KSB – open pit dewatering in mining demands durable, reliable 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 main KSB, the company outlines how this in flip influences the number of applied sciences utilized in pumping water. “Alongside the secure provide and recovery of course of water is the problem of eradicating ground water. Process water and groundwater include abrasive and corrosive components in various quantities which have an antagonistic affect on pump efficiency and life. Working situations, remote 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 hundreds of miles apart, however 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 environment friendly and efficient water and slurry pumps. Well-matched options help 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 countries and locations where previously the trade was small scale or non-existent. Consequently, mining companies and gear producers have had to develop new methods and merchandise. And with the most important mining companies having operations in many world locations, becoming a most well-liked equipment provider is crucial. “The dewatering market is slowly shifting from a pure CAPEX perspective to an increasingly OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is particularly true for the massive mines that realize that poorly designed gear that frequently fails, causes a major enhance in replacement and servicing price. Some mining companies are now committing to a carbon neutral target in the next 20 to 30 years, so are focussing on high efficiency gear. They want to phase out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it’s aware that mining companies are recording pump performance and are accumulating data to compare brands and higher rank their qualities or deficiencies. “This is sweet news for KSB as the corporate is dedicated to delivering excessive 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 could be a resounding ‘no’, however “by sharing experiences between places of work and likewise incessantly working with the identical worldwide mining corporations, 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 excessive floor water, monsoons and underground lakes are problems. To keep steady production water must be pumped to a dewatering lake which has a dynamic water stage that have to be raised two or 3 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 within the water stage so there is not a want for the pumps to be repositioned. This leads to cost-savings to the client. After 20 successful years it has turn out to be the usual for this type of tools in South America.
“The floating station supporting the pumps over the pontoon delivers the move fee requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, high power motors and associated equipment ends in the dimensions of the floating station being elevated. Stabilizing tools that weighs more than 200 t requires a lot of planning, in addition to the problem of building a system in such a remote 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 wide and eighty km lengthy. The mineral deposit sits between 90 m and 117 m under the floor. With the groundwater and water table often replenished in moist seasons and cyclones adding to the inundation, greater than 75% of the iron ore is under the water desk. If an extreme amount of water mixes with iron ore, it turns into low grade and unsuitable for export, which outcomes in huge income losses. Also, weksler pressure gauge ราคา dewatering processes are extraordinarily pricey if the water is very high.
The accepted dewatering process inside the region is to pump the water out via boreholes. However, this is not with out its challenges. High water temperatures and high salinity end in excessive corrosion, whilst iron bacteria can grow on motors which stop environment friendly motor cooling. The presence of gasoline is a constant threat in some areas as this causes gas lock on the impellers resulting in heavy vibrations, which places a fantastic pressure on the motor, loss of flow rate and motor failure.
This means that commonplace off-the-shelf merchandise are not all the time suitable and the incidence of failures is excessive. Typically, most bore pumps fail inside 12 months, and typically only some weeks. At its Hope Valley facility in Western Australia, KSB supplies mine operators with its UPA multistage borehole pump, customised to withstand web site circumstances. Although a dearer product than its rivals, the UPA has been proven to ship a significantly longer working life and reduced prices of possession. KSB’s proprietary technology that inhibits the expansion of iron bacteria makes the UPA a winner.
Trailer mounted items
In Africa the environment and minerals being mined require revolutionary approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, house to several open minimize and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering several different pumping solutions involving both UPA Z borehole pumps and surface-mounted Omega pumps. “To stop mining operations from being shut down, a quick localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our solution has been to produce 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 equipment including vacuum pump, control panels, displays and so forth that delivers excessive head pumping.”
A similar solution can additionally be supplied for the open solid Moatize coal mine in Mozambique where the water ranges should remain low for steady production reliability. Whilst borehole pumps provide good reliability on a relentless basis, when the wet season begins, extra sources are in demand KSB SA provides skid-mounted Omega items. 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 continuing problem. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water accommodates strong 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 speed, the impellers and the damage ring can suffer from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, wear is tremendously minimised. “We have had pumps running on this mine for over two years without the impellers being modified,” says Roberto Valenzuela. “It is a solution that no competitor offers, and adds value for the client by way of decreased upkeep, spare components and greater 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 excessive capacity 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 can be moved with the expansion of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The resolution is to use horizontally positioned borehole pumps with a particular configuration for sand filters encased in a strain shroud. This offers the customer flexibility and flexibility because the tools is compact, develops excessive pressures and is simple to maneuver across the website.
To accommodate rising flows and discharge stress pumps are configured in collection and in parallel particularly for the client’s requirements. Being coupled to diesel engines allows steady, autonomous operation in places without electricity 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 accumulation of water inside the mine, eliminating components corresponding to adverse suction head at high altitudes. KSB tools for mine drainage is supplied in commonplace versions, with variations for rafts or well pumps put in in stress jackets. Having viable solutions for dewatering provides value to the purchasers operations and is also important because annually minerals are discovered at deeper levels.
Innovation in Indonesia
Indonesia is probably certainly one of 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 extreme open pit mine sites. Its improvement of dewatering and dredge pump sets (DnD), as an answer for mining applications, especially for open-pit mine websites 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 installed in mines throughout Indonesia and South East Asia. In 2013, KSB Indonesia launched a brand new mannequin, the DnD Cruiser with enhancements requested by customers.
KSB builds the complete diesel pushed pump unit on a barge, full with gasoline tank, vacuum pump, management panel and so forth, and ships them on trailers for easy commissioning at website. Because monsoon rains are seasonal dewatering is also a seasonal activity and this implies pumps can stand idle for several months in the course of the dry intervals. Recognising this case, KSB has introduced a rental programme, whereby the pumps are equipped fully-kitted out based on 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 models they come prepared for operation.
KSB’s mine dewatering techniques enable 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 dealing with applied sciences that will match all eventualities. This situation has come about by way of the cross-fertilisation of ideas, technologies and experiences gained over many decades by our companies all over the world, supported by intensive funding in research and improvement. Wherever a pumping resolution is required, we can convey a co-ordinated response to the desk.

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