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

Water is current in all places in mining and its control varies in accordance with its function within the mining processes. In a recent in-depth article by pumps major KSB, the company outlines how this in flip influences the choice of technologies used in pumping water. “Alongside the safe provide and recovery of process water is the challenge of eradicating ground water. Process water and groundwater contain abrasive and corrosive elements in various quantities which have an antagonistic have an result on on pump performance and life. Working conditions, remote places, varying temperature ranges and the lack of electrical energy are additionally extremely influential factors.”
The copper mines in Chile and the iron ore mines in Western Australia may be many 1000’s of miles apart, however these mining operations still require dewatering and the secure disposal of probably contaminated water. “The same can be stated of the coal mines of Mozambique and the silver mines of Mexico. What they all have in widespread is a requirement for environment friendly and effective water and slurry pumps. Well-matched solutions assist 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 more rare and precious minerals and metals has opened up mining in countries and locations the place previously the trade was small scale or non-existent. Consequently, mining firms and tools manufacturers have needed to develop new strategies and products. And with the main mining companies having operations in lots of world locations, turning into a most popular equipment provider is essential. “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 large mines that understand that poorly designed tools that frequently fails, causes a significant improve in alternative and servicing cost. Some mining corporations at the moment are committing to a carbon impartial target in the next 20 to 30 years, so are focussing on excessive efficiency equipment. They wish to part out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is aware that mining corporations are recording pump efficiency and are accumulating knowledge to compare manufacturers and better rank their qualities or deficiencies. “This is nice information for KSB as the company is committed to delivering high reliability and efficiency 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 it is a resounding ‘no’, however “by sharing experiences between places of work and likewise frequently working with the identical worldwide mining companies, KSB has been in a place to develop appropriate options. KSB’ pressure gauge digital ราคา in 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 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 3 times a year. KSB Brazil’s solution is a floating station fitted with KSB vertical turbine B pumps positioned over a pontoon (Fig.1). The pontoon rises and falls with adjustments in the water degree so there isn’t any need for the pumps to be repositioned. This leads to cost-savings to the shopper. After 20 successful years it has become the standard for this kind of tools in South America.
“The floating station supporting the pumps over the pontoon delivers the flow fee requested by the client,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, high power motors and associated tools results in the dimensions of the floating station being elevated. Stabilizing gear that weighs greater than 200 t requires plenty of planning, in addition to the problem of constructing a system in such a distant space.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several areas around the Chichester hub zone, an area between 5 and 9 km broad and 80 km long. The mineral deposit sits between 90 m and 117 m beneath the surface. With the groundwater and water table frequently replenished in moist seasons and cyclones adding to the inundation, more 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 massive income losses. Also, surface dewatering processes are extremely costly if the water could be very excessive.
The accepted dewatering process within the region is to pump the water out by way of boreholes. However, this isn’t without its challenges. High water temperatures and excessive salinity lead to excessive corrosion, whilst iron bacteria 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 places a fantastic strain on the motor, lack of flow fee and motor failure.
This signifies that normal off-the-shelf products usually are not always suitable 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 supplies mine operators with its UPA multistage borehole pump, customised to withstand website situations. Although a dearer product than its rivals, the UPA has been shown to deliver a considerably longer working life and lowered costs of possession. KSB’s proprietary know-how that inhibits the growth of iron micro organism makes the UPA a winner.
Trailer mounted models
In Africa the environment and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to several open cut and underground copper mines rainy seasons wreak flooding havoc. Here, KSB is delivering several different pumping options involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To forestall 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 produce Omega pumps mounted on rough terrain trailers. We supply a whole package made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary equipment together with vacuum pump, management panels, monitors etc that delivers high head pumping.”
A comparable resolution is also provided for the open forged Moatize coal mine in Mozambique where the water ranges should stay low for continuous manufacturing reliability. Whilst borehole pumps provide good reliability on a relentless basis, when the wet season begins, extra assets are in demand KSB SA provides 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 drawback. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates stable particles so the high strain encapsulated UPA borehole pumps ought to be wear-resistant for long run efficiency. Because the dewatering pumps work at a high pace, the impellers and the wear and tear ring can suffer from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, wear is significantly 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 provides value for the customer by way of reduced 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 four,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 result in environmental air pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, driven by diesel motors.
“Our prospects require high-pressure pumps in a modular configuration that could be moved with the expansion of the open pit,” feedback Patricio Araya, Mining Head KSB Chile. “The answer is to use horizontally positioned borehole pumps with a special configuration for sand filters encased in a pressure shroud. This offers the customer flexibility and versatility because the gear is compact, develops high pressures and is straightforward to move across the site.
To accommodate rising flows and discharge stress pumps are configured in series and in parallel specifically for the client’s necessities. Being coupled to diesel engines allows steady, 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 handle the accumulation of water contained in the mine, eliminating elements such as adverse suction head at high altitudes. KSB tools for mine drainage is supplied in normal versions, with variations for rafts or properly pumps installed in strain jackets. Having viable solutions for dewatering provides value to the shoppers operations and can additionally be necessary as a end result of every year minerals are found at deeper ranges.
Innovation in Indonesia
Indonesia is doubtless certainly one of the world’s largest exporters of thermal coal, and likewise a significant participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their outstanding capacity to carry out in extreme open pit mine websites. Its improvement of dewatering and dredge pump sets (DnD), as an answer for mining purposes, especially for open-pit mine websites is one example of KSB’ dedication to continuous product improvement and improvement. To date, more than 260 DnD pumps with GWI® LCC and LSA pumps have been put in in mines throughout Indonesia and South East Asia. In 2013, KSB Indonesia launched a model new mannequin, the DnD Cruiser with enhancements requested by prospects.
KSB builds the complete diesel pushed pump unit on a barge, full with gas tank, vacuum pump, management panel etc, and ships them on trailers for easy commissioning at website. Because monsoon rains are seasonal dewatering is also a seasonal activity and this means pumps can stand idle for a quantity of months through the dry intervals. Recognising this situation, KSB has introduced a rental programme, whereby the pumps are equipped fully-kitted out according to the customer’s requirements. By not having to buy the pump units, clients are relieved of the costs of ownership and know that after they require items they arrive prepared for operation.
Summary
KSB’s mine dewatering techniques allow the protected and environment friendly decreasing of groundwater in open pit dewatering, underground drainage and borehole drainage applications. 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 will match all eventualities. This situation has come about by way of the cross-fertilisation of ideas, technologies and experiences gained over many many years by our firms around the world, supported by intensive investment in analysis and growth. Wherever a pumping solution is required, we can deliver a co-ordinated response to the table.
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