Tag Archives: mining pumps

Watson-Marlow brings higher flows to Qdos pump offering

Environmental, Mining services, Water management, , ,

Watson-Marlow Fluid Technology Solutions (WMFTS) has launched the Qdos™ H-FLO chemical metering and dosing pump, designed specifically for higher flow rates up to 600 litres per hour.

Qdos H-FLO delivers the same outstanding accuracy and reliability as other Qdos pumps but for higher flow rates with a variety of pumpheads and a range of different tube material to ensure chemical compatibility with the process fluid, the company claims. It offers flexibility to be scalable with a customer’s process, whether it is in water and wastewater treatment, mining and mineral processing, chemical applications in food and beverage or pulp and paper.

The release of Qdos H-FLO enhances the range of Qdos pumps by offering flow rates up to 600 l/h and pressure capability up to 7 bar (102 psi). The pump also comes with RFID Pumphead detection to ensure confirmation of correct pumphead; a revolution counter for pumphead service maintenance; leak detection and fluid containment to prevent spills and chemical exposure upon pumphead expiry; network integration, control and communication options include EtherNet/IP, PROFINET and PROFIBUS for easy integration with SCADA/PLC; and one common pump drive with several pumphead options for changing process conditions and chemistries.

Like the rest of the Qdos range of peristaltic pumps, Qdos H-FLO cuts costs through higher precision chemical metering, with an accuracy of ±1% and repeatability of ±0.5% in dosing, WMFTS says.

Applications for the pump include flocculants, acids/alkalis and mining reagents.

Adeel Hassan, Product Manager at WMFTS, said: “The high accuracy and repeatability of our pumps helps to achieve cost savings in chemical usage which also assists our customers in their journey towards net-zero targets. While the pump has inherited unique features from the current Qdos range, it also brings several new-to-market features to make chemical dosing simpler, safer and cost-effective.

“Customer feedback has been a fundamental driver in developing Qdos for higher flow rate applications. Qdos H-FLO aims to make chemical dosing simpler and efficient for operations, maintenance and EHS teams. It offers several onboard communication options for SCADA and PLC integration to achieve process optimisation.”

The Qdos H-FLO is supported with an optional pressure sensing kit that provides real-time pressure monitoring, which ensures process security and improves safety. The optional pressure sensing kit comes with configurable alarms for process monitoring.

Sykes Group boosts mine dewatering capabilities with XH250 pump

Environmental, Mine shafts and equipment, Mining equipment, Mining services, Water management, , , , ,

Sykes Group, a leading name in the realm of dewatering pump solutions, has launched its latest innovation, the Sykes/Primax XH250 for mining and quarry applications.

The XH250 is set to revolutionise dewatering operations in these sectors, offering a reliable solution for operations that are continually expanding, reaching greater depths and widths.

The pump, which complements Sykes’ existing range of Extra High Head pumps, delivers higher heads and flow rates than its predecessors to ensure consistent equipment access to all areas of mining and quarry sites, the company says.

Key features of the Sykes XH250 as stated by the company include:

  • Versatile drive options: The XH250 is available in both diesel- and electric-drive configurations, and it can be mounted on skids, trailers, or pontoons;
  • Impressive performance: The XH250 is engineered to deliver 200 litres/second at 220 m or 250 litres/second at 200 m, ensuring reliable and efficient dewatering;
  • Innovative pump design: The pump’s design incorporates several key features to enhance its longevity and performance, including extraordinary shaft stiffness ratios, multiple priming options, advanced bearing arrangements and exceptional sealing solutions;
  • Front and rear wear plates: Sykes Pumps’ inclusion of wear plates offers the ability to make fine adjustments to the impeller-wear plate clearance, enabling customers to restore pump efficiency without the need for extensive overhauls;
  • Material options: the Sykes XH250 is available with various material options to suit specific applications, including 316 SS Impeller, wear plates, and SG iron Volute, among others. Other options are Full 316 SS, CS340, CS500, CD4MCU, H7A SS, CD4MCU, SAF2205 and SAF2507.

The company concluded: “The Sykes XH250 is a testament to our commitment to providing efficient and reliable dewatering solutions for the mining and quarry industries.”

Sykes Group became part of the Atlas Copco Group Power and Flow Division this month.

Leveraging electric heat-trace cables to prevent freezing pipes and pipelines

Environmental, Equipment maintenance, Mineral processing, Mining equipment, Mining safety, Water management, , , , , , ,

Feeding water into a mine, the dewatering of groundwater out of it, and the recycling of used water all depend upon a network of reliable piping systems able to withstand mining’s extreme environments, whether the mine is underground or on the surface.

In remote areas such as Alaska or northwest Canada, pipes carrying water, slurry, tailings, chemicals or other liquids can be subjected to dangerously cold temperatures. Unprotected pipes can easily freeze in this cold, expand and then burst, no matter how strong the material they’re made of. A freeze can also result in ice blockages in pipes that cripple production, according to Matthew Gurreri and Kevin Green* write.

One burst or blocked pipe can bring an entire mining operation to a halt, resulting in punishing financial losses. In addition, lives can be put in jeopardy by the depressurising of fire suppression systems, for instance, or by the flooding of tunnels. Another issue is the environment. Leaks of contaminated water containing heavy metals like copper, lead and arsenic may spill into nearby waterways creating an ecological disaster. The high cost of downtime stemming from a frozen or blocked pipe can be exacerbated by a lack of on-site replacement parts. Icy roads are often impassable in winter, leaving delivery of replacement parts limited to cargo planes or sea lifts. Logistics can become extremely complicated, as well as expensive, in remote arctic locations.

Besides water, most air-filled lines operating inside or outside a mine can freeze, even at temperatures as warm as 40° F. As air pressure drops from 100 psi down to atmosphere, the compressed air, which is always at 100% humidity, super cools rapidly and can freeze up lines and seriously damage mining equipment.

The importance of preventing water pipes and air-filled lines from freezing cannot be overstated. Water is involved at every stage in production: mining, downstream processing and product conveyance. Large quantities of water are also used for cooling the cutting edges of machinery, heap leaching, dust suppression, general cleaning, fire sprinklers and fresh drinking water. Air-filled lines are needed to supply critical power to pneumatic tools and mining equipment.

Protecting pipes

Pipes installed in mining operations are made of materials appropriate to the duty required. Steel pipes are the industry standard. However, lightweight, corrosion-resistant and lower cost plastic pipes, such as HDPE and PE, are increasingly being deployed. Pipes are hung by chains from brackets typically attached to roof bolts.

Along with the threats posed by harsh weather conditions, pipes installed in mines must withstand high external loads and surges in pressure, exposure to corrosive chemicals and abrasive slurries, steam purging, caustic acids and accidental damage by moving equipment – all of which can weaken the pipe structure and make it more susceptible to bursting in a freeze. Hairline cracks could develop, causing leakage, and eventually break.

Explosion risks

Statistics from the Mine Safety and Health Administration (MSHA) indicate that mine explosions occur most often during colder months because of low barometric pressure and low humidity. In cold weather, coal dust can be dangerously suspended in dry cold atmospheres, increasing the hazard of explosion. Low barometric pressures help methane spread easily into active areas, further heightening the risk of explosion. All it takes is a spark from an electrical device, including the switching “on” and “off” of a non-rated heat-trace cable, to ignite a disaster in a classified area containing explosive dust or gases. A lower-quality, malfunctioning heat trace cable can also generate enough heat to set off an explosion in a hazardous location.

Heating cables must be certified for the hazardous location where they are installed. Period. It is extremely dangerous to trust the future of a mine and the lives of its employees to offshore heating cables that may or may not be engineered to the certifications they claim to carry.

Long-distance applications

Mining requires long pipelines and consequently, equally long heat-tracing applications both for freeze protection or for viscosity control and temperature maintenance. Measuring from a few hundred yards to several miles, long distance systems are typically custom engineered. Many variables must be taken into consideration to achieve the most reliable solution for the targeted distance, including factors like self-regulating or constant wattage, supply voltage, minimum temperature at start-up, circuit breaker amperage, pipe diameter, and wire gauge, among many others. In determining heating cable length, the pipe length must be added to the junction box entry and end seal, the number of flanges, and the size and number of valves.

Fire suppression in mines

Ice blockage hinders the suppression abilities of a fire sprinkler system and can break pipes altogether. Frozen sprinkler pipes are dangerous in a commercial building, of course, but can amount to even a greater risk in a mine. In the event of an underground mine fire, it is critical to extinguish the fire in its early stages. Any delay in initiating firefighting activities can result in an uncontrolled fire. Unfortunately, just as sprinkler pipes can freeze, so can the mine’s underground fire hydrants, fire water hoses and surface water storage tanks. All need freeze protection.

Often a sprinkler pipe doesn’t freeze completely. Instead, the water will freeze, thaw and freeze again when exposed to low temperatures. This phenomenon applies added stress to the pipe. Even if a pipe thaws out after a freezing event and appears stable, its integrity is compromised. Hairline cracks can be subtle and difficult to locate until too late.

A frozen pipe in a mine can be dangerous, even deadly.

For instance, in December 2004, a heavy equipment operator in a Kentucky mine was fatally injured while he was trying to dislodge frozen slurry from a slurry pipeline that had iced over.

In 2012 at an oil sands project, about 60 km south of Fort McMurray, Alberta, Canada, a worker was in the process of steaming a frozen pipe when a section of the pipe ruptured, striking the worker in the leg. The 62-year-old worker was transported to a hospital in nearby Lac La Biche where he passed away.

More commonthan these issues is frozen water in pipes that lead to crippling issues ranging from improper functioning of equipment and premature parts failure all the way to more costly damage caused by freeze-and-thaw issues or thermal shock.

Electric heat-trace cables will prevent water, compressed air, slurry and other liquids from freezing in pipes and lines, protecting your property, people and profits.

*Matthew Gurreri is Product Marketing Manager, Emerson Automation Systems, and Kevin Green is National Sales Manager, Emerson Automation Systems

Xylem boosts hydraulic efficiency of mine dewatering pumps with Godwin HL270M

Environmental, Mining equipment, Water management, , , , , ,

Global water technology company Xylem has released a new dewatering pump developed to, it says, significantly increase efficiency, cut costs, and minimise downtime for construction and mining customers.

Designed to meet the demands of deep-mine and high-pressure water transfers, the Godwin HL270M Dri-Prime® Pump can deliver cost savings of up to 10% when compared with competing solutions, according to Xylem.

With greater hydraulic efficiency and optimised head and flow, it reduces the need for multiple pumps in series, lowers energy consumption, simplifies operations and maintenance, and minimises premature wear, the company says. Field test participants have already used the pump to meet project goals with fewer assets, simpler operations and reduced maintenance costs, it added.

The solution, part of the Godwin Ultrahigh-head range, also enables operators to lower their carbon emissions, the company claims.

“Meeting the evolving needs of our customers is paramount,” Mike Ramos, Global Product Manager at Xylem, said. “The Godwin HL270M meets the unique demands of deep-mine and high-pressure water transfers. It allows our customers to go deeper and further while making operations more efficient, sustainable, and safe.”

“This product is also a great example of sustainable business being smart business. The pump uses less power, reduces the need for multiple pumps, minimises premature wear and offers longer life between repairs.”

With leading higher head and higher-pressure capabilities, the HL270M has delivered immediate and significant benefits during customer trials, Xylem said.

“The new Godwin HL270M Dri-Prime Pump is already proving to be durable and reliable in the field,” Jon Craig, Application Engineer at Xylem, said. “One of our customers was facing the challenge of transferring water through an existing pipeline covering seven miles (11.3 km). Ordinarily this would require using multiple pumps in series, making it an ideal fit for the HL270M. During subsequent testing, the pump has operated seamlessly for more than 1,400 hours and delivered significant operational efficiencies.”

The Godwin HL270M delivers a maximum head of 300 m and flows of up to 280 liters per second, Xylem said. It also delivers hydraulic efficiency of up to 70% through its enclosed impeller.

With extensive application flexibility, the product also handles a variety of fluids and liquids, including solids up to 30 mm in diameter.

Available in both diesel and electric drive packages, it will also be offered as a retrofit package for installation on existing customer-owned pumps. All Godwin portable pumps, Xylem says, are available with standard engines and motors compliant with regional emissions and efficiency legislation.

The pump is available with two standard material options – all duplex stainless steel as the primary offering and an option for cast steel pump casing paired with a duplex stainless-steel impeller.

RMI on testing mining pump reliability

Mining equipment, Mining services, Water management, , , ,

Mines and industry rely on critical high pressure pump technology to keep operations safe and efficient, which makes rigorous testing of this equipment an essential part of the manufacturing process.

According to Kathryn Poke, Director of Engineering at RMI Pressure Systems, dedicated test cells in the company’s Manchester (UK) production facility support a range of technical tests to ensure final product quality.

RMI Pressure Systems specialises in the design, manufacture and application of high-pressure reciprocating pumps to global longwall mining and industrial applications. It has more than a hundred years of experience designing, manufacturing and supporting this technology, the company says. On top of a primary manufacturing facility in the UK, the company has operations in China, the US, India and Australia – supporting equipment in countries around the globe.

Poke said RMI Pressure Systems’ quality and testing regime means new equipment and components can be put through as much as two million pump cycles – over periods of up to 160 hours – to prove their integrity.

“In robust and continuous applications, such as longwall coal mining, our customers rely on our high-pressure reciprocating pumps to deliver optimal uptime and safety,” she said. “Similarly, our steel industry customers look for quality and reliability in de-scaling and forging applications.”

In these demanding and often hazardous environments, pump pressures can reach 350 to 400 bar – making any leaks or defects potentially disastrous.

She highlighted that RMI Pressure Systems’ meticulous testing regime has been critical in building the company’s quality reputation for over a century.

“Before delivery, all of our equipment is put through its paces in our test cells,” Poke explained. “These well-resourced facilities measure and record temperatures, pressures, speeds and other indicators – generating data that is carefully reviewed and analysed by our engineering team.”

The test cells run alongside the company’s manufacturing processes, which are accredited in terms ISO9001 quality standards. This ensures extended periods of testing do not compromise RMI’s production rates, with the test facility able to accommodate three RMI high pressure pumps at a time.

“This means that our customers are confident RMI equipment is ready to go when it is installed and commissioned on site,” Poke said. “There is no run-in time or bedding down to be done, so the pumps’ contribution to productivity and uptime will be immediate.”

RMI’s manufacturing quality is enhanced by its careful selection of suppliers and components – items that are also subject to cycle testing to ensure a quality finished product.

Atlas Copco releases latest WEDA D electric submersible dewatering pump

Mining equipment, Mining services, Water management, , , , ,

Atlas Copco Power and Flow has launched a next-generation electric submersible dewatering pump, the WEDA D95, incorporating what it says is state-of-the-art Wear Deflector Technology (WDT).

The robust and reliable pump delivers best-in-class performance over a longer lifetime than comparable pumps in heavily-abrasive environments such as mining, tunnelling and construction, and enables operators to improve their sustainability and productivity, according to the company.

WEDA D95 has a power rating of 37-43 kW and is the latest pump in the WEDA D drainage range to feature the WDT designed to minimise wear and provide consistent performance over a longer operating life. Features such as a high chrome wear resistant impeller combined with solid-redirecting auxiliary vanes contribute towards its exceptional performance, Atlas Copco says. The pump also features re-adjustable hydraulics, which allow it to be simply realigned to compensate for any wear, thus prolonging its life. All these elements have a significant positive impact on the overall operational productivity, meaning users can achieve a lower total cost of ownership.

Bart Duijvelaar, Product Marketing Manager – Submersible pumps at Atlas Copco Power and Flow, said: “There are often many suspended solids in harsh applications which can cause excessive abrasion and wear to the internal workings of the pump. At Atlas Copco, we are driven by innovation, and so we have taken the fundamental design of the drainage pump back to the drawing board. We have optimised the hydraulic design using Computational Fluid Dynamics and applied 21st century manufacturing techniques combined with decades of experience to produce this new long-lasting and reliable pump.”

The pump has also been built with maintenance and serviceability front of mind. The design allows users to carry out inspection and maintenance on site themselves and reduce downtime and associated costs. For example, the mechanical seal is a unique stainless-steel single cartridge, rather than many separate components, and so it is easy to replace in one piece, according to the company.

The WEDA D95 also features external oil inspection screws. Operators can access the screws to check the quality of the oil and the health status of the seal without having to dismantle the whole pump. This makes preventive maintenance easy so users can detect problems before they lead to failure, according to the company. Overall, with the ease of service, it is possible to readjust the pump to the original performance without changing many parts, aiding sustainability.

Additionally, the pumps in the D range are available with various accessories including different types of discharge connections, pump rafts and zinc anodes to provide extra corrosion resistance.

Weir Minerals offers up slurry pumping advice with updated Warman handbook

Environmental, Mining equipment, Mining services, Water management, , , , , ,

Weir Minerals, manufacturer of the Warman® slurry pump, has released the latest edition of its Warman Slurry Pumping Handbook, with the sixth edition, the company says, featuring detailed engineering data required for most slurry pumping applications.

Drawing on decades of Weir Minerals’ in-house expertise in engineering and slurry pumping technology, the new handbook has updated reference material based on new learnings, improved understanding and technological developments within the mining industry, Weir Minerals says. The handbook aims to empower engineers to achieve optimal performance from their Warman slurry pumps.

An increased global focus on the environment, energy consumption and water conservation will influence slurry pump design and considerations – making this latest handbook an essential tool for all current and future pump engineers, the company added.

Marcus Lane, Director, Slurry Pumping Technology Group, said: “Pumping slurry has many challenges and I’m excited to publish our latest handbook, packed with fundamental theory, application advice, standard practices and latest Warman learnings from the field; all aimed to help our customers, present and future, deliver with excellence.”

Weir Minerals says it is looking to shape the next generation of smart, efficient and sustainable solutions with cutting-edge science and innovation. The handbook includes over 140 pages of detailed information, including performance charts, impeller design, part configuration, assembly and slurry considerations – supported by accurate technical renders and specifications.

John McNulty, Vice President Global Engineering & Technology, said: “The high quality of the reference material in this essential resource reflects the leading status of the Warman slurry pumps. As the industry leader, we have a responsibility to develop our future engineers; we will make the latest version of the Warman Slurry Pumping Handbook available not only to our customers, but also to the leading schools worldwide, so they can learn from the best in the industry.”

As part of Weir Minerals’ commitment to investing in STEM (science, technology, engineering and mathematics) education and developing the next generation of engineers, copies of this resource will be gifted to the leading mining and engineering educational facilities around the world, including the winner of the 2022 Warman Design & Build competition, Deakin University in Australia.

Thompson Pump looks for central US growth with Kirby-Smith Machinery partnership

Equipment maintenance, Mining equipment, Mining services, Water management, , , ,

Thompson Pump and Manufacturing Company says it has expanded its distribution in the central United States thanks to a new partnership with Kirby-Smith Machinery, Inc.

With this new partnership, Kirby-Smith, a distributor of heavy construction equipment in the central USA, will be selling, servicing and renting Thompson Pump’s products throughout Oklahoma and north and west Texas within markets like governmental sales, oil & gas, construction, mining and industrial, Thompson Pump said.

The company said: “In this region, terrain and geography can be tricky. Thompson Pump’s more than 50 years of experience in manufacturing pumps and operating its own rental branch locations has helped it to build heavy-duty, portable pumps that hold up to the rigours of the area.”

Combined with Kirby-Smith’s service in the territory for more than 40 years, Thompson Pump’s National Sales Manager, Pat Broderick, says this partnership is a natural fit.

“We are very excited about this partnership as it brings Thompson Pump’s products and name recognition to a region with plenty of competitors,” Broderick said. “Kirby-Smith is one of the premier equipment dealers in the central US and the continuity of products and services it provides to this market is key to our growth in the area.”

Kirby-Smith’s General Manager, Industrial Equipment, Sam Schneider, said: “Partnering with a company like Thompson Pump, which is known throughout the industries for its reliability, support and value, allows us to expand our reach and connect with customers in an entirely new way.”

Kirby-Smith Machinery is a full-service dealer serving the construction, mining and industrial markets since 1983. Headquartered in Oklahoma City, the company has branch locations in cities such as Tulsa, McAlester, Kansas City, St. Louis, Dallas, Fort Worth, Abilene, Amarillo, Odessa, Lubbock and Waco.

Babylon expands mine water management activities with RWG acquisition

Environmental, Mining equipment, Mining mergers and acquisitions, Mining services, Water management, , , , , ,

Babylon Pump and Power says it has executed a business asset acquisition agreement to acquire the operational assets of Resource Water Group (RWG) for A$3 million ($2.1 million) in a transaction that it hopes will result in more early-stage project engagement with mining companies.

Established in 2011 and based in Canning Vale, Western Australia, RWG provides bore field test pumping equipment and related data collection services as well as a range of water management disciplines to the mining industry. These services are critical to water users across the resources sector as they develop water management strategies in line with their environmental obligations and operational requirements, it says.

Back in June prior to the announced acquisition, Babylon said it was planning on expanding its mine water management activities.

Under the business acquisition agreement, Babylon will acquire the operational assets (independently valued at over A$2 million), goodwill, contracts and intellectual property of RWG. RWG’s founder, Frank Ashe, has entered a services contract and will become a member of the group’s senior executive. Three other RWG employees will also commence employment with Babylon.

Babylon Managing Director, Michael Shelby, said: “This is an exciting and well-priced acquisition for Babylon which will significantly expand our water management activities. The acquisition broadens our offering to new and existing clients, brings in additional technology and business development capability whilst complementing our existing business.

“RWG’s test pumping services are considered an early-stage project engagement service and have consequently led to relationships with a range of well recognised global and Australian mining companies including BHP, Rio Tinto, FMG, Roy Hill and Newcrest Mining. We expect that these relationships will also facilitate rental opportunities for our specialist pump rental assets, supporting the Company’s renewed strategic focus on multi-disciplined water management equipment and services.”

Babylon will move into new, purpose-built premises around November of this year and RWG will co-locate its assets and operations into the new facility.

RWG’s Ashe said: “This is an exciting time to be joining forces with Babylon as it builds into a diversified water services business. I am looking forward to joining the team and contributing to strategic growth initiatives and capitalising on RWG’s network of relationships.”

Watson-Marlow breaks ground on new US facility

Mineral processing, Mining equipment, Mining services, Water management, , ,

Watson-Marlow has announced the ground breaking of its new state-of-the-art manufacturing facility in Devens, Massachusetts, in the US.

A celebration ceremony was held on November 18 at the new facility, which will be dedicated to Watson-Marlow’s range of industry leading products, including peristaltic pumps, tubing, fluid path solutions and BioPure components.

The Devens 14,000 sq.m facility will be close to the life sciences hub in the Cambridge/Boston area, with the site incorporating a suite of eight ISO14644-1 Class 7 cleanrooms, warehousing and offices, with space for two further cleanrooms within the initial footprint.

With segregated cleanroom and non-cleanroom production capabilities, Watson-Marlow’s new facility will strengthen the support the company provides to customers in the region across its core sectors of pharmaceutical and biotechnology, medical diagnostics and process industries, the company said.

“The new US facility is an important milestone in the Watson-Marlow company history and marks a significant commitment to serving our customers in the Americas region,” Andrew Mines, Watson-Marlow Managing Director, said. “This exciting development is bringing us closer to our customers whose purpose is to help the world around us, from advancing cell and gene therapies through to ensuring people have access to clean drinking water. Together we will continue to develop market-leading fluid management solutions to engineer a more sustainable future.”

Production at the new facility will replicate that of Watson-Marlow’s European sites, ensuring continued product quality for customers, by using the same raw materials, components, processes and work instructions. Completion of the facility is due in late 2022, with the first products due to be shipped from the site late in the December quarter.