KSB – open pit dewatering in mining demands sturdy, reliable and environment friendly pumps

Water is current in all places in mining and its management varies based on its function in the mining processes. In a recent in-depth article by pumps major KSB, the corporate outlines how this in flip influences the number of technologies utilized in pumping water. “Alongside the safe supply and restoration of course of water is the challenge of eradicating floor water. Process water and groundwater contain abrasive and corrosive parts in varying portions which have an adverse have an result on on pump performance and life. Working situations, distant areas, varying temperature ranges and the lack of electrical power are additionally highly influential factors.”
The copper mines in Chile and the iron ore mines in Western Australia could also be many 1000’s of miles aside, but these mining operations nonetheless require dewatering and the secure disposal of probably contaminated water. “The identical may be mentioned of the coal mines of Mozambique and the silver mines of Mexico. What all of them have in common is a requirement for efficient and effective water and slurry pumps. Well-matched solutions help to maximise the longevity and effectivity of the system and also optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The altering face of mining
The search for extra rare and precious minerals and metals has opened up mining in countries and areas where previously the trade was small scale or non-existent. Consequently, mining firms and tools producers have needed to develop new strategies and merchandise. And with the major mining companies having operations in many global locations, changing into a most popular tools supplier is important. “The dewatering market is slowly shifting from a pure CAPEX viewpoint to an increasingly OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is particularly true for the large mines that realize that poorly designed equipment that frequently fails, causes a big increase in alternative and servicing value. Some mining corporations at the second are committing to a carbon impartial goal in the next 20 to 30 years, so are focussing on high effectivity tools. They wish to part out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is aware that mining companies are recording pump performance and are accumulating data to match brands and higher rank their qualities or deficiencies. “This is good information for KSB as the corporate is committed to delivering excessive reliability and efficiency pumps, so helping to reduce 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’, however “by sharing experiences between offices and in addition regularly working with the identical worldwide mining companies, KSB has been capable of develop applicable solutions. KSB’s involvement within the iron ore industries in Brazil and Australia show two totally different approaches to dewatering, each employing vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines excessive floor water, monsoons and underground lakes are problems. To preserve continuous production water needs to be pumped to a dewatering lake which has a dynamic water stage that should be raised two or thrice a 12 months. 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 stage so there isn’t any need for the pumps to be repositioned. This leads to cost-savings to the customer. After 20 profitable years it has become the standard for this kind of gear in South America.
“The floating station supporting the pumps over the pontoon delivers the move price requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive power motors and related equipment ends in the scale of the floating station being elevated. Stabilizing equipment that weighs more than 200 t requires lots of planning, along with the problem of constructing a system in such a distant area.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several areas around the Chichester hub zone, an space between 5 and 9 km wide and eighty km lengthy. The mineral deposit sits between 90 m and 117 m below the surface. With the groundwater and water table often replenished in wet seasons and cyclones adding to the inundation, greater than 75% of the iron ore is beneath the water desk. If too much water mixes with iron ore, it turns into low grade and unsuitable for export, which leads to large income losses. Also, surface 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 isn’t without its challenges. High water temperatures and high salinity result in extreme corrosion, whilst iron bacteria can grow on motors which stop environment friendly motor cooling. The presence of fuel is a constant menace in some areas as this causes gasoline lock on the impellers resulting in heavy vibrations, which places a great pressure on the motor, loss of flow fee and motor failure.
This signifies that normal off-the-shelf products aren’t always suitable and the incidence of failures is high. Typically, most bore pumps fail inside 12 months, and generally only some weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to resist web site circumstances. Although a more expensive product than its opponents, the UPA has been proven to deliver a significantly longer working life and decreased prices of ownership. KSB’s proprietary expertise that inhibits the growth of iron bacteria makes the UPA a winner.
Trailer mounted models
In Africa the setting and minerals being mined require revolutionary approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to a number of open cut and underground copper mines rainy seasons wreak flooding havoc. Here, pressure gauge trerice ราคา is delivering a quantity of completely different pumping solutions involving both 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 answer has been to provide 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 tools including vacuum pump, control panels, displays and so on that delivers excessive head pumping.”
A related resolution can be supplied for the open cast Moatize coal mine in Mozambique the place the water levels should remain low for steady production reliability. Whilst borehole pumps offer good reliability on a continuing foundation, when the rainy season starts, more assets are in demand KSB SA provides 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 problem. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates stable particles so the excessive strain encapsulated UPA borehole pumps ought to be wear-resistant for long term effectivity. Because the dewatering pumps work at a excessive velocity, the impellers and the damage ring can suffer from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 commonplace chrome coating, wear is tremendously minimised. “We have had pumps operating in this mine for over two years without the impellers being modified,” says Roberto Valenzuela. “It is an answer that no competitor provides, and adds value for the customer by way of decreased upkeep, spare elements and higher 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 wanted to drive excessive capability pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and end in environmental pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, driven by diesel motors.
“Our clients require high-pressure pumps in a modular configuration that may be moved with the expansion of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The resolution is to make use of horizontally positioned borehole pumps with a particular configuration for sand filters encased in a strain shroud. This offers the shopper flexibility and versatility as a end result of the equipment is compact, develops excessive pressures and is easy to maneuver across the web site.
To accommodate growing flows and discharge pressure pumps are configured in collection and in parallel specifically for the client’s necessities. Being coupled to diesel engines allows steady, autonomous operation in places without electrical energy for between 12 and 24 hours without refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps put in on a raft enabling them to handle the accumulation of water contained in the mine, eliminating components corresponding to negative suction head at high altitudes. KSB gear for mine drainage is supplied in commonplace variations, with variations for rafts or nicely pumps installed in pressure jackets. Having viable options for dewatering provides worth to the shoppers operations and can be necessary as a end result of every year minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is among the world’s largest exporters of thermal coal, and also a significant participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her excellent capacity to carry out in severe open pit mine sites. Its growth of dewatering and dredge pump units (DnD), as an answer for mining purposes, particularly for open-pit mine sites is one instance of KSB’ commitment to continuous product enchancment and development. To date, more than 260 DnD pumps with GWI® LCC and LSA pumps have been put in in mines across Indonesia and South East Asia. In 2013, KSB Indonesia launched a new model, the DnD Cruiser with enhancements requested by customers.
KSB builds the complete diesel driven pump unit on a barge, complete with fuel tank, vacuum pump, control panel and so forth, and ships them on trailers for easy commissioning at site. Because monsoon rains are seasonal dewatering is also a seasonal exercise and this means pumps can stand idle for several months during the dry periods. Recognising this situation, KSB has launched a rental programme, whereby the pumps are equipped fully-kitted out in accordance with the customer’s necessities. By not having to buy the pump units, customers are relieved of the prices of ownership and know that when they require models they arrive ready for operation.
Summary
KSB’s mine dewatering methods enable the protected and environment friendly reducing of groundwater in open pit dewatering, underground drainage and borehole drainage functions. Regardless of a mine’s location, the type of mining operation being carried out, the geological and the aggressive and corrosive nature of the water, KSB has fluid handling technologies that can fit all eventualities. This state of affairs has come about by way of the cross-fertilisation of concepts, technologies and experiences gained over many many years by our corporations around the world, supported by intensive funding in analysis and development. Wherever a pumping solution is required, we are in a position to bring a co-ordinated response to the table.
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