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

Water is current in all places in mining and its management varies based on its role in the mining processes. In a recent in-depth article by pumps major KSB, the corporate outlines how this in flip influences the choice of technologies utilized in pumping water. “Alongside the secure supply and restoration of course of water is the problem of eradicating ground water. Process water and groundwater contain abrasive and corrosive components in various quantities which have an adverse affect on pump performance and life. Working conditions, distant locations, various temperature ranges and the dearth of electric energy are additionally extremely influential factors.”
The copper mines in Chile and the iron ore mines in Western Australia could additionally be many hundreds of miles apart, but these mining operations still require dewatering and the secure disposal of probably contaminated water. “The identical could be said of the coal mines of Mozambique and the silver mines of Mexico. What all of them have in common is a requirement for efficient and effective water and slurry pumps. Well-matched solutions help 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.”
เกจวัดแรงดันเครื่องกรองน้ำ changing face of mining
The search for extra rare and valuable minerals and metals has opened up mining in countries and areas where previously the industry was small scale or non-existent. Consequently, mining corporations and gear producers have had to develop new strategies and merchandise. And with the main mining firms having operations in many world locations, changing into a most well-liked gear provider is crucial. “The dewatering market is slowly shifting from a pure CAPEX perspective to an more and more OPEX perspective,” reviews Brett Lewis, Mining Manager at KSB Australia. “This is very true for the large mines that understand that poorly designed gear that frequently fails, causes a big improve in substitute and servicing cost. Some mining firms are actually committing to a carbon neutral target in the next 20 to 30 years, so are focussing on high efficiency tools. They wish to section out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it is aware that mining corporations are recording pump efficiency and are accumulating knowledge to compare manufacturers and higher rank their qualities or deficiencies. “This is good news for KSB as the company is dedicated to delivering excessive reliability and effectivity pumps, so helping to scale back 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 offices and likewise incessantly working with the identical worldwide mining corporations, KSB has been in a position to develop acceptable solutions. KSB’s involvement in the iron ore industries in Brazil and Australia reveal 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 keep continuous production water has to be pumped to a dewatering lake which has a dynamic water stage that must be raised two or thrice a year. 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 adjustments within the water level so there is no want for the pumps to be repositioned. This ends in cost-savings to the customer. After 20 successful years it has turn out to be the usual for this sort of gear in South America.
“The floating station supporting the pumps over the pontoon delivers the move rate requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive power motors and associated gear results in the size of the floating station being increased. Stabilizing tools that weighs greater than 200 t requires a lot of planning, in addition to the challenge 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 around the Chichester hub zone, an space between 5 and 9 km extensive and eighty km long. The mineral deposit sits between 90 m and 117 m under the surface. With the groundwater and water desk 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 excessive quantity of water mixes with iron ore, it becomes low grade and unsuitable for export, which finally ends up in huge income losses. Also, floor dewatering processes are extraordinarily pricey if the water could be very high.
The accepted dewatering course of within the region is to pump the water out via boreholes. However, pressure gauge หน้าปัด 4 นิ้ว isn’t with out its challenges. High water temperatures and excessive salinity end in excessive corrosion, while iron micro organism can grow on motors which stop efficient motor cooling. The presence of gasoline is a continuing menace in some areas as this causes fuel lock on the impellers leading to heavy vibrations, which locations a great strain on the motor, loss of circulate rate and motor failure.
This signifies that normal off-the-shelf merchandise are not 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 offers mine operators with its UPA multistage borehole pump, customised to resist site situations. Although a costlier product than its competitors, the UPA has been proven to ship a significantly longer working life and decreased costs of ownership. KSB’s proprietary know-how that inhibits the growth of iron micro organism makes the UPA a winner.
Trailer mounted units
In Africa the environment and minerals being mined require progressive approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to a number of open cut and underground copper mines rainy seasons wreak flooding havoc. Here, KSB is delivering several totally 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 answer has been to provide Omega pumps mounted on tough terrain trailers. We provide a whole bundle made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear including vacuum pump, control panels, monitors and so on that delivers high head pumping.”
A comparable resolution is also supplied for the open cast Moatize coal mine in Mozambique where the water levels must stay low for continuous production reliability. Whilst borehole pumps offer good reliability on a continuing foundation, when the rainy season starts, more sources are in demand KSB SA supplies skid-mounted Omega items. To date, KSB SA has equipped 152 models 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 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 excessive pace, the impellers and the wear and tear ring can suffer from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, put on is significantly minimised. “We have had pumps working on this mine for over two years with out the impellers being changed,” says Roberto Valenzuela. “It is an answer that no competitor provides, and provides value for the shopper by way of decreased 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 sites, mine depths and the unavailability of electricity wanted to drive high capability 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 customers require high-pressure pumps in a modular configuration that can be moved with the enlargement of the open pit,” feedback Patricio Araya, Mining Head KSB Chile. “The resolution is to make use of horizontally positioned borehole pumps with a particular configuration for sand filters encased in a pressure shroud. This offers the shopper flexibility and versatility as a outcome of the gear is compact, develops high pressures and is straightforward to maneuver across the website.
To accommodate rising flows and discharge stress pumps are configured in sequence and in parallel particularly for the client’s necessities. 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 inside the mine, eliminating components such as adverse suction head at excessive altitudes. KSB gear for mine drainage is supplied in commonplace variations, with variations for rafts or well pumps installed in pressure jackets. Having viable solutions for dewatering provides value to the customers operations and is also necessary because every year minerals are found at deeper levels.
Innovation in Indonesia
Indonesia is 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 their outstanding capability to perform in severe open pit mine websites. Its improvement of dewatering and dredge pump units (DnD), as a solution for mining applications, especially for open-pit mine sites is one example of KSB’ commitment to steady product improvement and development. 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 new model, the DnD Cruiser with enhancements requested by customers.
KSB builds the complete diesel driven pump unit on a barge, complete with fuel tank, vacuum pump, control panel and so forth, and ships them on trailers for easy commissioning at site. Because monsoon rains are seasonal dewatering can also be a seasonal activity and this means pumps can stand idle for a quantity of months during the dry durations. Recognising this situation, KSB has introduced a rental programme, whereby the pumps are provided fully-kitted out according to the customer’s requirements. By not having to buy the pump units, customers are relieved of the prices of ownership and know that when they require items they arrive prepared for operation.
Summary
KSB’s mine dewatering methods allow the secure and efficient reducing 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 technologies that can fit all eventualities. This situation has come about via the cross-fertilisation of ideas, technologies and experiences gained over many decades by our firms all over the world, supported by in depth funding in research and growth. Wherever a pumping answer is required, we will bring a co-ordinated response to the table.
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