KSB – open pit dewatering in mining calls for durable, reliable and efficient pumps

Water is present everywhere in mining and its management varies according to its position within the mining processes. In a latest in-depth article by pumps main KSB, the company outlines how this in turn influences the selection of technologies utilized in pumping water. “Alongside the safe supply and recovery of course of water is the problem of eradicating ground water. Process water and groundwater include abrasive and corrosive parts in various quantities which have an opposed affect on pump efficiency and life. Working conditions, distant areas, various temperature ranges and the dearth of electric energy are additionally highly influential components.”
The copper mines in Chile and the iron ore mines in Western Australia could additionally be many 1000’s of miles apart, but these mining operations nonetheless require dewatering and the secure disposal of potentially contaminated water. “The identical can be stated of the coal mines of Mozambique and the silver mines of Mexico. What เกจวัดแรงดันลมคือ of them have in widespread is a requirement for efficient and effective water and slurry pumps. Well-matched options assist to maximize the longevity and efficiency of the system and also optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The changing face of mining
The search for extra rare and treasured minerals and metals has opened up mining in international locations and areas the place beforehand the business was small scale or non-existent. Consequently, mining corporations and tools manufacturers have had to develop new methods and products. And with the major mining companies having operations in plenty of world locations, becoming a most popular tools provider is essential. “The dewatering market is slowly shifting from a pure CAPEX point of view to an more and more OPEX perspective,” reviews Brett Lewis, Mining Manager at KSB Australia. “This is very true for the large mines that realize that poorly designed gear that often fails, causes a significant increase in substitute and servicing value. Some mining companies at the second are committing to a carbon impartial goal within the next 20 to 30 years, so are focussing on excessive efficiency tools. They need to section out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it is conscious that mining firms are recording pump efficiency and are accumulating knowledge to match brands and better rank their qualities or deficiencies. “This is good news for KSB as the corporate is committed to delivering high reliability and effectivity pumps, so helping to minimize 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 offices and likewise regularly working with the same worldwide mining firms, KSB has been in a place to develop acceptable options. KSB’s involvement within the iron ore industries in Brazil and Australia demonstrate two completely different approaches to dewatering, each employing 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 maintain steady production water needs to be pumped to a dewatering lake which has a dynamic water level that must be raised two or 3 times a year. KSB Brazil’s resolution is a floating station fitted with KSB vertical turbine B pumps positioned over a pontoon (Fig.1). The pontoon rises and falls with modifications in the water degree so there is not any need for the pumps to be repositioned. This leads to cost-savings to the customer. After 20 successful years it has turn into the usual for this kind of equipment in South America.
“The floating station supporting the pumps over the pontoon delivers the circulate price requested by the client,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive power motors and associated equipment leads to the scale of the floating station being elevated. Stabilizing tools that weighs more than 200 t requires lots of planning, in addition to the problem of constructing a system in such a remote space.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in a number of places across the Chichester hub zone, an space between 5 and 9 km broad and eighty km long. The mineral deposit sits between 90 m and 117 m below the floor. With the groundwater and water table often replenished in wet seasons and cyclones including to the inundation, greater than 75% of the iron ore is under the water table. If too much water mixes with iron ore, it turns into low grade and unsuitable for export, which leads to huge income losses. Also, floor dewatering processes are extraordinarily pricey if the water is very high.
The accepted dewatering course of inside the area is to pump the water out through boreholes. However, this is not with out its challenges. High water temperatures and high salinity end in extreme corrosion, while iron micro organism can develop on motors which stop environment friendly motor cooling. The presence of fuel is a constant risk in some areas as this causes fuel lock on the impellers resulting in heavy vibrations, which locations a great strain on the motor, loss of circulate rate and motor failure.
This implies that standard off-the-shelf products are not always appropriate and the incidence of failures is excessive. Typically, most bore pumps fail within 12 months, and sometimes only a few weeks. At its Hope Valley facility in Western Australia, KSB provides mine operators with its UPA multistage borehole pump, customised to withstand website conditions. Although a dearer product than its competitors, the UPA has been shown to deliver a considerably longer working life and lowered costs of possession. KSB’s proprietary expertise that inhibits the expansion of iron micro organism makes the UPA a winner.
Trailer mounted items
In Africa the setting and minerals being mined require revolutionary approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, home to several open reduce and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering several completely different pumping options involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To forestall mining operations from being shut down, a quick localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our resolution has been to produce Omega pumps mounted on tough terrain trailers. We provide an entire package made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear together with vacuum pump, control panels, screens and so on that delivers excessive head pumping.”
A similar solution is also offered for the open forged Moatize coal mine in Mozambique the place the water levels must remain low for continuous production reliability. Whilst borehole pumps provide good reliability on a constant basis, when the wet season starts, more resources are in demand KSB SA provides skid-mounted Omega units. To date, KSB SA has equipped 152 items and all are working reliably.
Latin America
In Mexico’s Zacatecas silver mines underground water is a constant drawback. According to เกจ์วัดแรงดันน้ำ , Sales Manager Mining KSB Mexico, the water incorporates solid particles so the high pressure encapsulated UPA borehole pumps must be wear-resistant for long run effectivity. Because the dewatering pumps work at a high velocity, the impellers and the damage ring can endure from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 standard chrome coating, wear is greatly minimised. “We have had pumps working on this mine for over two years without the impellers being modified,” says Roberto Valenzuela. “It is an answer that no competitor offers, and provides worth for the client through decreased upkeep, spare components 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 electrical energy needed to drive high capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and lead to environmental air pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, pushed by diesel motors.
“Our clients require high-pressure pumps in a modular configuration that could be moved with the enlargement of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The resolution is to use horizontally positioned borehole pumps with a special configuration for sand filters encased in a strain shroud. This provides the client flexibility and versatility as a outcome of the equipment is compact, develops high pressures and is straightforward to move around the site.
To accommodate rising flows and discharge strain pumps are configured in collection and in parallel particularly for the client’s requirements. Being coupled to diesel engines permits continuous, autonomous operation in places with out electricity for between 12 and 24 hours without refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps installed on a raft enabling them to deal with the accumulation of water inside the mine, eliminating components such as adverse suction head at excessive altitudes. KSB gear for mine drainage is supplied in standard variations, with variations for rafts or nicely pumps put in in stress jackets. Having viable solutions for dewatering provides value to the purchasers operations and is also important because each year minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is 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 their outstanding capability to carry out in extreme open pit mine sites. Its development of dewatering and dredge pump units (DnD), as an answer for mining purposes, especially for open-pit mine sites is one instance of KSB’ commitment to continuous product improvement and development. To date, more than 260 DnD pumps with GWI® LCC and LSA pumps have been installed in mines across Indonesia and South East Asia. In 2013, KSB Indonesia launched a brand new mannequin, the DnD Cruiser with enhancements requested by prospects.
KSB builds the whole diesel driven pump unit on a barge, complete with gasoline tank, vacuum pump, control panel etc, and ships them on trailers for straightforward commissioning at website. Because monsoon rains are seasonal dewatering can be a seasonal activity and this implies pumps can stand idle for several months through the dry intervals. Recognising this example, KSB has introduced a rental programme, whereby the pumps are supplied fully-kitted out according to the customer’s requirements. By not having to buy the pump units, customers are relieved of the prices of possession and know that when they require units they come ready for operation.
Summary
KSB’s mine dewatering methods allow the safe and efficient lowering of groundwater in open pit dewatering, underground drainage and borehole drainage functions. 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 technologies that can match all eventualities. This scenario has come about via the cross-fertilisation of ideas, technologies and experiences gained over many a long time by our companies around the world, supported by in depth investment in research and development. Wherever a pumping answer is required, we will convey a co-ordinated response to the table.
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