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

Water is present all over the place in mining and its control varies based on its function in the mining processes. In a recent in-depth article by pumps major KSB, the corporate outlines how this in turn influences the number of applied sciences used in pumping water. “Alongside the secure provide and recovery of course of water is the problem of removing ground water. Process water and groundwater contain abrasive and corrosive components in various portions which have an antagonistic affect on pump efficiency and life. Working situations, remote areas, various temperature ranges and the shortage of electric energy are also extremely influential components.”
The copper mines in Chile and the iron ore mines in Western Australia could additionally be many 1000’s of miles aside, however these mining operations still require dewatering and the protected disposal of doubtless contaminated water. “The same could be stated of the coal mines of Mozambique and the silver mines of Mexico. What they all have in frequent is a requirement for efficient and efficient water and slurry pumps. Well-matched options 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.”
The changing face of mining
The seek for extra rare and precious minerals and metals has opened up mining in international locations and locations the place previously the trade was small scale or non-existent. Consequently, mining firms and gear manufacturers have had to develop new techniques and merchandise. And with the main mining corporations having operations in many international areas, changing into a most popular equipment supplier is essential. “The dewatering market is slowly shifting from a pure CAPEX point of view 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 tools that frequently fails, causes a big increase in substitute and servicing cost. Some mining corporations are now committing to a carbon impartial target in the next 20 to 30 years, so are focussing on high effectivity equipment. They need to phase out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it is aware that mining firms are recording pump performance and are accumulating information to compare manufacturers and better rank their qualities or deficiencies. “This is sweet information for KSB as the company is dedicated to delivering high 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’, however “by sharing experiences between offices and also frequently working with the same international mining firms, KSB has been capable of develop applicable solutions. KSB’s involvement within the iron ore industries in Brazil and Australia reveal two completely different approaches to dewatering, both using vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines extreme ground water, monsoons and underground lakes are problems. To maintain continuous production water must be pumped to a dewatering lake which has a dynamic water degree that should be raised two or thrice a yr. 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 within the water degree so there is not any want for the pumps to be repositioned. This leads to cost-savings to the client. 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 fee requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive power motors and associated equipment leads to the scale of the floating station being increased. Stabilizing tools that weighs more than 200 t requires plenty of planning, in addition to the challenge of constructing a system in such a distant space.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in a number of areas around the Chichester hub zone, an space between 5 and 9 km extensive and 80 km long. The mineral deposit sits between ninety m and 117 m below the surface. With the groundwater and water table frequently replenished in moist seasons and cyclones adding to the inundation, greater than 75% of the iron ore is beneath the water desk. If an extreme quantity of water mixes with iron ore, it turns into low grade and unsuitable for export, which leads to huge income losses. Also, floor dewatering processes are extraordinarily costly if the water is very high.
The accepted dewatering course of within the region is to pump the water out via boreholes. However, this isn’t without its challenges. High water temperatures and high salinity result in extreme corrosion, while iron micro organism can develop on motors which prevent efficient motor cooling. The presence of gasoline is a continuing threat in some areas as this causes gas lock on the impellers leading to heavy vibrations, which locations a great pressure on the motor, lack of move price and motor failure.
This signifies that normal off-the-shelf merchandise aren’t at all times suitable and the incidence of failures is high. Typically, most bore pumps fail inside 12 months, and typically only some weeks. At its Hope Valley facility in Western Australia, KSB provides mine operators with its UPA multistage borehole pump, customised to withstand site situations. Although a dearer product than its competitors, the UPA has been shown to deliver a considerably longer working life and lowered prices of possession. KSB’s proprietary technology that inhibits the expansion 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, home to a quantity of open minimize and underground copper mines rainy seasons wreak flooding havoc. Here, KSB is delivering a number of completely different pumping solutions involving both UPA Z borehole pumps and surface-mounted Omega pumps. “To forestall 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 provide Omega pumps mounted on rough terrain trailers. We supply a complete bundle made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary equipment including vacuum pump, management panels, screens etc that delivers excessive head pumping.”
A similar resolution is also supplied for the open forged Moatize coal mine in Mozambique the place the water ranges should remain low for continuous production reliability. Whilst borehole pumps provide good reliability on a relentless foundation, when the rainy season begins, more assets are in demand KSB SA offers skid-mounted Omega items. To date, KSB SA has supplied 152 models 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 incorporates stable particles so the excessive strain 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 untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, wear is tremendously minimised. “We have had pumps running on this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “It is an answer that no competitor offers, and adds worth for the shopper through lowered upkeep, spare elements and larger 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 needed to drive excessive capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and end in environmental pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, pushed by diesel motors.
“Our clients require high-pressure pumps in a modular configuration that might be moved with the enlargement of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The resolution is to use horizontally positioned borehole pumps with a particular configuration for sand filters encased in a stress shroud. เกจวัดแรงดัน250bar offers the client flexibility and flexibility as a outcome of the equipment is compact, develops excessive pressures and is simple to move across the site.
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 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 put in on a raft enabling them to handle the accumulation of water contained in the mine, eliminating factors similar to unfavorable suction head at excessive altitudes. KSB equipment for mine drainage is supplied in standard versions, with variations for rafts or nicely pumps put in in strain jackets. Having viable solutions for dewatering adds worth to the shoppers operations and is also essential because every year minerals are found at deeper levels.
Innovation in Indonesia
Indonesia is certainly one of the world’s largest exporters of thermal coal, and in addition a major participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their excellent capacity to carry out in severe open pit mine sites. Its development of dewatering and dredge pump units (DnD), as a solution for mining purposes, especially for open-pit mine websites is one instance of KSB’ commitment 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 prospects.
KSB builds the entire diesel driven pump unit on a barge, complete with gas tank, vacuum pump, control panel and so forth, and ships them on trailers for simple commissioning at web site. Because monsoon rains are seasonal dewatering can additionally be a seasonal exercise and this means pumps can stand idle for a number of months during the dry durations. Recognising this example, KSB has launched a rental programme, whereby the pumps are provided fully-kitted out in accordance with the customer’s requirements. By not having to buy the pump sets, prospects are relieved of the costs of ownership and know that after they require units they come ready for operation.
KSB’s mine dewatering methods enable the secure 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 dealing with technologies that will match all eventualities. This situation has come about via the cross-fertilisation of ideas, technologies and experiences gained over many a long time by our corporations all over the world, supported by extensive investment in analysis and improvement. Wherever a pumping resolution is required, we are ready to convey a co-ordinated response to the desk.

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