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

Water is current in all places in mining and its control varies according to its position in the mining processes. In a latest in-depth article by pumps major KSB, the company outlines how this in flip influences the number of technologies utilized in pumping water. “Alongside the protected provide and restoration of course of water is the problem of eradicating floor water. Process water and groundwater comprise abrasive and corrosive elements in various quantities which have an opposed have an result on on pump performance and life. Working circumstances, remote areas, varying temperature ranges and the shortage of electric energy are additionally extremely influential elements.”
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 stated of the coal mines of Mozambique and the silver mines of Mexico. What they all have in frequent is a requirement for efficient and efficient water and slurry pumps. Well-matched solutions help to maximise the longevity and efficiency 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 seek for extra rare 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 companies and equipment manufacturers have had to develop new strategies and merchandise. And with the most important mining corporations having operations in many world locations, becoming a most popular tools provider is crucial. “The dewatering market is slowly shifting from a pure CAPEX viewpoint to an increasingly OPEX perspective,” stories Brett Lewis, Mining Manager at KSB Australia. “This is especially true for the massive mines that understand that poorly designed tools that frequently fails, causes a major increase in substitute and servicing value. Some mining firms at the second are committing to a carbon neutral goal in the subsequent 20 to 30 years, so are focussing on excessive effectivity equipment. They need to part out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it is conscious that mining companies are recording pump efficiency and are accumulating data to compare brands and better rank their qualities or deficiencies. “This is nice information for KSB as the corporate is dedicated to delivering excessive reliability and effectivity pumps, so serving to to minimize back the carbon footprint of mining dewatering operations.
Is there a ‘one-fits-all’ pump solution?
KSB says the answer to it is a resounding ‘no’, but “by sharing experiences between places of work and also regularly working with the same worldwide mining companies, KSB has been capable of develop acceptable options. KSB’s involvement within the iron ore industries in Brazil and Australia show two different approaches to dewatering, both using vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines excessive ground water, monsoons and underground lakes are issues. To maintain continuous production water has 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 resolution is a floating station fitted with KSB vertical turbine B pumps positioned over a pontoon (Fig.1). The pontoon rises and falls with changes in the water degree so there is not a want for the pumps to be repositioned. This leads to cost-savings to the customer. After 20 profitable years it has turn into the usual for this type of equipment in South America.
“The floating station supporting the pumps over the pontoon delivers the circulate rate requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, high power motors and related equipment results in the dimensions of the floating station being elevated. Stabilizing equipment that weighs more than 200 t requires a lot of planning, in addition to the problem of building a system in such a distant area.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several locations across the Chichester hub zone, an area between 5 and 9 km extensive and 80 km lengthy. The mineral deposit sits between 90 m and 117 m under the floor. With the groundwater and water desk regularly replenished in moist seasons and cyclones adding to the inundation, greater than 75% of the iron ore is below the water desk. If an excessive amount of water mixes with iron ore, it becomes low grade and unsuitable for export, which results in massive income losses. Also, surface dewatering processes are extraordinarily pricey if the water is very high.
The accepted dewatering process throughout the area is to pump the water out via boreholes. However, this is not with out its challenges. High water temperatures and high salinity result in excessive corrosion, whilst iron micro organism can grow on motors which stop environment friendly motor cooling. The presence of gas is a constant menace in some areas as this causes fuel lock on the impellers leading to heavy vibrations, which locations an excellent pressure on the motor, loss of circulate price and motor failure.
This signifies that standard off-the-shelf products aren’t all the time appropriate and the incidence of failures is high. Typically, most bore pumps fail within 12 months, and sometimes only some weeks. At its Hope Valley facility in Western Australia, KSB provides mine operators with its UPA multistage borehole pump, customised to resist site situations. Although a more expensive product than its competitors, the UPA has been shown to ship a considerably longer working life and reduced prices of ownership. KSB’s proprietary technology that inhibits the growth of iron micro organism makes the UPA a winner.
Trailer mounted models
In Africa the setting and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, house to several open minimize and underground copper mines rainy seasons wreak flooding havoc. Here, KSB is delivering a number of totally different pumping solutions involving both 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 resolution has been to supply Omega pumps mounted on rough terrain trailers. We provide a whole bundle made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear together with vacuum pump, control panels, monitors and so on that delivers excessive head pumping.”
A related solution can be provided for the open forged Moatize coal mine in Mozambique where the water ranges must stay low for continuous manufacturing reliability. Whilst borehole pumps offer good reliability on a relentless foundation, when the rainy season begins, more resources are in demand KSB SA offers skid-mounted Omega units. To date, KSB SA has provided 152 units and all are working reliably.
Latin America
In Mexico’s Zacatecas silver mines underground water is a constant downside. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates stable particles so the high stress encapsulated UPA borehole pumps must be wear-resistant for long run effectivity. Because the dewatering pumps work at a high pace, the impellers and the wear ring can undergo from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 commonplace chrome coating, wear is greatly minimised. “We have had pumps running on this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “ pressure gauge วัด แรง ดัน น้ำ is a solution that no competitor presents, and provides worth for the client by way of reduced maintenance, 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 websites, mine depths and the unavailability of electrical energy needed to drive excessive 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 clients require high-pressure pumps in a modular configuration that might be moved with the expansion of the open pit,” feedback Patricio Araya, Mining Head KSB Chile. “The solution is to use horizontally positioned borehole pumps with a special configuration for sand filters encased in a pressure shroud. This gives the customer flexibility and versatility because the tools is compact, develops high pressures and is simple to maneuver around the website.
To accommodate rising flows and discharge strain pumps are configured in collection and in parallel specifically for the client’s requirements. Being coupled to diesel engines permits continuous, autonomous operation in places with out 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 deal with the buildup of water contained in the mine, eliminating elements corresponding to unfavorable suction head at high altitudes. KSB gear for mine drainage is equipped in normal versions, with variations for rafts or properly pumps put in in stress jackets. Having viable solutions for dewatering provides value to the purchasers operations and can be essential as a outcome of annually minerals are found at deeper ranges.
Innovation in Indonesia
Indonesia is certainly one of the world’s largest exporters of thermal coal, and likewise a serious participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her excellent capability to perform in extreme open pit mine sites. Its development of dewatering and dredge pump sets (DnD), as an answer for mining purposes, particularly for open-pit mine sites is one instance of KSB’ commitment to steady product improvement and improvement. To date, more than 260 DnD pumps with GWI® LCC and LSA pumps have been installed in mines throughout Indonesia and South East Asia. In 2013, KSB Indonesia launched a new mannequin, the DnD Cruiser with enhancements requested by prospects.
KSB builds the entire diesel driven pump unit on a barge, complete with gas tank, vacuum pump, management panel and so forth, and ships them on trailers for straightforward commissioning at site. Because monsoon rains are seasonal dewatering can be a seasonal activity and this implies pumps can stand idle for a quantity of 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 requirements. By not having to purchase the pump units, customers are relieved of the prices of possession and know that when they require models they come ready for operation.
Summary
KSB’s mine dewatering methods allow the secure and environment friendly 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 situation has come about via the cross-fertilisation of ideas, applied sciences and experiences gained over many decades by our companies around the globe, supported by extensive investment in analysis and improvement. Wherever a pumping solution is required, we can convey a co-ordinated response to the desk.
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