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

Water is present all over the place in mining and its control varies according to its function within the mining processes. In a recent in-depth article by pumps main KSB, the corporate outlines how this in flip influences the choice of technologies used in pumping water. “Alongside the safe provide and restoration of course of water is the problem of removing floor water. Process water and groundwater contain abrasive and corrosive parts in various portions which have an opposed have an result on on pump performance and life. Working circumstances, remote places, various temperature ranges and the dearth of electrical power are also highly 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 potentially contaminated water. “The same can be said 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 effective water and slurry pumps. Well-matched solutions assist to maximise the longevity and effectivity of the system and in addition optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The changing face of mining
The seek for more uncommon and treasured minerals and metals has opened up mining in nations and areas where previously the trade was small scale or non-existent. Consequently, mining companies and gear producers have needed to develop new methods and products. And with the most important mining firms having operations in lots of global places, turning into a most popular equipment provider is crucial. “The dewatering market is slowly shifting from a pure CAPEX perspective to an increasingly OPEX perspective,” stories Brett Lewis, Mining Manager at KSB Australia. “This is especially true for the large mines that understand that poorly designed tools that frequently fails, causes a big increase in substitute and servicing value. Some mining companies at the moment are committing to a carbon neutral target within the next 20 to 30 years, so are focussing on excessive effectivity equipment. They want to section out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it’s aware that mining companies are recording pump efficiency and are accumulating knowledge to compare brands and better rank their qualities or deficiencies. “This is nice news for KSB as the corporate is dedicated to delivering excessive reliability and effectivity pumps, so serving to to reduce the carbon footprint of mining dewatering operations.
Is there a ‘one-fits-all’ pump solution?
KSB says the answer to this can be a resounding ‘no’, but “by sharing experiences between workplaces and also frequently working with the same international mining corporations, KSB has been able to develop applicable solutions. KSB’s involvement within the iron ore industries in Brazil and Australia demonstrate two different approaches to dewatering, both employing vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines excessive floor water, monsoons and underground lakes are issues. To keep continuous 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 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 is not a need for the pumps to be repositioned. This results in cost-savings to the client. After 20 successful years it has turn out to be the standard for this kind of gear in South America.
“The floating station supporting the pumps over the pontoon delivers the flow rate requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive energy motors and related tools results in the scale of the floating station being increased. Stabilizing tools that weighs greater than 200 t requires a lot 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 several places around the Chichester hub zone, an area between 5 and 9 km broad and 80 km long. The mineral deposit sits between ninety m and 117 m under the floor. With the groundwater and water table regularly replenished in moist seasons and cyclones including to the inundation, greater than 75% of the iron ore is beneath the water desk. If too much water mixes with iron ore, it becomes low grade and unsuitable for export, which leads to large income losses. Also, surface dewatering processes are extremely expensive if the water is very excessive.
The accepted dewatering course of inside the region is to pump the water out through boreholes. However, this is not with out its challenges. High water temperatures and high salinity lead to extreme corrosion, whilst iron micro organism can develop on motors which forestall efficient 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 locations a fantastic pressure on the motor, lack of move fee and motor failure.
This means that commonplace off-the-shelf merchandise are not always suitable and the incidence of failures is high. Typically, most bore pumps fail inside 12 months, and typically only some weeks. At Bizarre in Western Australia, KSB provides mine operators with its UPA multistage borehole pump, customised to withstand website circumstances. Although a costlier product than its opponents, the UPA has been proven to ship a considerably longer working life and reduced costs of possession. KSB’s proprietary expertise that inhibits the expansion of iron micro organism makes the UPA a winner.
Trailer mounted models
In Africa the surroundings and minerals being mined require progressive approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, house to several open reduce and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering a number of different pumping solutions involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To stop 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 provide Omega pumps mounted on tough terrain trailers. We supply a complete package made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear together with vacuum pump, management panels, monitors etc that delivers excessive head pumping.”
A comparable answer is also provided for the open cast Moatize coal mine in Mozambique where the water ranges must stay low for steady production reliability. Whilst borehole pumps supply good reliability on a continuing basis, when the rainy season begins, extra assets are in demand KSB SA offers 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 continuing drawback. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates stable particles so the high pressure encapsulated UPA borehole pumps ought to be wear-resistant for long run effectivity. Because the dewatering pumps work at a high speed, the impellers and the put on and tear ring can endure from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, put on is tremendously minimised. “We have had pumps running in this mine for over two years with out the impellers being changed,” says Roberto Valenzuela. “It is an answer that no competitor offers, and adds worth for the customer via reduced upkeep, spare parts and larger mining uptime.”
In Chile’s Atacama Desert copper and gold is mined at altitudes ranging between 2,000 m and 4,500 m. Remote websites, mine depths and the unavailability of electricity wanted to drive high capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and end in environmental air pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, pushed by diesel motors.
“Our prospects require high-pressure pumps in a modular configuration that can be moved with the growth 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 pressure shroud. This provides the customer flexibility and versatility as a result of the gear is compact, develops high pressures and is straightforward to maneuver around the site.
To accommodate increasing flows and discharge stress pumps are configured in sequence and in parallel specifically for the client’s requirements. Being coupled to diesel engines allows steady, autonomous operation in locations with out 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 contained in the mine, eliminating elements similar to negative suction head at excessive altitudes. KSB gear for mine drainage is supplied in normal versions, with variations for rafts or well pumps installed in strain jackets. Having viable solutions for dewatering adds value to the customers operations and is also necessary as a result of annually minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is among the world’s largest exporters of thermal coal, and in addition a major participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her excellent capability to carry out in severe open pit mine websites. Its development of dewatering and dredge pump units (DnD), as an answer for mining purposes, especially for open-pit mine sites is one example of KSB’ dedication to steady product improvement and improvement. To date, greater 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 new model, the DnD Cruiser with enhancements requested by prospects.
KSB builds the whole diesel driven pump unit on a barge, full with gas tank, vacuum pump, management panel and so on, and ships them on trailers for easy commissioning at site. Because monsoon rains are seasonal dewatering can additionally be a seasonal activity and this implies pumps can stand idle for a number of months through the dry intervals. Recognising this situation, KSB has introduced a rental programme, whereby the pumps are supplied fully-kitted out according to the customer’s necessities. By not having to purchase the pump sets, prospects are relieved of the prices of ownership and know that when they require units they arrive ready for operation.
Summary
KSB’s mine dewatering techniques allow the protected and efficient reducing of groundwater in open pit dewatering, underground drainage and borehole drainage purposes. 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 dealing with technologies that can fit all eventualities. This state of affairs has come about through the cross-fertilisation of ideas, applied sciences and experiences gained over many a long time by our corporations around the globe, supported by in depth funding in research and development. Wherever a pumping resolution is required, we will convey a co-ordinated response to the desk.
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