Water is current all over the place in mining and its control varies based on its role 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 technologies utilized in pumping water. “Alongside the secure provide and restoration of course of water is the problem of removing floor water. Process water and groundwater contain abrasive and corrosive components in various quantities which have an opposed affect on pump performance and life. Working conditions, distant locations, various temperature ranges and the dearth of electrical power are also highly influential components.”
The copper mines in Chile and the iron ore mines in Western Australia may be many hundreds of miles apart, but these mining operations nonetheless 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 all of them have in widespread is a requirement for efficient and effective water and slurry pumps. Well-matched options help to maximise the longevity and effectivity of the system and in addition optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The changing face of mining
The seek for extra uncommon and precious minerals and metals has opened up mining in nations and locations the place previously the business was small scale or non-existent. Consequently, mining corporations and equipment producers have had to develop new strategies and merchandise. And with the most important mining companies having operations in lots of global locations, becoming a preferred tools supplier is important. “The dewatering market is slowly shifting from a pure CAPEX viewpoint to an more and more OPEX perspective,” reviews Brett Lewis, Mining Manager at KSB Australia. “This is very true for the large mines that understand that poorly designed tools that frequently fails, causes a big improve in alternative and servicing cost. Some mining corporations are actually committing to a carbon impartial goal within the next 20 to 30 years, so are focussing on excessive efficiency tools. They want to phase out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is conscious that mining firms are recording pump efficiency and are accumulating knowledge to check manufacturers and higher rank their qualities or deficiencies. “This is nice information for KSB as the company is dedicated to delivering excessive reliability and efficiency pumps, so helping to minimize 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’, however “by sharing experiences between offices and in addition regularly working with the identical worldwide mining companies, KSB has been in a position to develop applicable options. KSB’s involvement within the iron ore industries in Brazil and Australia reveal two totally different approaches to dewatering, each employing 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 manufacturing water has to be pumped to a dewatering lake which has a dynamic water level that should be raised two or thrice a 12 months. 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 stage so there is no need for the pumps to be repositioned. This ends in cost-savings to the customer. After 20 successful years it has become the usual for this kind of equipment in South America.
“The floating station supporting the pumps over the pontoon delivers the flow price requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive power motors and related tools results in the scale of the floating station being elevated. Stabilizing เกจวัดแรงดันไฟฟ้า that weighs more than 200 t requires a lot of planning, along with the challenge of building 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 places around the Chichester hub zone, an space between 5 and 9 km extensive and 80 km lengthy. The mineral deposit sits between ninety m and 117 m beneath the floor. With the groundwater and water table frequently replenished in wet seasons and cyclones adding to the inundation, greater than 75% of the iron ore is beneath the water desk. If too much water mixes with iron ore, it becomes low grade and unsuitable for export, which leads to massive income losses. Also, surface dewatering processes are extraordinarily expensive if the water is very excessive.
The accepted dewatering process inside the area is to pump the water out by way of boreholes. However, this isn’t without its challenges. High water temperatures and excessive salinity lead to extreme corrosion, while iron bacteria can grow on motors which stop environment friendly motor cooling. The presence of fuel is a continuing threat in some areas as this causes gas lock on the impellers leading to heavy vibrations, which places a great strain on the motor, lack of move fee and motor failure.
This signifies that standard off-the-shelf products are not at all times suitable and the incidence of failures is high. Typically, most bore pumps fail inside 12 months, and generally 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 dearer product than its rivals, the UPA has been shown to ship a significantly longer working life and lowered costs of possession. KSB’s proprietary technology that inhibits the growth of iron bacteria makes the UPA a winner.
Trailer mounted units
In Africa the surroundings and minerals being mined require progressive approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, house to a number of open cut and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering several different pumping options involving both 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 resolution has been to supply Omega pumps mounted on rough terrain trailers. We supply a whole package deal made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear together with vacuum pump, control panels, monitors and so forth that delivers high head pumping.”
A similar resolution can also be provided for the open solid Moatize coal mine in Mozambique where the water ranges must remain low for steady production reliability. Whilst borehole pumps provide good reliability on a relentless basis, when the rainy season begins, more assets are in demand KSB SA provides 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 drawback. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates 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 excessive pace, the impellers and the wear and tear ring can undergo from premature wear. Using Multitec horizontal multistage pumps with KSB’s C6 commonplace chrome coating, wear is greatly minimised. “We have had pumps working on this mine for over two years without the impellers being changed,” says Roberto Valenzuela. “It is a solution that no competitor provides, and provides value for the shopper via lowered maintenance, spare components and higher mining uptime.”
In Chile’s Atacama Desert copper and gold is mined at altitudes ranging between 2,000 m and 4,500 m. Remote websites, mine depths and the unavailability of electrical energy needed to drive high capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and result in environmental pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, driven by diesel motors.
“Our prospects require high-pressure pumps in a modular configuration that may 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 strain shroud. This gives the customer flexibility and versatility because the gear is compact, develops high pressures and is simple to move across the site.
To accommodate increasing flows and discharge strain pumps are configured in sequence and in parallel specifically for the client’s necessities. Being coupled to diesel engines permits 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 elements similar to negative suction head at high altitudes. KSB gear for mine drainage is equipped in normal versions, with variations for rafts or nicely pumps installed in stress jackets. Having viable options for dewatering provides worth to the shoppers operations and can also be important because annually minerals are discovered at deeper levels.
Innovation in Indonesia
Indonesia is considered one of the world’s largest exporters of thermal coal, and likewise a serious player in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their outstanding capability to carry out in extreme open pit mine sites. Its development of dewatering and dredge pump units (DnD), as a solution for mining applications, especially for open-pit mine websites is one instance of KSB’ dedication to continuous product enchancment and development. 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 model new mannequin, the DnD Cruiser with enhancements requested by customers.
KSB builds the entire diesel driven pump unit on a barge, complete with gasoline tank, vacuum pump, control panel and so on, and ships them on trailers for easy commissioning at web site. Because monsoon rains are seasonal dewatering can also be a seasonal exercise and this implies pumps can stand idle for several months during the dry periods. Recognising this case, KSB has launched a rental programme, whereby the pumps are supplied fully-kitted out in accordance with the customer’s necessities. By not having to buy the pump sets, prospects are relieved of the prices of ownership and know that after they require models they come ready for operation.
Summary
KSB’s mine dewatering techniques allow the secure and environment friendly decreasing of groundwater in open pit dewatering, underground drainage and borehole drainage functions. 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 dealing with applied sciences that can match all eventualities. This situation has come about via the cross-fertilisation of ideas, technologies and experiences gained over many many years by our companies around the globe, supported by in depth investment in analysis and improvement. Wherever a pumping answer is required, we will convey a co-ordinated response to the desk.
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