Tag Archives: mining pumps

Integrated Pump Rental keeps its head during Lesotho mine dewatering project

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

Integrated Pump Rental says the quick deployment of its dewatering solution has allowed a Lesotho mine to keep operating as normal.

A constant flow of water into the mine’s pit area demanded water be urgently and reliably pumped out, according to the company. A fuel-efficient Sykes Xtra High Head pump set was chosen for the job, pumping into a 200 mm HDPE line with a head of 127 m to a holding dam.

According to Integrated Pump Rental’s Andre Strydom, timing was of the essence to the customer: “We secured this dewatering contract due to our quick and effective response. The Sykes XH150 unit was on site and commissioned just 24 hours after receiving the call from the customer.”

Strydom highlighted that, as mines and quarries go deeper, conditions require a solution like the Sykes XH150. With its automatic priming and solids handling capacity, it is designed to dewater more efficiently and effectively.

“The unit has one of the best shaft stiffness ratios of any automatic priming pump on the market,” he says. “Sykes engineers have ensured that the enormous pressures and heads associated with such performance do not compromise seal integrity through shaft flexing.”

All models have the ability to operate unattended at high discharge heads, with the pumps able to be primed with long suction hoses and the ability to manage suction lifts of up to 9 m.

“The units can even run dry for extended periods due to the oil bath mechanical seal assembly,” the company said. “Designed for robust and reliable performance with high volumes of water, Sykes pumps have an established reputation for the fast and effective control and removal of sub-surface water.”

The pumps can even operate in “snore” condition, Integrated Pump Rental says, which accommodates fluctuating suction levels. “In these conditions, the pump will snore until the liquid is available for the pump to fully re-prime itself automatically,” the company added.

Weir Minerals on optimising mine dewatering

Environmental, Mining consumables, Mining equipment, Mining services, Sustainable mining, Water management, , , , , ,

As public scrutiny over the mining sector’s use of water continues to grow amid global shortages, Weir Minerals has issued its own guide on how to optimise the dewatering component of a mine site.

“Water is critical for every mine site, it’s used for minerals processing to dust suppression and slurry transport, and without it the entire operation would stop,” Weir said. “Every mine site faces a different challenge with water; it’s either scarce, or in excess and causing an issue.”

A comprehensive, reliable and flexible dewatering plan is essential to ensuring there is a steady supply of process water throughout the site, according to Weir. Conversely, the removal of excess water from working areas to allow excavation to continue while safeguarding the operators and maintaining productivity also requires a dewatering plan.

Ian Ross, Global Product Manager for Dewatering at Weir Minerals, said: “There is no ‘one size fits all’ approach to dewatering. It can be an expensive and complex challenge, which is why we deliver bespoke strategies that are cost effective and manageable.

“At Weir Minerals our strength lies in our engineering and project management capabilities. We have the knowledge, expertise and range of equipment to optimise the entire dewatering component of a site.”

Major considerations for any dewatering project

Weather and environment

Each site’s dewatering requirements vary and present unique challenges, with environmental and geological considerations, as well as local climatic variations.

Differences in weather conditions and environmental changes can have a significant effect on an operation. The challenges operators face with water will change from region to region.

“From the outback of Australia where water is scarce, the recovery of water is desperately required compared to the tropical climates of Brazil, where open pits rapidly fill with water, or sub-zero (-50°C) arctic operations in northern Canada that operate year-round – they all require effective water management systems,” Weir said. “Every site, in every country, experiences varying issues with water management and requires a strong partner to support them, whatever the issue.”

Ross said: “We have extensive experience helping either open-pit or underground mine sites with their water management challenges. From designing and implementing a unified, fully-automated dewatering system in Czech Republic to delivering a dewatering system to withstand high wind speeds and tropical storms in Africa, we rarely meet a challenge we cannot overcome.”

There are also a number of factors affecting the dewatering system, from the permeability and porosity of the ground, the amount of surface water, and geological features such as seasonal rainfall.

All of these must all be assessed and factored into a detailed dewatering system before work can begin, Weir said. The dewatering system put in place must be able to cope with this to provide a safe solution and minimise production delays.

What’s in the water?

The composition of water being moved has a notable impact on the equipment and materials used, according to Weir. “The pH range, temperature, corrosive and abrasive content all play a critical role in selecting the equipment to transport water effectively. The presence of solids in the water, the specific gravity, size distribution and content percentage will determine the type of pumps required.”

Equally, the pipework and valves are also subject to corrosion and abrasion from the products handled and must be designed accordingly, the company said.

“For every dewatering project, it’s important the original equipment manufacturer (OEM) understands the environment before developing the strategy, to deliver the optimal solution,” Weir said.

“The pitfalls of over- or under-sized equipment include excessive energy use, high cost investment and maintenance and also risk to equipment and personnel, as well as lost production in the case of insufficient capacity.”

Cameron Murphy, Regional Director of Dewatering for Weir Minerals, said the company has a range of flexible solutions that allow it to use several types of pumping equipment, from self-primed diesel driven, submersibles, vertical turbine and multi-stage to high-wall pump designs for sites that have limited access due to high-sided mine pits.

“Our development of sophisticated pontoon and barge designs allows our equipment to float out over water bodies for easier access. All designs are rigorously tested and include safety features to help prevent risk to operators. Each of our pontoons is designed with a fully-tested anchoring system and can be customised for extreme weather conditions,” he said.

Waste not, want not

With depleting ore grades around the world, there is an emphasis on turning waste into energy, and the dewatering process is no different. Weir Minerals produces equipment which not only dewaters mine sites, but also enables the operator to recycle and re-use back through the plant, it said.

Weir said: “Reclaiming process water for reuse is an increasing demand from operators as it can help overcome the issue of water scarcity, and ensure the operation is gaining maximum use of its resources. Weir Minerals has successfully partnered with a number of customers around the world to make this happen.”

There are multiple ways in which Weir can help its customers reclaim water from their tailings and re-use it throughout the mine site, according to Ross. “From pump house systems to innovative and customised barge solutions, we find a solution that is right for the customer. These options can be complex, and we work with the customer to educate them on how the systems work and showcase the benefits, it’s a collaborative approach,” he said.

More than just equipment

“Operators usually rely on multiple OEMs for dewatering projects; a labour intensive task dealing with different providers and ensuring a solution comes together in a streamlined process,” Weir said.

“Weir Minerals can remove this headache by project managing the entire dewatering solution, utilising products from our extensive dewatering range. This involves a thorough assessment of the requirements of the site, including the mine plan, operating depths, and existing infrastructure, as well as required water in-flow.”

Ross concluded: “We provide a resilient process against the backdrop of increasingly difficult conditions in which many of our customers operate. What we deliver is an optimal dewatering plan, backed up by recommendation for regular equipment maintenance to keep unscheduled stoppages to a minimum.”

GIW pumped with Anglo American Quellaveco copper project order

Base metals, Bulk handling, Environmental, Mining equipment, Mining project news, Mining services, Water management, , , , , , , , , ,

GIW Industries says it is to deliver four MDX 600 cyclone feed pumps to Anglo American’s Quellaveco copper project in Peru.

GIW, a subsidiary of KSB, won the order based on the reputation of its centrifugal slurry pumps and the firm’s commitment to customer support, it said. “Decades of experience in slurry transport means GIW is in the perfect position to partner with Quellaveco.”

Anglo American plans on first copper production coming out of Quellaveco in 2022, which, with a reserve of 1,300 Mt at 0.58% Cu, is expected to have a 30-year mine life at an average production capacity of 127,500 t/d. This could see the mine produce around 300,000 t/y of copper.

The Quellaveco project marks a significant milestone for GIW as it continues to invest in the region, the company said. In 2018, it expanded its service capabilities in South America to meet the needs of current and future customers.

Local GIW technicians will be on-site to assist Quellaveco for the installation, commissioning, and start-up of the four MDX 600 cyclone feed pumps, according to the company.

“The MDX pump was selected for the Quellaveco project because of its success in copper and gold applications around the world,” GIW said. “The MDX product line has undergone extensive development; in fact, the latest technology features a remotely adjusted mechanical suction liner.

“The pumps for Quellaveco are specially designed to operate in the most extreme duty conditions. Critical wear parts are made of GIW’s proprietary white-iron alloy, Endurasite. This material extends wear life and optimises pump performance.

“These features combined have a direct impact on Quellaveco’s total cost of ownership – proving the MDX is the most reliable pump on the market.”

Hernan Palavecino, South America Region Manager for GIW, said economic stability and continuous growth in the country have facilitated the investment of new mining projects in Peru, with the country, over recent years, becoming a key player in the global market.

“GIW recognises the importance of the Quellaveco mine to the region,” he said. “The greenfield project solidifies Peru’s position as a substantial player in the South American and global mining markets. The award is a result of GIW’s drive for continuous improvements in slurry technologies. We are committed to offering high-quality service while building a long-term partnership with Quellaveco.”

Integrated Pump Rental’s SlurrySucker saves the day at Botswana diamond mine

Diamond mining, Environmental, Mine operation news, Mining equipment, Mining services, Water management, , , , , , , ,

Dredging technology provider, Integrated Pump Rental, says its innovative SlurrySucker has resolved a process water challenge for a diamond mine in Botswana.

Managing Director, Lee Vine, said attempts by the mine to desilt the main process tank using different methods of dredging had proved inadequate and the challenge of this reservoir continuously filling with slurry remained a concern, especially with regards to storage capacity. In addition, the silt build-up was causing damage to the process pumps resulting in unscheduled downtime and unnecessary maintenance expenditure.

Initially, Integrated Pump Rental proposed a SlurrySucker rental unit as this was deemed the quickest solution and there were also some reservations on the part of the mine due to failures with other equipment. The rental unit was installed on the main process tank for a trial period of two weeks.

The SlurrySucker dredging unit was required to pump 250 cu.m of mixed material out of the 40-m diameter by 8-m deep process water tank. This translates into 60 t/h of dry material.

“The performance of the SlurrySucker in that initial two-week period was so good the mine made the decision to purchase its own unit. Our equipment quickly proved itself capable of dealing with the silt issue, and keeping the level of the main process water tank within acceptable parameters,” Vine said.

Vine said that the SlurrySucker, equipped with the Grindex Bravo 700 submersible pump, suited the mine so well because of the mobility it offers.

“The unit can be moved from one tank to another, facilitating desilting of all process water and other water storage tanks and dams, ensuring these remain fully operational and silt free,” he said.

ANDRITZ pumps draining flooded mining tunnels in South Africa

Environmental, Mining equipment, Mining services, Precious metals, Water management, , , , , , , ,

Just as IM’s water management feature goes live, ANDRITZ has released details of a project it has been working on to de-water old mines in Johannesburg, South Africa.

South Africa has been dealing with an acid water problem in recent years. Underneath the old gold mining city of Johannesburg is a lake containing heavily contaminated water, which spreads horizontally and vertically into the abandoned pits of the former gold mines, according to ANDRITZ.

The water line has reached a critically high level, as determined by the specialists from the ANDRITZ subsidiary, ANDRITZ Ritz, in Schwaebisch Gmuend, Germany, which was given the first order to drain the mine water back in 2010.

The execution of the project was delayed by four years, however, and it was only in Spring 2014 that two powerful ANDRITZ submersible motor pumps were installed in the middle of Johannesburg city centre, in the so-called ‘Central Basin’. Each pump is capable of bringing 1,500 m³/h (1.5 million litres per hour) of water to the surface, according to ANDRITZ; with 60 million litres of water per day pump, it is a never-ending task, ANDRITZ said.

“In Johannesburg, however, acid mine water is an ongoing problem. Rainwater seeps into the tunnels and reacts chemically with residual minerals like pyrite, producing corrosive sulphuric acids. In the worst case scenario, this can result in a pH value of 2, which is enough to cause lasting damage to humans and the environment.

“Because of this corrosive acid, the Johannesburg pumps had to be completely redesigned. The design is based on ANDRITZ’s proven HDM (Heavy Duty Mining) technology, which uses the concept of a double-suction pump. The thrusts produced are offset by the counter-rotating arrangement of the impellers and the pumps run without axial thrust, giving a properly maintained pump a service life of 10 to 15 years.”

The pumps for the Johannesburg project are a tailor-made, customised design built for this special individual application, according to ANDRITZ. Part of the new system is an encapsulation of the submersible motors (see top photo), which enables the creation of an internal pressure higher than the external pressure. This prevents the intrusion of the corrosive water and the components inside the motor being attacked and possibly destroyed. “At the same time, the water being drained is used to cool the motor by means of a heat exchanger,” ANDRITZ said.

ANDRITZ engineers spent weeks developing the sophisticated technology needed to encapsulate the motor so it could withstand the higher internal pressure. The first two pumps have been running since June 2014. These 21-t pumps, each 15 m long with a 1-m diameter, were installed side by side in March, 5 m apart, but could only be started after completion of the water treatment plant.

Freely suspended on 430-m-long duplex steel pipes, they transport the acid mine water to the surface and onwards into an adjacent treatment plant (pictured). Here, through the addition of lime, the pH value is raised, the acid is neutralised and the heavy metals dissolved in the water are absorbed and precipitated as hydroxides, ANDRITZ said.

The South African authorities are planning a total of three pumping stations, which will each be developed at the mines’ disused extraction shafts. In addition to the Central Basin in Johannesburg’s city centre, invitations to tender for the ‘Eastern Basin’ and the ‘Western Basin’ are currently in progress, according to ANDRITZ.

“The long-term goal is to force the water level in the flooded mines back from its current level of approximately 200 m to a depth of 1,000 m, and to keep it there, to then be able to begin mining gold and gold ore in the drained upper layers of the mines once again,” the company said.

Atlas Copco extends WEDA dewatering range to slurry pump applications

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

Atlas Copco Power and Flow has completed its portfolio of WEDA electric submersible dewatering pumps, in the process adding a new range for slurry applications.

The range now comprises three families; the expanded WEDA D for dewatering, WEDA S – also expanded – for sludge, and the entirely new WEDA L slurry family.

WEDA D pumps handle either clean or dirty water, even with small solids, while the WEDA S range supports dewatering of liquid sludge containing larger solids. The WEDA L products are the toughest, Atlas Copco says, having the largest apertures to facilitate handling of slurry with the most challenging solids.

“The WEDA D family expansion is marked by the D80, a new model for dewatering,” Atlas Copco said. “S30, and S60, as the new models for the WEDA S sludge family, can handle thick, soft, wet mud or other similarly viscous mixtures of liquids and solids, especially the product of an industrial or refining process. The completely new WEDA L family handles semi-liquid slurry mixtures, typically of fine particles of manure, cement or coal, and water.”

Aside from optimising performance, a lot of focus has been given to making the pumps lighter, enhancing electrical safety, improving the seal design and easing installation, Atlas Copco said. All pumps in the D and S range are available with WEDA+ features, which include phase failure protection, rotation control, thermal switches and a 20 m cable with phase shifter plug for all three phase pumps. The WEDA+ features are also available as an option on the L range.

Overall, the WEDA D pumps, which use top-discharge, can handle water of specific gravity to 1,100 kg/m³, and, depending on model, solids of 4-12 mm diameter. The bottom side discharging WEDA S pumps’ capabilities extend to water with specific gravity to 1,400 kg/m³, and solids of 25-50 mm, depending on model. The WEDA L pumps, which also use bottom side discharge, handle water of specific gravity up to 1,700 kg/m³, and, depending on model, solids of 20-60 mm diameter.

The company said: “The pumps’ specifications equip them well for an extensive range of dewatering applications; they provide the performance, reliability and ease of use and maintenance essential to users across multiple industries.

“All models feature a built-in starter and motor protection system along with optional automatic level control. Adjustable wear-resistant rubber diffusors and hardened high-chrome impellers ensure durability in tough environments.”

Hrishi Kulkarni, Product Manager, Atlas Copco Power and Flow division, said: “The WEDA pumps can handle flow rates of up to 16,500 l/min, with power ratings up to 54 kW. Accordingly, they make ideal dewatering solutions across many, diverse applications within the construction, industrial, emergency and maintenance sectors. Now, our ubiquitous coverage has been highlighted by these latest additions to the range, as they make our portfolio complete.”

Handling and transportation are eased by the pumps’ weight, which is 20% lower than competitor products, Atlas Copco said, adding that this makes them especially attractive for rental use.
Ease of operation is carefully balanced with high performance, with some models’ ability to pass solids of up to 2 in (51 mm) through the pump. An improved aluminium alloy provides higher corrosion resistance over all applications, while reinforced cable entries assure higher resistance to water leakage.

“Uptime is maximised through several measures,” the company said. “All pumps have seal types appropriate to their size, and an external plug for grease filling or an oil inspection plug for easy maintenance. With many connection options and sizes, discharge connections are adjustable, with flow direction changeable from 90-180°.

Grundfos to premiere new CR inline multistage pumps at Electra Mining

Environmental, Equipment maintenance, Mineral processing, Mining services, Precious metals, Steel and iron ore, , , ,

Grundfos South Africa will have something new to show attendees at the upcoming Electra Mining exhibition in Johannesburg next month, with the launch of a new generation of its CR inline multistage pumps.

The Grundfos CR pumps will increase efficiency and maximum working pressure while almost doubling maximum flow to 320 m³/h, the company said.

Grundfos will also introduce three extra-large flow sizes based on extensive research, development and testing of new hydraulic designs. These have been engineered using state-of-the-art production methods, including a fully automated and flexible production line, it said.

Niren Rohanlal, Lead Business Development Manager at Grundfos, Sub-Saharan Africa, said: “The new CR will significantly move the limits for energy efficiency, which is extra-important when
you are working with large pumps. The increases to maximum working pressure and flow will also mean that the new generation can be used even more widely.”

The new 40 bar standard working pressure is suited to applications like filtration, reverse osmosis and boiler feed, Grundfos said. “And, with its increased 320 m³/h flow capacity, the CR will even be able to take on high-flow applications – such as large waterworks – which have until now been served by other pump designs,” the company added.

Grundfos will be unveiling the new generation of pumps at its stand, H31, in hall six of the Expo Centre Nasrec on September 11 at 11am.