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

Water is present in all places in mining and its management varies according to its role within the mining processes. In a current in-depth article by pumps main KSB, the corporate outlines how this in flip influences the number of technologies used in pumping water. “Alongside the protected provide and recovery of process water is the challenge of removing floor water. Process water and groundwater contain abrasive and corrosive parts in various portions which have an adverse affect on pump efficiency and life. Working conditions, remote areas, various temperature ranges and the shortage of electric energy are additionally extremely influential components.”
The copper mines in Chile and the iron ore mines in Western Australia may be many thousands of miles apart, but these mining operations nonetheless require dewatering and the protected disposal of probably contaminated water. “The identical 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 effective water and slurry pumps. Well-matched solutions help to maximise the longevity and efficiency of the system and likewise optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The altering face of mining
The search for extra rare and precious minerals and metals has opened up mining in nations and areas where beforehand the trade was small scale or non-existent. Consequently, mining corporations and gear manufacturers have needed to develop new methods and merchandise. And with the major mining corporations having operations in many global areas, turning into a most well-liked gear provider is crucial. “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 particularly true for the massive mines that realize that poorly designed gear that frequently fails, causes a big improve in replacement and servicing value. Some mining firms at the second are committing to a carbon neutral goal in the subsequent 20 to 30 years, so are focussing on excessive efficiency tools. They want to phase out diesel reliance by connecting most bores to their native electrical grid.”
KSB says it’s aware that mining corporations are recording pump efficiency and are accumulating data to compare manufacturers and higher rank their qualities or deficiencies. “This is sweet news for KSB as the company is dedicated to delivering excessive reliability and efficiency pumps, so serving to 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 in addition frequently working with the same worldwide mining corporations, KSB has been able to develop acceptable options. KSB’s involvement in the iron ore industries in Brazil and Australia demonstrate two completely 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 manufacturing water must be pumped to a dewatering lake which has a dynamic water degree that must 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 adjustments in the water level so there is no need for the pumps to be repositioned. This leads to cost-savings to the shopper. After 20 profitable years it has become the standard for this sort of tools in South America.
“The floating station supporting the pumps over the pontoon delivers the move fee requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive energy motors and associated equipment ends in the dimensions of the floating station being increased. Stabilizing gear that weighs greater than 200 t requires plenty of planning, in addition to 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 a number of places around the Chichester hub zone, an area between 5 and 9 km wide and eighty km lengthy. The mineral deposit sits between ninety m and 117 m under the surface. 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 below the water desk. If too much water mixes with iron ore, it turns into low grade and unsuitable for export, which finally ends up in massive revenue losses. Also, surface dewatering processes are extraordinarily costly if the water could be very high.
The accepted dewatering course of inside the region is to pump the water out via boreholes. However, this is not with out its challenges. pressure gauge trerice ราคา and high salinity result in excessive corrosion, while iron bacteria can develop on motors which prevent efficient motor cooling. The presence of fuel is a constant menace in some areas as this causes fuel lock on the impellers resulting in heavy vibrations, which locations a great pressure on the motor, loss of circulate fee and motor failure.
This means that standard off-the-shelf merchandise are not at all times appropriate 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 supplies mine operators with its UPA multistage borehole pump, customised to resist site situations. Although a more expensive product than its rivals, the UPA has been shown to ship a significantly longer working life and reduced 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 setting and minerals being mined require revolutionary approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to several open minimize and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering a quantity of 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 answer has been to supply Omega pumps mounted on tough terrain trailers. We supply an entire package made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear together with vacuum pump, management panels, screens and so on that delivers high head pumping.”
A comparable answer is also offered for the open cast Moatize coal mine in Mozambique where the water levels should stay low for steady manufacturing reliability. Whilst borehole pumps provide good reliability on a continuing foundation, when the rainy season begins, extra assets are in demand KSB SA supplies skid-mounted Omega units. 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 constant drawback. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates strong particles so the excessive strain encapsulated UPA borehole pumps must be wear-resistant for long run efficiency. Because the dewatering pumps work at a high speed, the impellers and the damage ring can undergo from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 standard chrome coating, wear is significantly minimised. “We have had pumps operating in this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “It is an answer that no competitor offers, and provides worth for the shopper through reduced 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 four,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 lead to environmental air pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, driven by diesel motors.
“Our clients require high-pressure pumps in a modular configuration that could be moved with the enlargement 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 stress shroud. This provides the shopper flexibility and versatility as a result of the equipment is compact, develops high pressures and is straightforward to maneuver across the website.
To accommodate rising flows and discharge strain pumps are configured in sequence and in parallel specifically for the client’s necessities. Being coupled to diesel engines allows continuous, autonomous operation in places without 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 buildup of water inside the mine, eliminating components corresponding to unfavorable suction head at high altitudes. KSB equipment for mine drainage is equipped in normal versions, with variations for rafts or nicely pumps installed in pressure jackets. Having viable solutions for dewatering adds worth to the shoppers operations and can be necessary as a end result of annually minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is amongst the world’s largest exporters of thermal coal, and also a serious participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her excellent capability to carry out in severe open pit mine sites. Its growth of dewatering and dredge pump units (DnD), as a solution for mining purposes, especially for open-pit mine sites is one instance of KSB’ dedication to steady product improvement and development. To date, more than 260 DnD pumps with GWI® LCC and LSA pumps have been installed in mines across Indonesia and South East Asia. In 2013, KSB Indonesia launched a new mannequin, the DnD Cruiser with enhancements requested by clients.
KSB builds the entire diesel pushed pump unit on a barge, complete with gas tank, vacuum pump, control panel etc, and ships them on trailers for simple commissioning at website. Because monsoon rains are seasonal dewatering can also be a seasonal activity and this implies pumps can stand idle for several months in the course of the dry periods. Recognising this situation, KSB has introduced a rental programme, whereby the pumps are provided fully-kitted out in accordance with the customer’s necessities. By not having to purchase the pump units, prospects are relieved of the costs of possession and know that after they require models they come prepared for operation.
KSB’s mine dewatering methods enable the safe and environment friendly lowering 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 match all eventualities. This situation has come about via the cross-fertilisation of concepts, technologies and experiences gained over many decades by our corporations all over the world, supported by in depth investment in research and development. Wherever a pumping solution is required, we are in a position to deliver a co-ordinated response to the table.

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