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 major KSB, the company outlines how this in turn influences the number of applied sciences used in pumping water. “Alongside the protected provide and restoration of course of water is the problem of removing ground water. Process water and groundwater comprise abrasive and corrosive elements in varying quantities which have an adverse have an effect on on pump efficiency and life. Working situations, distant places, various temperature ranges and the dearth of electrical energy are also extremely influential factors.”

The copper mines in Chile and the iron ore mines in Western Australia could additionally be many hundreds of miles apart, but these mining operations nonetheless require dewatering and the protected disposal of probably contaminated water. “The identical can be stated of the coal mines of Mozambique and the silver mines of Mexico. What they all have in widespread is a requirement for efficient and efficient water and slurry pumps. Well-matched options assist to maximize the longevity and effectivity of the system and likewise optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”

The changing face of mining

The seek for more uncommon and treasured minerals and metals has opened up mining in international locations and areas where previously the industry was small scale or non-existent. Consequently, mining firms and tools producers have needed to develop new strategies and merchandise. And with the most important mining firms having operations in lots of world areas, changing into a most well-liked tools supplier is crucial. “The dewatering market is slowly shifting from a pure CAPEX point of view to an more and more OPEX perspective,” reports Brett Lewis, Mining Manager at KSB Australia. “This is very true for the big mines that notice that poorly designed tools that often fails, causes a major increase in replacement and servicing value. Some mining corporations are now committing to a carbon neutral goal in the next 20 to 30 years, so are focussing on high efficiency gear. They want to part out diesel reliance by connecting most bores to their native electrical grid.”

KSB says it’s aware that mining firms are recording pump performance and are accumulating knowledge to check brands and higher rank their qualities or deficiencies. “This is nice information for KSB as the corporate is dedicated 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 it is a resounding ‘no’, but “by sharing experiences between workplaces and in addition frequently working with the same international mining firms, KSB has been capable of develop acceptable options. KSB’s involvement within the iron ore industries in Brazil and Australia demonstrate two completely 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 keep continuous production water has to be pumped to a dewatering lake which has a dynamic water stage that must be raised two or 3 times a year. 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 changes in the water stage so there is not a want for the pumps to be repositioned. This results in cost-savings to the customer. After 20 profitable years it has become the usual for this kind of tools in South America.
“The floating station supporting the pumps over the pontoon delivers the move price requested by the customer,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, high energy motors and associated gear leads to the scale of the floating station being elevated. Stabilizing equipment that weighs greater than 200 t requires lots of planning, along with the challenge of building 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 locations across the Chichester hub zone, an area between 5 and 9 km broad and eighty km long. The mineral deposit sits between 90 m and 117 m below the floor. With the groundwater and water desk 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 amount of water mixes with iron ore, it turns into low grade and unsuitable for export, which results in massive revenue losses. Also, floor dewatering processes are extremely pricey if the water could be very excessive.
The accepted dewatering course of inside the region is to pump the water out by way of boreholes. However, this is not with out its challenges. High water temperatures and excessive salinity result in excessive corrosion, while iron bacteria can develop on motors which prevent efficient motor cooling. The presence of fuel is a continuing menace in some areas as this causes fuel lock on the impellers resulting in heavy vibrations, which places an excellent strain on the motor, loss of flow price and motor failure.
This means that commonplace off-the-shelf products are not at all times suitable and the incidence of failures is excessive. Typically, most bore pumps fail inside 12 months, and sometimes just a few weeks. At its Hope Valley facility in Western Australia, KSB supplies mine operators with its UPA multistage borehole pump, customised to resist website situations. Although a more expensive product than its competitors, the UPA has been proven to ship a considerably longer working life and reduced costs of possession. KSB’s proprietary expertise that inhibits the growth of iron bacteria makes the UPA a winner.
Trailer mounted units

In Africa the setting and minerals being mined require progressive approaches to dewatering. In pressure gauge ไฮ ด รอ ลิ ค of the Democratic Republic of Congo, house to several open minimize and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering a number of completely different pumping solutions involving each 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 produce 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, screens and so on that delivers high head pumping.”

A comparable answer can be offered for the open cast 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 wet season starts, more resources are in demand KSB SA supplies skid-mounted Omega models. 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 drawback. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water accommodates stable particles so the excessive strain encapsulated UPA borehole pumps ought to be wear-resistant for long term effectivity. Because the dewatering pumps work at a excessive speed, the impellers and the damage ring can suffer from untimely wear. Using Multitec horizontal multistage pumps with KSB’s C6 normal chrome coating, put on is significantly minimised. “We have had pumps running in this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “It is a solution that no competitor offers, and provides value for the shopper via lowered upkeep, spare components and larger 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 electricity needed to drive excessive capacity pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and lead to 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 can be moved with the enlargement of the open pit,” comments Patricio Araya, Mining Head KSB Chile. “The answer is to make use of horizontally positioned borehole pumps with a special configuration for sand filters encased in a strain shroud. This provides the customer flexibility and flexibility as a result of the equipment is compact, develops high pressures and is straightforward to move across the site.
To accommodate increasing flows and discharge strain pumps are configured in collection and in parallel particularly for the client’s necessities. Being coupled to diesel engines allows continuous, autonomous operation in places without electrical energy 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 contained in the mine, eliminating components such as negative suction head at excessive altitudes. KSB tools for mine drainage is provided in normal variations, with variations for rafts or properly pumps put in in stress jackets. Having viable options for dewatering provides worth to the customers operations and is also essential as a result of annually minerals are found at deeper ranges.
Innovation in Indonesia

Indonesia is certainly one of the world’s largest exporters of thermal coal, and likewise a significant participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their excellent capability to perform in extreme open pit mine websites. Its development of dewatering and dredge pump units (DnD), as an answer for mining functions, especially for open-pit mine websites is one instance of KSB’ dedication to steady product improvement and growth. To date, greater than 260 DnD pumps with GWI® LCC and LSA pumps have been put in in mines throughout Indonesia and South East Asia. In 2013, KSB Indonesia launched a model new mannequin, the DnD Cruiser with enhancements requested by clients.
KSB builds the complete diesel driven pump unit on a barge, full with gasoline tank, vacuum pump, management panel etc, and ships them on trailers for easy commissioning at website. Because monsoon rains are seasonal dewatering can be a seasonal exercise and this means pumps can stand idle for several months in the course of the dry durations. Recognising this situation, KSB has introduced a rental programme, whereby the pumps are provided fully-kitted out based on the customer’s necessities. By not having to purchase the pump sets, customers are relieved of the prices of ownership and know that when they require units they arrive prepared for operation.

KSB’s mine dewatering systems enable the protected and efficient reducing of groundwater in open pit dewatering, underground drainage and borehole drainage functions. Regardless of a mine’s location, the sort of mining operation being carried out, the geological and the aggressive and corrosive nature of the water, KSB has fluid handling technologies that may fit all eventualities. This state of affairs has come about via the cross-fertilisation of concepts, technologies and experiences gained over many a long time by our firms around the globe, supported by extensive investment in analysis and development. Wherever a pumping resolution is required, we can bring a co-ordinated response to the table.

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