KSB – open pit dewatering in mining calls for durable, dependable and environment friendly pumps

Water is present everywhere in mining and its control varies based on its role within the mining processes. In a current in-depth article by pumps main KSB, the company outlines how this in turn influences the choice of technologies utilized in pumping water. “Alongside the safe provide and recovery of course of water is the challenge of eradicating floor water. Process water and groundwater comprise abrasive and corrosive parts in various quantities which have an opposed affect on pump performance and life. Working conditions, remote locations, varying temperature ranges and the shortage of electrical energy are additionally extremely influential factors.”
The copper mines in Chile and the iron ore mines in Western Australia may be many 1000’s of miles aside, but these mining operations nonetheless require dewatering and the safe disposal of doubtless contaminated water. “The identical can be said of the coal mines of Mozambique and the silver mines of Mexico. What all of them have in widespread is a requirement for efficient and effective water and slurry pumps. Well-matched options assist to maximise the longevity and efficiency of the system and likewise optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The changing face of mining
The seek for extra uncommon and treasured minerals and metals has opened up mining in nations and areas where beforehand the business was small scale or non-existent. Consequently, mining firms and equipment manufacturers have had to develop new methods and merchandise. And with the major mining companies having operations in many international places, changing into a preferred equipment supplier is important. “The dewatering market is slowly shifting from a pure CAPEX perspective to an more and more OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is very true for the large mines that realize that poorly designed gear that frequently fails, causes a big improve in replacement and servicing value. Some mining firms are actually committing to a carbon neutral goal within the subsequent 20 to 30 years, so are focussing on high effectivity equipment. They wish to phase out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is conscious that mining corporations are recording pump efficiency and are accumulating data to match manufacturers and higher rank their qualities or deficiencies. “This is nice information for KSB as the corporate is committed to delivering excessive reliability and effectivity pumps, so helping to scale back the carbon footprint of mining dewatering operations.
Is there a ‘one-fits-all’ pump solution?
KSB says the answer to this is a resounding ‘no’, but “by sharing experiences between workplaces and in addition frequently working with the identical worldwide mining companies, KSB has been in a place to develop acceptable solutions. KSB’s involvement within the iron ore industries in Brazil and Australia show two completely different approaches to dewatering, both using vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines extreme floor water, monsoons and underground lakes are problems. To keep continuous manufacturing water needs to be pumped to a dewatering lake which has a dynamic water level that have to be raised two or three times a yr. 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 adjustments within the water level so there is no want for the pumps to be repositioned. This results in cost-savings to the shopper. After 20 successful 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 move price requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive energy motors and related equipment leads to the dimensions of the floating station being elevated. Stabilizing tools that weighs more than 200 t requires plenty of planning, along with the challenge 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 around the Chichester hub zone, an area between 5 and 9 km broad and eighty km long. The mineral deposit sits between 90 m and 117 m under the surface. With the groundwater and water table regularly replenished in moist seasons and cyclones including to the inundation, more than 75% of the iron ore is beneath the water table. If too much water mixes with iron ore, it turns into low grade and unsuitable for export, which ends up in massive income losses. Also, floor dewatering processes are extremely pricey if the water may be very high.
The accepted dewatering course of within the region is to pump the water out through boreholes. However, เกจวัดแรงดันลมขนาดเล็ก is not without its challenges. High water temperatures and high salinity lead to excessive corrosion, while iron micro organism can grow on motors which stop environment friendly motor cooling. The presence of fuel is a continuing threat in some areas as this causes gasoline lock on the impellers leading to heavy vibrations, which places a fantastic strain on the motor, loss of circulate rate and motor failure.
This implies that commonplace off-the-shelf products usually are not always appropriate and the incidence of failures is excessive. Typically, most bore pumps fail within 12 months, and sometimes just a few weeks. At its Hope Valley facility in Western Australia, KSB supplies mine operators with its UPA multistage borehole pump, customised to resist web site circumstances. Although a dearer product than its competitors, the UPA has been proven to deliver a considerably longer working life and decreased costs of possession. KSB’s proprietary know-how that inhibits the growth of iron micro organism makes the UPA a winner.
Trailer mounted models
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 rainy seasons wreak flooding havoc. Here, KSB is delivering several completely different pumping solutions involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To forestall mining operations from being shut down, a fast localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our answer has been to supply Omega pumps mounted on rough terrain trailers. We provide a complete bundle made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary equipment together with vacuum pump, control panels, monitors and so on that delivers excessive head pumping.”
A related resolution can additionally be supplied for the open solid Moatize coal mine in Mozambique where the water ranges must stay low for continuous manufacturing reliability. Whilst borehole pumps offer good reliability on a constant foundation, when the rainy season starts, more resources are in demand KSB SA offers skid-mounted Omega units. To date, KSB SA has supplied 152 models 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 strong particles so the excessive stress encapsulated UPA borehole pumps should be wear-resistant for long term effectivity. Because the dewatering pumps work at a high speed, the impellers and the damage ring can undergo from premature put on. Using Multitec horizontal multistage pumps with KSB’s C6 standard chrome coating, wear is greatly 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 shopper via lowered upkeep, spare components and larger mining uptime.”
In Chile’s Atacama Desert copper and gold is mined at altitudes ranging between 2,000 m and four,500 m. Remote websites, mine depths and the unavailability of electrical energy needed to drive high capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and result in 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 expansion of the open pit,” feedback 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 offers the customer flexibility and versatility as a result of the equipment is compact, develops high pressures and is simple to maneuver across the web site.
To accommodate increasing flows and discharge stress pumps are configured in series and in parallel specifically for the client’s requirements. Being coupled to diesel engines allows continuous, autonomous operation in places without electrical energy for between 12 and 24 hours with out refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps installed on a raft enabling them to handle the accumulation of water inside the mine, eliminating elements similar to unfavorable suction head at excessive altitudes. KSB equipment for mine drainage is provided in normal versions, with variations for rafts or properly pumps installed in pressure jackets. Having viable solutions for dewatering adds value to the shoppers operations and can also be essential as a result of annually minerals are found at deeper levels.
Innovation in Indonesia
Indonesia is certainly one of the world’s largest exporters of thermal coal, and likewise a serious player in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her excellent capacity to carry out in extreme open pit mine sites. Its growth of dewatering and dredge pump units (DnD), as an answer for mining applications, especially for open-pit mine sites is one instance of KSB’ dedication to steady product enchancment and growth. 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 brand new model, the DnD Cruiser with enhancements requested by prospects.
KSB builds the whole diesel driven pump unit on a barge, full with fuel tank, vacuum pump, control panel etc, and ships them on trailers for easy commissioning at site. Because monsoon rains are seasonal dewatering can also be a seasonal exercise and this means pumps can stand idle for several months during the dry periods. Recognising this case, KSB has launched a rental programme, whereby the pumps are equipped fully-kitted out based on the customer’s necessities. By not having to buy the pump sets, customers are relieved of the costs of possession and know that when they require units they arrive prepared for operation.
Summary
KSB’s mine dewatering methods enable the safe and environment friendly lowering of groundwater in open pit dewatering, underground drainage and borehole drainage functions. Regardless of a mine’s location, the sort of mining operation being carried out, the geological and the aggressive and corrosive nature of the water, KSB has fluid dealing with technologies that will match all eventualities. This scenario has come about via the cross-fertilisation of concepts, applied sciences and experiences gained over many a long time by our corporations around the globe, supported by intensive funding in analysis and growth. Wherever a pumping solution is required, we will deliver a co-ordinated response to the desk.
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