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

Water is current everywhere in mining and its management varies in accordance with its role in the mining processes. In a current in-depth article by pumps major KSB, the corporate outlines how this in turn influences the number of applied sciences utilized in pumping water. “Alongside the secure supply and recovery of course of water is the problem of removing floor water. Process water and groundwater contain abrasive and corrosive elements in varying quantities which have an opposed affect on pump performance and life. Working circumstances, remote locations, 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 could additionally be many 1000’s of miles apart, but these mining operations still require dewatering and the protected disposal of doubtless contaminated water. “The similar could be mentioned of the coal mines of Mozambique and the silver mines of Mexico. What all of them have in widespread is a requirement for efficient and efficient water and slurry pumps. Well-matched options assist to maximize 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 seek for extra uncommon and valuable minerals and metals has opened up mining in nations and locations where beforehand the trade was small scale or non-existent. Consequently, mining corporations and gear manufacturers have needed to develop new strategies and merchandise. And with the main mining companies having operations in many global places, turning into a preferred gear 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 especially true for the large mines that understand that poorly designed equipment that frequently fails, causes a significant enhance in replacement and servicing value. Some mining firms are now committing to a carbon impartial target in the next 20 to 30 years, so are focussing on excessive effectivity tools. They need to phase out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it’s conscious that mining corporations are recording pump efficiency and are accumulating knowledge to compare brands and higher rank their qualities or deficiencies. “This is good news for KSB as the corporate is committed 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 reply to this is a resounding ‘no’, but “by sharing experiences between workplaces and also frequently working with the same international mining companies, KSB has been capable of develop appropriate options. KSB’s involvement in the iron ore industries in Brazil and Australia demonstrate two different approaches to dewatering, each using vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines extreme floor water, monsoons and underground lakes are issues. To maintain steady manufacturing water must 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 answer is a floating station fitted with KSB vertical turbine B pumps positioned over a pontoon (Fig.1). The pontoon rises and falls with modifications within the water level so there is no need for the pumps to be repositioned. This results in cost-savings to the customer. After 20 successful years it has become the standard for this kind of equipment in South America.
“The floating station supporting the pumps over the pontoon delivers the circulate fee requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive energy motors and related gear leads to the scale of the floating station being elevated. Stabilizing tools that weighs more than 200 t requires lots of planning, along with the problem of constructing a system in such a remote area.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in a number of areas across the Chichester hub zone, an area between 5 and 9 km extensive and 80 km lengthy. The mineral deposit sits between ninety m and 117 m beneath the floor. With the groundwater and water table regularly replenished in moist seasons and cyclones adding to the inundation, greater than 75% of the iron ore is beneath the water desk. If an excessive amount of 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 costly if the water is very excessive.
The accepted dewatering course of within the region is to pump the water out via boreholes. However, this is not without its challenges. High water temperatures and excessive salinity end in extreme corrosion, while iron bacteria can develop on motors which prevent efficient motor cooling. เกจวัดแรงดูด of fuel is a continuing menace in some areas as this causes fuel lock on the impellers leading to heavy vibrations, which locations a fantastic pressure on the motor, lack of circulate rate and motor failure.
This means that commonplace off-the-shelf merchandise usually are not always appropriate and the incidence of failures is high. Typically, most bore pumps fail inside 12 months, and typically only a few weeks. At its Hope Valley facility in Western Australia, KSB supplies mine operators with its UPA multistage borehole pump, customised to withstand web site conditions. 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 expertise that inhibits the expansion of iron bacteria makes the UPA a winner.
Trailer mounted items
In Africa the surroundings and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to a quantity of open cut and underground copper mines rainy seasons wreak flooding havoc. Here, KSB is delivering several completely different pumping options 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 solution has been to supply Omega pumps mounted on rough terrain trailers. We provide an entire bundle made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear including vacuum pump, management panels, monitors and so forth that delivers excessive head pumping.”
A similar solution is also provided for the open forged Moatize coal mine in Mozambique the place the water ranges must remain low for continuous manufacturing reliability. Whilst borehole pumps provide good reliability on a relentless foundation, when the rainy season starts, more assets are in demand KSB SA provides skid-mounted Omega items. To date, KSB SA has provided 152 items and all are working reliably.
Latin America
In Mexico’s Zacatecas silver mines underground water is a continuing downside. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates stable particles so the high pressure encapsulated UPA borehole pumps should be wear-resistant for long run effectivity. Because the dewatering pumps work at a excessive speed, the impellers and the damage ring can endure from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 commonplace chrome coating, put on is significantly minimised. “We have had pumps operating on this mine for over two years without the impellers being changed,” says Roberto Valenzuela. “It is a solution that no competitor presents, and provides value for the shopper 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 sites, mine depths and the unavailability of electricity needed to drive high capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and result in environmental 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 may be moved with the growth of the open pit,” feedback Patricio Araya, Mining Head KSB Chile. “The resolution 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 equipment is compact, develops high pressures and is simple to move around the website.
To accommodate rising flows and discharge strain pumps are configured in series and in parallel particularly 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 put in on a raft enabling them to deal with the buildup of water inside the mine, eliminating elements corresponding to adverse suction head at excessive altitudes. KSB gear for mine drainage is equipped in standard versions, with variations for rafts or properly pumps put in in strain jackets. Having viable options for dewatering provides value to the shoppers operations and can additionally be important as a outcome of annually minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is amongst the world’s largest exporters of thermal coal, and likewise a major player in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their outstanding capability to perform in severe open pit mine sites. Its improvement of dewatering and dredge pump units (DnD), as an answer for mining applications, particularly for open-pit mine websites is one example of KSB’ dedication to steady product enchancment and development. To date, greater 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 whole diesel pushed pump unit on a barge, complete with gas tank, vacuum pump, control panel and so forth, and ships them on trailers for straightforward commissioning at web site. Because monsoon rains are seasonal dewatering is also a seasonal exercise and this means pumps can stand idle for a number of months through the dry periods. Recognising this case, KSB has launched a rental programme, whereby the pumps are provided fully-kitted out based on the customer’s requirements. By not having to buy the pump units, prospects are relieved of the costs of ownership and know that when they require units they arrive prepared for operation.
Summary
KSB’s mine dewatering techniques allow the protected and environment friendly lowering of groundwater in open pit dewatering, underground drainage and borehole drainage applications. 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 applied sciences that can fit all eventualities. This state of affairs has come about via the cross-fertilisation of ideas, applied sciences and experiences gained over many many years by our firms around the globe, supported by in depth funding in analysis and development. Wherever a pumping solution is required, we will bring a co-ordinated response to the table.
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