KSB – open pit dewatering in mining calls for sturdy, dependable and efficient pumps

Water is present all over the place in mining and its control varies in accordance with its position within the mining processes. In a current in-depth article by pumps major KSB, the corporate outlines how this in turn influences the selection of applied sciences utilized in pumping water. “Alongside the safe supply and recovery of process water is the problem of removing ground water. Process water and groundwater contain abrasive and corrosive parts in various portions which have an opposed affect on pump efficiency and life. Working circumstances, remote places, various temperature ranges and the lack of electrical energy are also highly influential components.”
The copper mines in Chile and the iron ore mines in Western Australia may be many thousands of miles aside, however these mining operations still require dewatering and the secure disposal of doubtless contaminated water. “The similar may be mentioned of the coal mines of Mozambique and the silver mines of Mexico. What all of them have in frequent is a requirement for efficient and efficient water and slurry pumps. Well-matched solutions assist to maximize the longevity and efficiency of the system and in addition optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The altering face of mining
The search for more rare and precious minerals and metals has opened up mining in nations and locations the place previously the trade was small scale or non-existent. Consequently, mining corporations and tools producers have needed to develop new strategies and merchandise. And with the main mining firms having operations in many global places, turning into a most popular gear provider is crucial. “The dewatering market is slowly shifting from a pure CAPEX point of view to an more and more OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is particularly true for the large mines that understand that poorly designed gear that regularly fails, causes a big increase in substitute and servicing cost. Some mining companies are now committing to a carbon impartial target within the next 20 to 30 years, so are focussing on high effectivity tools. They need to part out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is conscious that mining companies are recording pump performance and are accumulating information to compare manufacturers and higher rank their qualities or deficiencies. “This is good information for KSB as the company is committed to delivering excessive reliability and efficiency pumps, so helping to cut back the carbon footprint of mining dewatering operations.
Is there a ‘one-fits-all’ pump solution?
KSB says the reply to this is a resounding ‘no’, but “by sharing experiences between offices and also frequently working with the same worldwide mining corporations, KSB has been in a place to develop applicable options. KSB’s involvement in the iron ore industries in Brazil and Australia demonstrate two different approaches to dewatering, each employing vertical multi-stage pumps.”
In pressure gauge ด้าน ดูด ’s Minas Gerais State open pit iron ore mines extreme ground water, monsoons and underground lakes are problems. To maintain continuous production water must be pumped to a dewatering lake which has a dynamic water stage that must be raised two or thrice a year. KSB Brazil’s answer is a floating station fitted with KSB vertical turbine B pumps positioned over a pontoon (Fig.1). The pontoon rises and falls with modifications within the water level so there is no need for the pumps to be repositioned. This results in cost-savings to the client. After 20 profitable years it has turn into the usual for this kind of tools in South America.
“The floating station supporting the pumps over the pontoon delivers the circulate price requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive energy motors and related tools results in the dimensions of the floating station being increased. Stabilizing gear that weighs greater than 200 t requires lots of planning, in addition to the problem of constructing a system in such a distant space.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several areas across the Chichester hub zone, an space between 5 and 9 km extensive and 80 km lengthy. The mineral deposit sits between ninety m and 117 m below the surface. With the groundwater and water desk often replenished in moist seasons and cyclones including to the inundation, more than 75% of the iron ore is under the water desk. If too much water mixes with iron ore, it turns into low grade and unsuitable for export, which outcomes in huge income losses. Also, surface dewatering processes are extremely costly if the water may be very high.
The accepted dewatering process within the area is to pump the water out through boreholes. However, this isn’t without its challenges. High water temperatures and high salinity end in excessive corrosion, whilst iron bacteria can develop on motors which prevent environment friendly motor cooling. The presence of fuel is a constant threat in some areas as this causes gas lock on the impellers leading to heavy vibrations, which places an excellent pressure on the motor, lack of flow price and motor failure.
This signifies that standard off-the-shelf merchandise are not all the time suitable and the incidence of failures is excessive. Typically, most bore pumps fail within 12 months, and sometimes only some weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to resist website situations. Although a dearer product than its rivals, the UPA has been shown to ship a significantly longer working life and reduced costs of possession. KSB’s proprietary technology that inhibits the growth of iron bacteria makes the UPA a winner.
Trailer mounted units
In Africa the surroundings and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, house to a quantity of open cut and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering a number of completely different pumping solutions involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To stop mining operations from being shut down, a quick localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our solution has been to supply Omega pumps mounted on rough terrain trailers. We supply a whole package deal made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary equipment including vacuum pump, control panels, monitors and so forth that delivers excessive head pumping.”
A similar solution can additionally be offered for the open forged Moatize coal mine in Mozambique the place the water ranges should remain low for continuous manufacturing reliability. Whilst borehole pumps offer good reliability on a constant foundation, when the rainy season begins, more sources are in demand KSB SA offers skid-mounted Omega models. To date, KSB SA has supplied 152 items and all are working reliably.
Latin America
In Mexico’s Zacatecas silver mines underground water is a constant drawback. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water contains stable particles so the excessive strain encapsulated UPA borehole pumps ought to be wear-resistant for long run efficiency. Because the dewatering pumps work at a high speed, the impellers and the wear ring can undergo from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, wear is significantly minimised. “We have had pumps working in this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “It is a solution that no competitor presents, and adds value for the client via decreased maintenance, spare elements and higher mining uptime.”
In Chile’s Atacama Desert copper and gold is mined at altitudes ranging between 2,000 m and 4,500 m. Remote sites, mine depths and the unavailability of electricity needed to drive excessive capability pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and lead to environmental pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, pushed by diesel motors.
“Our customers require high-pressure pumps in a modular configuration that can be moved with the enlargement of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The resolution is to make use of horizontally positioned borehole pumps with a special configuration for sand filters encased in a strain shroud. This provides the shopper flexibility and flexibility because the gear is compact, develops excessive pressures and is straightforward to maneuver across the website.
To accommodate increasing flows and discharge pressure pumps are configured in sequence and in parallel particularly for the client’s necessities. Being coupled to diesel engines permits steady, autonomous operation in locations without electrical energy for between 12 and 24 hours with out refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps put in on a raft enabling them to handle the buildup of water contained in the mine, eliminating factors corresponding to negative suction head at high altitudes. KSB equipment for mine drainage is supplied in standard variations, with variations for rafts or well pumps installed in pressure jackets. Having viable options for dewatering provides worth to the customers operations and is also important because annually minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is certainly one of the world’s largest exporters of thermal coal, and also a major participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her excellent capability to perform in severe open pit mine sites. Its improvement of dewatering and dredge pump sets (DnD), as an answer for mining purposes, especially for open-pit mine websites is one example of KSB’ commitment to continuous product enchancment and improvement. To date, greater than 260 DnD pumps with GWI® LCC and LSA pumps have been put in in mines throughout Indonesia and South East Asia. In 2013, KSB Indonesia launched a new model, the DnD Cruiser with enhancements requested by customers.
KSB builds the whole diesel driven pump unit on a barge, full with gasoline tank, vacuum pump, control panel and so forth, and ships them on trailers for simple commissioning at website. Because monsoon rains are seasonal dewatering can additionally be a seasonal exercise and this means pumps can stand idle for a number of months in the course of the dry intervals. Recognising this example, KSB has launched a rental programme, whereby the pumps are supplied fully-kitted out according to the customer’s necessities. By not having to purchase the pump units, prospects are relieved of the costs of possession and know that after they require models they come ready for operation.
Summary
KSB’s mine dewatering methods allow the secure and environment friendly lowering of groundwater in open pit dewatering, underground drainage and borehole drainage applications. Regardless of a mine’s location, the kind of mining operation being carried out, the geological and the aggressive and corrosive nature of the water, KSB has fluid handling applied sciences that may match all eventualities. This scenario has come about via the cross-fertilisation of ideas, applied sciences and experiences gained over many decades by our corporations around the world, supported by extensive investment in research and development. Wherever a pumping resolution is required, we will convey a co-ordinated response to the desk.
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