Water is present all over the place in mining and its control varies in accordance with its role within the mining processes. In a latest in-depth article by pumps major KSB, the corporate outlines how this in flip influences the selection of technologies utilized in pumping water. “Alongside the protected supply and restoration of process water is the problem of eradicating ground water. Process water and groundwater include abrasive and corrosive components in varying quantities which have an antagonistic have an effect on on pump efficiency and life. Working situations, remote places, various temperature ranges and the lack of electrical energy are additionally extremely influential components.”
The copper mines in Chile and the iron ore mines in Western Australia may be many 1000’s of miles aside, however these mining operations nonetheless 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 all of them have in widespread is a requirement for efficient and efficient water and slurry pumps. Well-matched solutions help to maximise the longevity and effectivity 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 uncommon and valuable minerals and metals has opened up mining in countries and areas the place previously the trade was small scale or non-existent. Consequently, mining firms and tools manufacturers have needed to develop new strategies and products. And with the main mining firms having operations in lots of global places, becoming a most well-liked gear supplier is crucial. “The dewatering market is slowly shifting from a pure CAPEX viewpoint to an more and more OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is especially true for the large mines that notice that poorly designed equipment that often fails, causes a major increase in substitute and servicing cost. Some mining companies at the moment are committing to a carbon impartial target in the subsequent 20 to 30 years, so are focussing on high effectivity gear. They wish to section out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it’s aware that mining companies are recording pump performance and are accumulating information to match manufacturers and higher rank their qualities or deficiencies. “This is nice news for KSB as the company is committed to delivering excessive reliability and efficiency 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 may be a resounding ‘no’, however “by sharing experiences between workplaces and likewise regularly working with the same worldwide mining corporations, KSB has been in a position to develop applicable solutions. KSB’ เกจ์แรงดัน within the iron ore industries in Brazil and Australia reveal two completely different approaches to dewatering, both employing vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines excessive floor water, monsoons and underground lakes are problems. To maintain continuous manufacturing water must be pumped to a dewatering lake which has a dynamic water level that should be raised two or three times a 12 months. KSB Brazil’s resolution 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 stage so there isn’t a want for the pumps to be repositioned. This leads to cost-savings to the client. After 20 profitable 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 circulate fee requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive power motors and related gear ends in the dimensions of the floating station being elevated. Stabilizing gear that weighs greater than 200 t requires plenty of planning, in addition to the challenge of building a system in such a remote space.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in a number of areas across the Chichester hub zone, an area between 5 and 9 km extensive and 80 km long. The mineral deposit sits between 90 m and 117 m beneath the surface. With the groundwater and water desk frequently replenished in moist seasons and cyclones including to the inundation, more than 75% of the iron ore is beneath the water desk. If an extreme amount of water mixes with iron ore, it turns into low grade and unsuitable for export, which outcomes in massive income losses. Also, surface dewatering processes are extremely expensive if the water may be very excessive.
The accepted dewatering process throughout the area 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 bacteria can grow on motors which forestall efficient motor cooling. The presence of fuel is a continuing threat in some areas as this causes fuel lock on the impellers resulting in heavy vibrations, which places a great strain on the motor, loss of circulate rate and motor failure.
This means that commonplace off-the-shelf products aren’t all the time appropriate and the incidence of failures is high. Typically, most bore pumps fail within 12 months, and sometimes only some weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to withstand website situations. Although a dearer product than its competitors, the UPA has been proven to deliver a considerably longer working life and reduced prices of possession. KSB’s proprietary expertise that inhibits the expansion of iron micro organism makes the UPA a winner.
Trailer mounted models
In Africa the surroundings and minerals being mined require progressive approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to several open reduce and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering several different pumping options involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To stop mining operations from being shut down, a quick localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our answer has been to provide Omega pumps mounted on tough terrain trailers. We provide a whole package deal made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary tools together with vacuum pump, control panels, displays and so on that delivers excessive head pumping.”
A similar answer can also be supplied for the open cast Moatize coal mine in Mozambique the place the water levels must stay low for continuous manufacturing reliability. Whilst borehole pumps offer good reliability on a constant foundation, when the rainy season starts, more assets are in demand KSB SA supplies skid-mounted Omega units. 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 problem. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water accommodates strong particles so the excessive pressure encapsulated UPA borehole pumps must be wear-resistant for long run effectivity. Because the dewatering pumps work at a high velocity, the impellers and the wear and tear ring can suffer from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 commonplace chrome coating, put on is significantly minimised. “We have had pumps running in this mine for over two years without the impellers being changed,” says Roberto Valenzuela. “It is an answer that no competitor offers, and provides value for the shopper via decreased 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 websites, mine depths and the unavailability of electricity wanted to drive excessive capability pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and result in 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 can be moved with the enlargement of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The solution is to make use of horizontally positioned borehole pumps with a particular configuration for sand filters encased in a stress shroud. This offers the customer flexibility and flexibility as a outcome of the tools is compact, develops excessive pressures and is straightforward to move across the web site.
To accommodate growing flows and discharge stress pumps are configured in sequence and in parallel particularly for the client’s necessities. Being coupled to diesel engines permits steady, autonomous operation in locations without electrical energy for between 12 and 24 hours with out refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps installed on a raft enabling them to handle the buildup of water contained in the mine, eliminating components corresponding to negative suction head at high altitudes. KSB gear for mine drainage is provided in standard variations, with variations for rafts or properly pumps put in in strain jackets. Having viable solutions for dewatering provides value to the purchasers operations and is also important as a end result of annually minerals are discovered at deeper levels.
Innovation in Indonesia
Indonesia is likely considered one of the world’s largest exporters of thermal coal, and in addition a serious participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her outstanding capability to carry out in extreme open pit mine sites. Its growth of dewatering and dredge pump sets (DnD), as an answer for mining applications, especially for open-pit mine sites is one instance of KSB’ commitment to steady product improvement 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 brand new model, the DnD Cruiser with enhancements requested by customers.
KSB builds the complete diesel pushed pump unit on a barge, full with gas tank, vacuum pump, control panel etc, and ships them on trailers for simple commissioning at website. Because monsoon rains are seasonal dewatering is also a seasonal activity and this means pumps can stand idle for several months through the dry intervals. Recognising this case, 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 units, clients are relieved of the prices of possession and know that once they require items they arrive prepared for operation.
Summary
KSB’s mine dewatering methods allow the safe and efficient 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 scenario has come about by way of the cross-fertilisation of ideas, applied sciences and experiences gained over many a long time by our corporations around the globe, supported by intensive investment in research and development. Wherever a pumping answer is required, we are in a position to bring a co-ordinated response to the table.
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