Water is current everywhere in mining and its control varies based on its position within the mining processes. In a current in-depth article by pumps major KSB, the company outlines how this in flip influences the selection of applied sciences utilized in pumping water. “Alongside the safe supply and restoration of process water is the challenge of eradicating floor water. Process water and groundwater comprise abrasive and corrosive elements in various quantities which have an opposed affect on pump performance and life. Working conditions, remote locations, various temperature ranges and the lack of electric power are additionally highly influential factors.”
The copper mines in Chile and the iron ore mines in Western Australia could also be many 1000’s of miles apart, however 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 all of them have in common is a requirement for environment friendly and efficient 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 seek for more rare and treasured minerals and metals has opened up mining in nations and places where beforehand the industry was small scale or non-existent. Consequently, mining corporations and gear producers have needed to develop new strategies and products. And with the main mining companies having operations in plenty of global areas, becoming a most well-liked tools provider is essential. “The dewatering market is slowly shifting from a pure CAPEX perspective to an more and more OPEX perspective,” stories Brett Lewis, Mining Manager at KSB Australia. “This is particularly true for the large mines that understand that poorly designed tools that regularly fails, causes a big enhance in substitute and servicing value. Some mining corporations are actually committing to a carbon neutral goal in the subsequent 20 to 30 years, so are focussing on high efficiency tools. They wish to phase out diesel reliance by connecting most bores to their local electrical grid.”
KSB says it is aware that mining companies are recording pump efficiency and are accumulating information to check manufacturers and higher rank their qualities or deficiencies. “ เกจวัดแรงดันดิจิตอล is good news for KSB as the company is committed to delivering excessive reliability and effectivity 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 answer to this is a resounding ‘no’, but “by sharing experiences between workplaces and likewise frequently working with the same international mining companies, KSB has been able to develop appropriate solutions. KSB’s involvement within the iron ore industries in Brazil and Australia demonstrate two different approaches to dewatering, each using vertical multi-stage pumps.”
In Brazil’s Minas Gerais State open pit iron ore mines excessive floor water, monsoons and underground lakes are issues. To keep continuous manufacturing water needs to be pumped to a dewatering lake which has a dynamic water stage that must be raised two or three times a year. 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 within the water level so there is not a want 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 type 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, excessive power motors and associated gear leads to the size of the floating station being elevated. Stabilizing equipment that weighs greater than 200 t requires plenty of planning, along with 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 quantity of locations across the Chichester hub zone, an space between 5 and 9 km extensive and 80 km lengthy. The mineral deposit sits between 90 m and 117 m beneath the floor. With the groundwater and water table regularly replenished in moist seasons and cyclones adding to the inundation, more than 75% of the iron ore is below the water table. If too much water mixes with iron ore, it turns into low grade and unsuitable for export, which results in large revenue losses. Also, surface dewatering processes are extremely costly if the water is very excessive.
The accepted dewatering course of 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 result in extreme corrosion, while iron bacteria can grow on motors which prevent efficient motor cooling. The presence of gas is a continuing risk in some areas as this causes gas lock on the impellers leading to heavy vibrations, which locations a great strain on the motor, lack of flow rate and motor failure.
This signifies that normal 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 only some weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to withstand web site circumstances. Although a costlier product than its opponents, the UPA has been proven to deliver a significantly longer working life and lowered costs of ownership. KSB’s proprietary expertise that inhibits the expansion of iron micro organism makes the UPA a winner.
Trailer mounted units
In Africa the setting and minerals being mined require innovative approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, residence to a quantity of open cut and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering a quantity of totally different pumping options involving each UPA Z borehole pumps and surface-mounted Omega pumps. “To prevent mining operations from being shut down, a fast localised response is required,” says Rob Bond, Area Manager Mining-Sub-Saharan Africa. “Our solution has been to provide Omega pumps mounted on tough terrain trailers. We provide a complete package deal made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary equipment including vacuum pump, management panels, monitors and so forth that delivers high head pumping.”
A similar answer is also offered for the open solid Moatize coal mine in Mozambique where the water levels must remain low for steady manufacturing reliability. Whilst borehole pumps supply good reliability on a relentless basis, when the rainy season starts, more resources are in demand KSB SA offers skid-mounted Omega models. To date, KSB SA has supplied 152 units 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 ought to be wear-resistant for long run efficiency. Because the dewatering pumps work at a excessive speed, the impellers and the damage ring can endure from untimely put on. Using Multitec horizontal multistage pumps with KSB’s C6 commonplace chrome coating, wear is significantly minimised. “We have had pumps working in this mine for over two years without the impellers being changed,” says Roberto Valenzuela. “It is a solution that no competitor provides, and provides worth for the customer through reduced upkeep, 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 electrical energy wanted to drive excessive capacity 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 prospects require high-pressure pumps in a modular configuration that might 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 particular configuration for sand filters encased in a stress shroud. This provides the customer flexibility and versatility as a result of the gear is compact, develops high pressures and is straightforward to maneuver across the web site.
To accommodate increasing flows and discharge pressure pumps are configured in series and in parallel particularly for the client’s necessities. Being coupled to diesel engines allows continuous, autonomous operation in places with out electricity for between 12 and 24 hours with out refuelling. Vertical Etanorm pumps and cantilever-type UPA pumps put in on a raft enabling them to deal with the buildup of water contained in the mine, eliminating factors similar to adverse suction head at high altitudes. KSB equipment for mine drainage is supplied in standard versions, with variations for rafts or well pumps put in in stress jackets. Having viable options for dewatering provides worth to the shoppers operations and can also be necessary as a result of every year minerals are found at deeper ranges.
Innovation in Indonesia
Indonesia is one of the world’s largest exporters of thermal coal, and in addition a significant participant in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for his or her outstanding capacity to perform in severe open pit mine websites. Its development of dewatering and dredge pump sets (DnD), as a solution for mining purposes, especially for open-pit mine sites is one example of KSB’ commitment to continuous product enchancment and growth. 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 prospects.
KSB builds the complete diesel driven pump unit on a barge, complete with gas tank, vacuum pump, control panel etc, and ships them on trailers for easy commissioning at web site. Because monsoon rains are seasonal dewatering can be a seasonal activity and this means pumps can stand idle for several months through the dry durations. Recognising this example, KSB has introduced 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 units, prospects are relieved of the prices of ownership and know that when they require models they come prepared for operation.
Summary
KSB’s mine dewatering systems enable the secure and efficient reducing 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 may fit all eventualities. This state of affairs has come about by way of the cross-fertilisation of concepts, applied sciences and experiences gained over many many years by our companies around the globe, supported by in depth funding in research and growth. Wherever a pumping solution is required, we will bring a co-ordinated response to the desk.
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