Transforming dust management at Rosh Pinah Zinc Mine’s TSF

Client:
Rosh Pinah Zinc mine
Location:
Namibia
Challenge:
Excessive dust and potential disruption of local environmentÂ
Use-Case:
Erosion control on tailings storage facilities

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.

“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.”
General Manager Bind-X South Africa
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.

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