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

Water is current in all places in mining and its control varies based on its function in the mining processes. In a recent in-depth article by pumps main KSB, the company outlines how this in turn influences the selection of applied sciences utilized 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 components in various portions which have an adverse affect on pump efficiency and life. Working situations, remote places, varying temperature ranges and the shortage of electric energy are additionally extremely influential elements.”
The copper mines in Chile and the iron ore mines in Western Australia may be many hundreds of miles aside, but these mining operations still require dewatering and the secure disposal of potentially contaminated water. “The same could be mentioned of the coal mines of Mozambique and the silver mines of Mexico. What all of them have in widespread is a requirement for environment friendly and effective water and slurry pumps. Well-matched options help 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 search for more uncommon and treasured minerals and metals has opened up mining in countries and areas the place previously the industry was small scale or non-existent. Consequently, mining companies and gear producers have had to develop new strategies and products. And with the major mining companies having operations in many international locations, becoming a preferred tools provider is important. “The dewatering market is slowly shifting from a pure CAPEX perspective to an increasingly OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is especially true for the massive mines that understand that poorly designed equipment that frequently fails, causes a major improve in replacement and servicing value. Some mining firms are actually committing to a carbon impartial target in the subsequent 20 to 30 years, so are focussing on high efficiency equipment. They need to section out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is aware that mining corporations are recording pump performance and are accumulating information to compare manufacturers and better rank their qualities or deficiencies. “This is nice news for KSB as the corporate is committed to delivering excessive reliability and effectivity pumps, so helping to cut back the carbon footprint of mining dewatering operations.
Is there a ‘one-fits-all’ pump solution?
KSB says the answer to this could be a resounding ‘no’, but “by sharing experiences between places of work and also regularly working with the identical international mining corporations, KSB has been able to develop appropriate options. KSB’s involvement in the iron ore industries in Brazil and Australia show 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 problems. To preserve steady production water has to be pumped to a dewatering lake which has a dynamic water degree that should be raised two or 3 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 adjustments within the water level so there isn’t a need for the pumps to be repositioned. This ends in cost-savings to the client. After 20 profitable years it has turn out to be the usual for this type of tools in South America.
“The floating station supporting the pumps over the pontoon delivers the move rate requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, high energy motors and related tools leads to the size of the floating station being elevated. Stabilizing gear that weighs greater than 200 t requires a lot of planning, in addition to the challenge of building a system in such a distant area.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several locations across the Chichester hub zone, an space between 5 and 9 km extensive and eighty km long. เกจวัดแรงดันpsi sits between ninety m and 117 m beneath 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 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, surface dewatering processes are extraordinarily costly if the water may be very excessive.
The accepted dewatering process throughout the region is to pump the water out by way of boreholes. However, this is not with out its challenges. High water temperatures and high salinity result in extreme corrosion, while iron bacteria can develop on motors which forestall efficient motor cooling. The presence of gas is a constant threat in some areas as this causes gasoline lock on the impellers resulting in heavy vibrations, which locations an excellent pressure on the motor, lack of circulate fee and motor failure.
This signifies that standard off-the-shelf products are not all the time appropriate and the incidence of failures is excessive. Typically, most bore pumps fail within 12 months, and generally only some weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to withstand site conditions. Although a costlier product than its rivals, the UPA has been proven to deliver a significantly longer working life and decreased costs of possession. KSB’s proprietary expertise that inhibits the expansion of iron bacteria makes the UPA a winner.
Trailer mounted models
In Africa the surroundings and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, home to several open reduce and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering several completely different pumping solutions involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To forestall 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 produce 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 gear including vacuum pump, control panels, monitors and so forth that delivers high head pumping.”
A similar answer can also be provided for the open solid Moatize coal mine in Mozambique the place the water ranges should remain low for steady production reliability. Whilst borehole pumps provide good reliability on a continuing basis, when the rainy season starts, more assets are in demand KSB SA provides skid-mounted Omega models. To date, KSB SA has supplied 152 items and all are working reliably.
Latin America
In Mexico’s Zacatecas silver mines underground water is a constant downside. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water accommodates stable particles so the high strain encapsulated UPA borehole pumps must be wear-resistant for long term effectivity. Because the dewatering pumps work at a excessive speed, the impellers and the wear and tear ring can suffer from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 standard chrome coating, put on is significantly minimised. “We have had pumps operating in this mine for over two years with out the impellers being changed,” says Roberto Valenzuela. “It is a solution that no competitor presents, and provides value for the client through reduced maintenance, spare elements and greater 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 needed to drive excessive 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, pushed by diesel motors.
“Our clients require high-pressure pumps in a modular configuration that can 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 special configuration for sand filters encased in a stress shroud. This gives the client flexibility and flexibility as a outcome of the gear is compact, develops excessive pressures and is easy to maneuver across the website.
To accommodate increasing flows and discharge pressure pumps are configured in collection and in parallel particularly for the client’s necessities. Being coupled to diesel engines permits steady, autonomous operation in locations with out electricity for between 12 and 24 hours without refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps installed on a raft enabling them to deal with the accumulation of water inside the mine, eliminating components similar to unfavorable suction head at high altitudes. KSB gear for mine drainage is equipped in standard versions, with variations for rafts or nicely pumps put in in pressure jackets. Having viable options for dewatering provides worth to the customers operations and can additionally be important as a result of annually 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 serious player in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their outstanding capability to carry out in severe open pit mine sites. Its development of dewatering and dredge pump sets (DnD), as an answer for mining functions, especially for open-pit mine websites is one instance of KSB’ dedication to steady product enchancment and improvement. To date, greater 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 prospects.
KSB builds the whole diesel pushed pump unit on a barge, full with gasoline tank, vacuum pump, management panel and so on, 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 periods. Recognising this case, KSB has introduced a rental programme, whereby the pumps are supplied 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 once they require items they arrive prepared for operation.
KSB’s mine dewatering methods allow the secure and efficient lowering of groundwater in open pit dewatering, underground drainage and borehole drainage applications. Regardless of a mine’s location, the type of mining operation being carried out, the geological and the aggressive and corrosive nature of the water, KSB has fluid handling applied sciences that can fit all eventualities. This scenario has come about through the cross-fertilisation of concepts, applied sciences and experiences gained over many many years by our companies around the world, supported by extensive investment in analysis and improvement. Wherever a pumping resolution is required, we will deliver a co-ordinated response to the table.

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