Water is current everywhere in mining and its management varies according to its position within the mining processes. In a latest in-depth article by pumps major KSB, the corporate outlines how this in turn influences the choice of technologies used in pumping water. “Alongside the secure supply and recovery of course of water is the problem of eradicating ground water. Process water and groundwater comprise abrasive and corrosive components in varying portions which have an opposed have an effect on on pump performance and life. Working circumstances, distant areas, varying temperature ranges and the lack of electrical energy are also highly influential elements.”
The copper mines in Chile and the iron ore mines in Western Australia could additionally be many thousands of miles aside, however these mining operations still require dewatering and the secure disposal of potentially contaminated water. “The same may be said of the coal mines of Mozambique and the silver mines of Mexico. What they all have in widespread is a requirement for efficient and effective water and slurry pumps. Well-matched solutions help to maximise 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 more rare and valuable minerals and metals has opened up mining in nations and places where previously the trade was small scale or non-existent. Consequently, mining corporations and tools producers have needed to develop new strategies and products. And with the major mining companies having operations in plenty of global locations, turning into a preferred tools provider is important. “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 massive mines that realize that poorly designed tools that regularly fails, causes a significant increase in replacement and servicing value. Some mining corporations at the moment are committing to a carbon impartial target within the subsequent 20 to 30 years, so are focussing on high effectivity tools. They want to part out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it’s conscious that mining companies are recording pump efficiency and are accumulating data to compare brands 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 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’, however “by sharing experiences between offices and in addition incessantly working with the same worldwide mining companies, KSB has been capable of develop acceptable options. KSB’s involvement in the iron ore industries in Brazil and Australia demonstrate two totally different approaches to dewatering, both employing 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 have to be raised two or three times a 12 months. 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 in the water degree so there is no want for the pumps to be repositioned. This ends in cost-savings to the client. After 20 successful years it has become the standard for this type of equipment in South America.
“The floating station supporting the pumps over the pontoon delivers the circulate fee requested by the client,” 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 increased. Stabilizing gear that weighs greater than 200 t requires plenty of planning, in addition to 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 quantity of locations around the Chichester hub zone, an area between 5 and 9 km extensive and 80 km lengthy. The mineral deposit sits between 90 m and 117 m below the floor. With the groundwater and water table regularly replenished in moist seasons and cyclones including to the inundation, greater than 75% of the iron ore is beneath the water table. If too much water mixes with iron ore, it becomes low grade and unsuitable for export, which results in massive income losses. Also, surface dewatering processes are extraordinarily costly if the water could be very excessive.
The accepted dewatering course of inside the area is to pump the water out through boreholes. However, this isn’t without its challenges. High water temperatures and excessive salinity lead to extreme corrosion, whilst iron micro organism can grow on motors which forestall efficient motor cooling. The presence of gas is a continuing menace in some areas as this causes gasoline lock on the impellers leading to heavy vibrations, which places a great pressure on the motor, lack of move rate and motor failure.
This signifies that normal off-the-shelf merchandise usually are not at all times suitable and the incidence of failures is high. Typically, most bore pumps fail within 12 months, and generally only a few weeks. At its Hope Valley facility in Western Australia, KSB provides mine operators with its UPA multistage borehole pump, customised to resist site conditions. Although a costlier product than its opponents, the UPA has been shown to ship a considerably longer working life and lowered 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 setting and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, home to several open minimize and underground copper mines rainy seasons wreak flooding havoc. Here, KSB is delivering a quantity of completely different pumping solutions involving both 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 provide Omega pumps mounted on rough terrain trailers. We supply a complete package made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary tools including vacuum pump, management panels, displays etc that delivers high head pumping.”
A comparable answer is also supplied for the open forged Moatize coal mine in Mozambique where the water levels should remain low for steady manufacturing reliability. เกจวัดco2 supply good reliability on a relentless foundation, when the wet season starts, extra assets are in demand KSB SA offers skid-mounted Omega items. To date, KSB SA has equipped 152 units 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 contains solid particles so the high pressure encapsulated UPA borehole pumps should be wear-resistant for long run efficiency. Because the dewatering pumps work at a excessive velocity, the impellers and the put on and tear ring can suffer from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 standard chrome coating, wear is tremendously minimised. “We have had pumps operating on this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “It is a solution that no competitor presents, and adds worth for the shopper through lowered 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 sites, mine depths and the unavailability of electrical energy wanted to drive excessive capability pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and end in environmental air 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 expansion of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The answer is to use horizontally positioned borehole pumps with a particular configuration for sand filters encased in a stress shroud. This offers the shopper flexibility and flexibility because the tools is compact, develops excessive pressures and is straightforward to maneuver across the website.
To accommodate increasing flows and discharge pressure pumps are configured in series and in parallel particularly for the client’s necessities. Being coupled to diesel engines permits steady, autonomous operation in locations without electricity 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 such as negative suction head at excessive altitudes. KSB equipment for mine drainage is equipped in commonplace versions, with variations for rafts or properly pumps put in in stress jackets. Having viable options for dewatering adds value to the purchasers operations and is also necessary as a result of annually minerals are found at deeper levels.
Innovation in Indonesia
Indonesia is doubtless considered one of the world’s largest exporters of thermal coal, and also a major participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their excellent capability to carry out in severe open pit mine websites. Its development of dewatering and dredge pump sets (DnD), as a solution for mining applications, especially for open-pit mine sites is one instance 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 model, the DnD Cruiser with enhancements requested by customers.
KSB builds the whole diesel driven pump unit on a barge, complete with fuel tank, vacuum pump, management panel etc, and ships them on trailers for straightforward commissioning at website. Because monsoon rains are seasonal dewatering is also a seasonal activity and this implies pumps can stand idle for a number of months through the dry intervals. Recognising this example, KSB has introduced a rental programme, whereby the pumps are equipped fully-kitted out based on the customer’s requirements. By not having to buy the pump units, clients are relieved of the prices of possession and know that when they require items they come prepared for operation.
Summary
KSB’s mine dewatering systems allow the secure and efficient decreasing 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 handling technologies that can match all eventualities. This state of affairs has come about through the cross-fertilisation of ideas, technologies and experiences gained over many many years by our companies all over the world, supported by in depth funding in analysis and growth. Wherever a pumping solution is required, we can bring a co-ordinated response to the desk.
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