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

Water is current in all places in mining and its control varies in accordance with its role within the mining processes. In a latest in-depth article by pumps main KSB, the company outlines how this in flip influences the selection of applied sciences utilized in pumping water. “Alongside the secure supply and restoration of course of water is the challenge of eradicating ground water. Process water and groundwater comprise abrasive and corrosive components in various quantities which have an opposed affect on pump efficiency and life. Working circumstances, remote areas, varying temperature ranges and the shortage of electric power are additionally extremely influential factors.”
The copper mines in Chile and the iron ore mines in Western Australia may be many hundreds of miles apart, but these mining operations still require dewatering and the secure disposal of doubtless contaminated water. “The identical can be said of the coal mines of Mozambique and the silver mines of Mexico. What they all have in frequent is a requirement for efficient and effective water and slurry pumps. Well-matched options assist to maximize the longevity and efficiency of the system and in addition 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 precious minerals and metals has opened up mining in international locations and places the place previously the business was small scale or non-existent. Consequently, mining companies and equipment manufacturers have needed to develop new strategies and merchandise. And with the most important mining corporations having operations in plenty of world areas, turning into a most well-liked tools supplier is essential. “The dewatering market is slowly shifting from a pure CAPEX perspective to an more and more OPEX perspective,” stories Brett Lewis, Mining Manager at KSB Australia. “This is particularly true for the large mines that notice that poorly designed tools that frequently fails, causes a big improve in alternative and servicing value. Some mining corporations at the second are committing to a carbon neutral goal in the next 20 to 30 years, so are focussing on excessive effectivity tools. They want to section 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 match manufacturers and better rank their qualities or deficiencies. “This is nice information for KSB as the company is committed 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 could be a resounding ‘no’, however “by sharing experiences between places of work and likewise frequently working with the same international mining firms, KSB has been capable of develop acceptable 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 ground water, monsoons and underground lakes are issues. To preserve steady production water has to be pumped to a dewatering lake which has a dynamic water level that should be raised two or 3 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 adjustments in the water level so there is no need for the pumps to be repositioned. This ends in cost-savings to the shopper. After 20 profitable years it has turn into the standard for this sort of tools 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, excessive power motors and related gear ends in the size of the floating station being elevated. Stabilizing gear that weighs greater than 200 t requires a lot of planning, along with the challenge of constructing a system in such a distant area.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several areas across the Chichester hub zone, an space between 5 and 9 km broad and 80 km lengthy. The mineral deposit sits between ninety m and 117 m beneath the floor. With the groundwater and water desk regularly replenished in moist seasons and cyclones adding to the inundation, more than 75% of the iron ore is under the water desk. If too much water mixes with iron ore, it becomes low grade and unsuitable for export, which leads to large revenue losses. Also, floor dewatering processes are extraordinarily pricey if the water may be very high.
The accepted dewatering course of within the region is to pump the water out through boreholes. However, this isn’t with out its challenges. High water temperatures and excessive salinity end in excessive corrosion, whilst iron micro organism can develop on motors which forestall environment friendly motor cooling. The presence of gas is a continuing risk in some areas as this causes gas lock on the impellers resulting in heavy vibrations, which locations an excellent pressure on the motor, lack of circulate rate and motor failure.
This means that normal off-the-shelf merchandise aren’t all the time suitable and the incidence of failures is excessive. Typically, most bore pumps fail inside 12 months, and typically just a few weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to withstand site situations. Although a more expensive product than its opponents, the UPA has been proven to ship a significantly longer working life and lowered costs of ownership. KSB’s proprietary expertise that inhibits the growth of iron bacteria makes the UPA a winner.
Trailer mounted items
In Africa the surroundings 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 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 stop mining operations from being shut down, a quick localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our resolution has been to produce Omega pumps mounted on tough terrain trailers. We provide a whole package 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 high head pumping.”
A similar answer is also provided for the open cast Moatize coal mine in Mozambique the place the water levels must remain low for continuous production reliability. Whilst borehole pumps supply good reliability on a constant foundation, when the rainy season starts, extra resources are in demand KSB SA offers skid-mounted Omega models. 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 continuing downside. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water contains solid particles so the excessive strain encapsulated UPA borehole pumps must be wear-resistant for long run effectivity. Because the dewatering pumps work at a high velocity, the impellers and the put on and tear ring can endure from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, wear is tremendously minimised. “We have had pumps working on this mine for over two years without the impellers being changed,” says Roberto Valenzuela. “It is an answer that no competitor provides, and adds worth for the shopper via decreased maintenance, spare components and larger mining uptime.”
In เกจวัดแรงดันน้ำ ’s Atacama Desert copper and gold is mined at altitudes ranging between 2,000 m and four,500 m. Remote sites, mine depths and the unavailability of electrical energy needed 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 might be moved with the expansion of the open pit,” feedback Patricio Araya, Mining Head KSB Chile. “The solution 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 tools is compact, develops high pressures and is straightforward to move across the website.
To accommodate growing flows and discharge strain pumps are configured in sequence and in parallel specifically for the client’s requirements. Being coupled to diesel engines permits steady, autonomous operation in locations without electrical energy for between 12 and 24 hours with out refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps installed on a raft enabling them to handle the buildup of water inside the mine, eliminating elements such as negative suction head at high altitudes. KSB tools for mine drainage is equipped in normal versions, with variations for rafts or nicely pumps installed in pressure jackets. Having viable options for dewatering provides value to the shoppers operations and can also be essential as a end result of each year minerals are found at deeper ranges.
Innovation in Indonesia
Indonesia is amongst the world’s largest exporters of thermal coal, and also a serious player in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their outstanding capacity to perform in extreme open pit mine websites. Its development of dewatering and dredge pump units (DnD), as a solution for mining purposes, particularly for open-pit mine websites is one example of KSB’ dedication to steady product improvement and improvement. To date, more 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 mannequin, the DnD Cruiser with enhancements requested by customers.
KSB builds the entire diesel pushed pump unit on a barge, complete with gasoline tank, vacuum pump, control panel and so forth, and ships them on trailers for easy commissioning at web site. Because monsoon rains are seasonal dewatering can also be a seasonal activity and this implies pumps can stand idle for several months during the dry durations. Recognising this case, KSB has introduced a rental programme, whereby the pumps are supplied fully-kitted out in accordance with the customer’s requirements. By not having to buy the pump units, customers are relieved of the costs of ownership and know that when they require units they come prepared for operation.
Summary
KSB’s mine dewatering systems enable the safe 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 handling technologies that may match all eventualities. This scenario has come about by way of the cross-fertilisation of ideas, applied sciences and experiences gained over many a long time by our corporations around the world, supported by extensive investment in research and growth. Wherever a pumping answer is required, we are able to bring a co-ordinated response to the table.
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