Water is current all over the place in mining and its control varies according to its function within the mining processes. In a recent in-depth article by pumps main KSB, the corporate outlines how this in turn influences the choice of applied sciences utilized in pumping water. “Alongside the protected provide and restoration of process water is the problem of removing floor water. Process water and groundwater contain abrasive and corrosive parts in various quantities which have an opposed have an result on on pump efficiency and life. Working circumstances, remote locations, various temperature ranges and the shortage of electric power 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 apart, 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 they all 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 also optimise cost-performance ratios, all attributes fulfilled by KSB’s Hard Rock Mining Division.”
The altering face of mining
The seek for extra uncommon and treasured minerals and metals has opened up mining in international locations and areas the place previously the business was small scale or non-existent. Consequently, mining firms and tools producers have had to develop new techniques and products. And with เกจแรงดันน้ำ mining firms having operations in plenty of global places, changing into a most popular gear supplier is important. “The dewatering market is slowly shifting from a pure CAPEX point of view to an increasingly OPEX perspective,” stories Brett Lewis, Mining Manager at KSB Australia. “This is especially true for the large mines that understand that poorly designed gear that often fails, causes a major increase in alternative and servicing cost. Some mining corporations are now committing to a carbon neutral goal in the subsequent 20 to 30 years, so are focussing on high effectivity tools. 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 data to check brands and higher rank their qualities or deficiencies. “This is sweet news for KSB as the company is dedicated to delivering high reliability and effectivity pumps, so serving to to minimize back the carbon footprint of mining dewatering operations.
Is there a ‘one-fits-all’ pump solution?
KSB says the reply to this is a resounding ‘no’, but “by sharing experiences between places of work and also regularly working with the identical international mining corporations, KSB has been in a place to develop appropriate options. KSB’s involvement within the iron ore industries in Brazil and Australia show two totally 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 keep continuous production water needs to be pumped to a dewatering lake which has a dynamic water stage that should be raised two or 3 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 changes within the water stage so there is not any want for the pumps to be repositioned. This ends in cost-savings to the shopper. After 20 profitable years it has turn into the standard for this type of gear in South America.
“The floating station supporting the pumps over the pontoon delivers the circulate fee requested by the shopper,” explains Jardel Ribeiro, Sales Manager, KSB Brazil. “Sometimes the pumps, excessive energy motors and associated gear leads to the size of the floating station being increased. Stabilizing equipment that weighs more than 200 t requires a lot of planning, along with the problem of constructing a system in such a distant area.”
Boreholes in Australia
In the Pilbara Region of Western Australia iron ore is mined in several locations around the Chichester hub zone, an area between 5 and 9 km broad and 80 km lengthy. The mineral deposit sits between 90 m and 117 m under the surface. With the groundwater and water table frequently replenished in moist seasons and cyclones adding to the inundation, more than 75% of the iron ore is under the water desk. If an extreme amount of water mixes with iron ore, it becomes low grade and unsuitable for export, which ends up in massive revenue losses. Also, surface dewatering processes are extremely expensive if the water is very high.
The accepted dewatering process within the region is to pump the water out through boreholes. However, this isn’t without its challenges. High water temperatures and excessive salinity end in excessive corrosion, while iron bacteria can grow on motors which stop environment friendly motor cooling. The presence of gas is a continuing risk in some areas as this causes fuel lock on the impellers leading to heavy vibrations, which locations a great pressure on the motor, loss of move rate and motor failure.
This signifies that standard off-the-shelf merchandise aren’t at all times appropriate and the incidence of failures is excessive. Typically, most bore pumps fail within 12 months, and typically just a few weeks. At its Hope Valley facility in Western Australia, KSB offers mine operators with its UPA multistage borehole pump, customised to resist web site conditions. Although a dearer product than its competitors, the UPA has been shown to ship a considerably longer working life and reduced prices of possession. KSB’s proprietary expertise that inhibits the expansion of iron bacteria makes the UPA a winner.
Trailer mounted items
In Africa the environment and minerals being mined require revolutionary approaches to dewatering. In the Katanga Province of the Democratic Republic of Congo, home to a quantity of open minimize and underground copper mines wet seasons wreak flooding havoc. Here, KSB is delivering a number of completely 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 answer has been to produce Omega pumps mounted on rough terrain trailers. We supply a whole package made up of the pump, engine/motor, couplings, gearbox, hydraulic drives and auxiliary gear including vacuum pump, control panels, displays etc that delivers high head pumping.”
A comparable resolution is also provided for the open solid Moatize coal mine in Mozambique the place the water ranges should remain low for continuous production reliability. Whilst borehole pumps provide good reliability on a continuing foundation, when the wet season begins, extra assets are in demand KSB SA provides skid-mounted Omega units. To date, KSB SA has provided 152 items and all are working reliably.
Latin America
In Mexico’s Zacatecas silver mines underground water is a constant problem. According to Roberto Valenzuela, Sales Manager Mining KSB Mexico, the water incorporates solid particles so the high pressure encapsulated UPA borehole pumps should be wear-resistant for long run efficiency. Because the dewatering pumps work at a high speed, the impellers and the wear ring can undergo from untimely wear. Using Multitec horizontal multistage pumps with KSB’s C6 standard chrome coating, wear is tremendously minimised. “We have had pumps running on this mine for over two years with out the impellers being modified,” says Roberto Valenzuela. “It is an answer that no competitor provides, and provides worth for the shopper through lowered maintenance, spare parts and higher 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 electrical energy needed to drive excessive capability pumps complicate dewatering. High volumes of water contaminated by minerals can delay drilling and blasting and end in environmental pollution. KSB Chile has met these challenges by supplying encapsulated borehole pumps and cantilevered Etanorm pumps, driven by diesel motors.
“Our customers require high-pressure pumps in a modular configuration that may be moved with the enlargement of the open pit,” feedback Patricio Araya, Mining Head KSB Chile. “The answer is to use horizontally positioned borehole pumps with a particular configuration for sand filters encased in a pressure shroud. This gives the client flexibility and versatility as a result of the gear is compact, develops high pressures and is simple to maneuver across the website.
To accommodate rising 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 electrical energy 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 inside the mine, eliminating components similar to adverse suction head at high altitudes. KSB gear for mine drainage is supplied in commonplace variations, with variations for rafts or nicely pumps installed in pressure jackets. Having viable options for dewatering provides worth to the purchasers operations and can also be essential as a end result of annually minerals are discovered at deeper ranges.
Innovation in Indonesia
Indonesia is likely certainly one of the world’s largest exporters of thermal coal, and also a significant player in copper, gold, tin, bauxite, and nickel. Here KSB pumps are acknowledged for their excellent capability to carry out in severe open pit mine websites. Its development of dewatering and dredge pump sets (DnD), as an answer for mining functions, particularly for open-pit mine websites is one example of KSB’ dedication to steady product enchancment 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 new mannequin, the DnD Cruiser with enhancements requested by customers.
KSB builds the complete diesel pushed 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 is also a seasonal exercise and this implies pumps can stand idle for a number of months in the course of the dry periods. Recognising this example, KSB has introduced a rental programme, whereby the pumps are provided fully-kitted out based on the customer’s requirements. By not having to buy the pump units, clients are relieved of the prices of possession and know that when they require units they come ready for operation.
Summary
KSB’s mine dewatering methods enable the protected and efficient reducing of groundwater in open pit dewatering, underground drainage and borehole drainage purposes. 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 technologies that can fit all eventualities. This situation has come about through the cross-fertilisation of ideas, technologies and experiences gained over many a long time by our firms all over the world, supported by extensive funding in analysis and development. Wherever a pumping resolution is required, we can convey a co-ordinated response to the desk.
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