challenges. With Terrabind, the mine site could reduce daily dust suppression applications by 30%, conserving water and lowering labor costs.

The product’s application also proved simpler, required less frequent attention, and left no staining or residue on vehicles. And from an environmental perspective, it was clean for plants, animals, and waterways.

Soil testing and compatibility

First, Bind-X conducted soil sample tests to confirm compatibility with the mine’s iron ore haul roads. With positive results, they chose to move forward, providing training on the product’s application methods. As Alex explains, “They initially queried whether less water and fewer applications would mean reduced effectiveness, but they were thrilled when we achieved the opposite: better dust results with less water.”

A biological approach also aligned with the mine’s strict budget and commitment to environmental safety. Instead of multiple daily sprays with high water volumes, the team could now apply a concentrated solution at less frequent intervals. This adjustment helped the operation reduce water and labour costs, optimise haul road durability, and prevent vehicle staining and equipment wear.

30% less water truck trips

With the new dust control method in place, the mine experienced substantial and immediate improvements. By reducing dust suppression applications by 30%, they cut water usage significantly, which allowed the operation to redirect water to essential mining processes. As a result, the haul roads required less maintenance, improving cycle times and production targets.

Moreover, they began to consistently meet the DMRE’s strict dust fallout regulations, ensuring the mine operated without regulatory interruptions. “Since switching to Bind-X, we haven’t faced any DMRE warnings in over 20 months,” reported the Mining Manager.

He also noted that vehicle maintenance had declined as the new dust control solution left no residue.

Mining manager
A South African iron ore mine

“It allowed us to achieve outcomes that meet or even surpass those from previous products. The application aligns perfectly with our environmental safety goals and also safeguards our equipment. We’re seeing superior dust control at lower costs, with the added benefit of reducing our carbon footprint. Each regulatory visit confirms our full compliance, and we’ve set a new benchmark for dust control on site.”

By implementing a biological dust control method, the mine addressed critical water and dust control challenges head-on, and made their operation more environmentally responsible at the same time. The mine’s success exemplifies how strategic, sustainable choices can drive operational excellence, allowing the mine to set a new standard in water efficiency, regulatory compliance, and long-term productivity.

Topic

Find out about biological dust control for your site

Enquire now

Transforming dust management at Rosh Pinah Zinc Mine’s TSF

Written by Janet Reznicek on 29. January 2025. Posted in Case study. No Comments on Transforming dust management at Rosh Pinah Zinc Mine’s TSF

article

Client:
Rosh Pinah Zinc mine

Location:
Namibia

Challenge:
Excessive dust and potential disruption of local environment

Use-Case:
Erosion control on tailings storage facilities

Content

The Problem: Dust and Durability

The Solution: A Biological Approach

Environmental and Operational Benefits

A Sustainable Future

Managing the environmental and community risk of dust emissions is a big priority for the mine owners, that’s why they explored innovative methods to reduce dust and be more sustainable.

Today, the mine demonstrates how new dust control technology can improve operations, reduce costs, and pave the way for long-term rehabilitation.

The problem: dust and durability

At Rosh Pinah, the TSF has two main sections—one active and one dormant. Over time, the dormant sections became a significant source of dust, particularly during the windy season. Prior to 2021, the mine controlled dust by spraying polymers mixed with water on the TSF surface, particularly on the flat “beach” areas and the sidewalls.

Polymers initially seemed effective—they reduced dust fallout to acceptable limits—their application came with challenges. “Using polymers required specialised equipment and frequent maintenance,” explains Alex McHaffie, General Manager at Bind-X. “It was hard on the pumps and water carts, often clogging seals and damaging centrifugal pumps. They would see two or three pumps wear out in a single application cycle.”

Additionally, the plastic film created by the polymer spray was a long-term environmental liability, particularly for future rehabilitation. Polymers prevent vegetation growth and complicate efforts to return the land to its natural state when rehabilitation takes place.

The solution: a biological approach

In 2021, Rosh Pinah began trialing Bind-X’s biological dust control approach, Terrabind, as part of its broader push for sustainable mining practices. Unlike polymers, biological dust control is non-toxic, inert, and water-soluble. The trial, conducted on a two-hectare section of the TSF, focused on erosion resistance and binding performance over a two-month period.

“The results spoke for themselves,” says McHaffie. “The biological product formed a solid crust 20-30 millimeters thick—thicker and more durable than the polymers they’d used before.”

And the best part? It was far easier to apply.

Unlike polymers, which require specialised pumps and extensive flushing to prevent sticky residues, biological dust control can be mixed easily with water and applied using standard equipment. “It’s an entirely new category of dust control and it’s a game-changer in terms of simplicity and cost-effectiveness,” adds McHaffie.

Environmental and operational benefits

Beyond performance, a biological approach offers clear environmental advantages. Unlike polymers, which form a plastic-like layer that hinders plant growth, the biological cap binds the soil together with a solid rock-like consistency, while remaining water-soluble. This allows the area to be rehabilitated without additional cleanup or disruption.

“One of the biggest advantages is how well the biological product integrates into rehabilitation efforts,” McHaffie explains. “It provides a solid buffer for dust control while buying time to manage rehabilitation costs and timelines.”

In the two years since adopting Terrabind, Rosh Pinah has reported 30-40% cost savings compared to polymers. These savings are due not only to the lower product cost but also to reduced equipment wear, faster application, and easier handling.

A sustainable future

With the new dust control approach, Rosh Pinah has successfully reduced dust levels, met environmental regulations, and enhanced sustainability efforts. Dust control applications now last 6-12 months per cycle, providing consistent performance without the drawbacks of polymers.

Alexander McHaffie
General Manager Bind-X South Africa

This wouldn’t have been possible a few years ago with older dust control technologies. They’re not just controlling dust, they’re actively setting the stage for rehabilitation and long-term environmental stewardship.

As mining operations face increased pressure to adopt sustainable practices, the Rosh Pinah Zinc mine offers a compelling example of how new and proven technologies now available can balance environmental responsibility with operational efficiency.

Topic

Find out about biological dust control for your site

Enquire now

Eramet’s GCO reduces road water usage by 85% with biological dust control approach

Written by Janet Reznicek on 28. January 2025. Posted in Case study. No Comments on Eramet’s GCO reduces road water usage by 85% with biological dust control approach

Client:
Client Grande Côte Opérations (GCO)

Location:
Location Senegal

Challange:
Challenge Water damages road infrastructure

Use-Case:
use-case haul road stabilisation and dust control

Content

The problem: Water damages road infrastructure

Trialling bitumen emulsion and biological dust control

The results

The mine is close to a local community, so there’s always pressure to do things better — reducing environmental impact and using less water are top priorities.

In 2022, the mining services team realised they were spraying over 242,000 litres of water per day on the roads just to keep road dust under control. They wanted to reduce water consumption, so the business proactively decided to test other options. One of the tests, a biological dust control method, reduced water usage by 85% and created a three-fold drop in dust fallout. Here’s how they did it.

The problem: Water damages road infrastructure

With a local community living nearby, the mine services team had to keep a close eye on air quality. And from a production point of view, any fines kicked-up from the road reduced visibility for the drivers and slowed down cycle time.

At that time, the mining services team was using only ground water to control dust on very arid land. All of their water trucks were being run at maximum capacity, and they had even bought new trucks to expand the fleet and keep the dust down.

As they increased the frequency of watering, they noticed another problem.

“Once you apply water to a road, it evaporates and afterwards you’ve got no stability in that road infrastructure,” says Alex McHaffie, General Manager, Bind-X.

“GCO has got some of the better road construction teams that I’ve seen across Africa, and they take a lot of pride in managing their roads the right way,” he explains.

Losing fines from the road surface forced them to frequently re-lay the wearing course layer, trapping them in an endless maintenance cycle.

Trialling bitumen emulsion and biological dust control

The team at GCO decided to trial different dust control options to conserve water and stabilise the roads.

They had already tried bitumen-based emulsion products and were reasonably happy with the road stabilisation and dust control results. However, it’s expensive, especially to get the product into West Africa. And there were other challenges like shipping and handling bituminous liquids on site. From an environmental standpoint, there were concerns about the risk of water and soil contamination.

Eramet had recently discovered a new, cleaner option — biological dust control — that had just won the Responsible Mining Innovation Challenge. This is a new method of dust control by Bind-X that binds the upper road layer, forming a stable cement-like structure in the soil. Made from a natural bio-based technology, it’s completely clean for the soil and waterways. Solidifying as hard as bitumen, it improves rolling resistance on the road surface, and dust fallout.

They decided to trial the biological method on an extremely dusty 3 km section of primary haul road, and a smaller section of secondary road, over 3 months. The well-built road was laterite on top of a chert bed, built to handle heavy vehicles passing once every minute.

They applied it two ways:

Building it into the road surface
Spraying it on top of the existing road

The results

Three months later, the water trucks were no longer running at full capacity. The GCO team had reduced water use on the roads to just 36,000 litres on average per day — a 85% reduction.

“We drastically reduced water truck trips from three times a day to once every third day,” said Alex.

Also, onsite dust monitoring data showed a three-fold reduction in dust fallout.

18 months on, GCO now uses it routinely across the site.

“It had a huge impact on water usage,” says Alex. “Not to mention, they reduced chemical use on site, and reduced the ongoing cost to manage the roads.”

Because Bind-X’s biological product is a solid powder-based product, not a liquid, the operations team finds it easier to handle on site. And it eases logistics, too. Where they would ship two and a half containers, they now ship one container to treat a similar area on the mine.