One of the largest costs in the aggregate and quarrying sector is energy, and it has been estimated that pumping systems make up between 10-20% of total energy use. This means that using already efficient pumps more effectively can save in energy costs, and companies are now producing units that offer sophisticated additions.
Indeed, because of the nature of the terrain in which they are used, dewatering pumps have to be not only rugged but reliable and easy to maintain.
For example,
“We strive to offer a pump for every need: drainage, sludge and slurry, in the most challenging environments imaginable.”
The company says that design features include fewer components that make inspection and service faster; air valves to cool pumps should they run dry; Smart motor protection against electrical problems, and a temperature switch cuts the power if the temperature gets too high.
“Phase guard protects the pump by cutting the power if a phase fails, while Grindex Rotasense guard ensures the impeller turns in the right direction, and built-in start equipment in almost all pumps means no need of external start equipment,” says Grindex.
“After some 50 years of designing and manufacturing submersible electrical dewatering pumps and listening to the customers, Grindex offers a drainage and sludge pump family designed to dramatically reduce operational costs.
The pumps in the range have an output of 1.3-140hp [1kW-140.5kW] and cover almost any application within building and construction, mining, quarries and tunnelling as well as municipal and other demanding industries.”
Only recently, Grindex representative ACH Equipos, Chile, has received an order for ten Mega-pumps from the Codelco-Andina mine in Chile, which produces around 188,494tonnes of fine copper/year and delivers 2,901tonnes molybdenum/year.
The Codelco-Andina is 80km north-east of Santiago and between 3,700-4,200m above sea level, and the order is for seven stainless steel pumps and three in standard cast iron.
As another reference point, Grindex is able to point to the Chinese province of Gansu where contractors Gansu Sino-Italy, excavating an 18km tunnel, realised they needed Grindex pumps to handle the large-scale dewatering problems they were encountering.
At the time, the sales manager of Grindex China said: “Grindex has spent over 50 years perfecting pumps for the toughest conditions, applying its experience from applications in over 100 countries to develop its products. Domestic pumps are not constructed in the same way: they often struggle to handle the type of media that a project of this scale and with these conditions throws at them.”
In the event, two Grindex Major pumps were chosen for the job, each being able to handle up to 40litres/second and pump abrasive media up to heads of 25m. They pumped at an average rate of about 172.8m³/hour (the required flow at that time was 24litres/second).
Meanwhile,
The Pumpex new Super Drainer has a built-in WIP (work in progress) computer, which makes operation, maintenance and service significantly easier for the user, reducing downtime and service cost to a minimum.
While protecting the pump against damage, which can be caused by overheating, low motor insulation and water intrusion, the WIP control system is automatically checking the condition of the pump and indicates when service and maintenance is recommended.
“A sturdy and easy-to-use WIP plug is replacing all starters or control panels. The WIP plug is made as a three-phase power plug and contains all Controls and indicating lights. It communicates with the WIP computer inside the pump via the standard power cable,” says Pumpex.
The pump’s operation history can be checked by connecting it to a PC via a USB cable.
Pumpex Super Drainer ranges from 2.5-8.3kW and consists of four basic models of drainage pumps, series PS, in 16 versions and four models of sludge pumps, series SPS, in eight versions.
Late last year,
Weir Minerals will supply Warman pumps and Isogate valves for use in the transport of tailings at the site, which is currently undergoing a significant modernisation as part of a capital expenditure programme.
Ongoing repair and maintenance services will also be supplied by Weir Minerals from its service centre in Krivoy Rog, Ukraine. The order is due to be delivered in 2014.
Ferrexpo’s Poltava site is an open pit mine producing 30 million tonnes of iron ore/year, and the mine is 330m deep and 7km long. Ferrexpo is currently investing US$138 million to extend the life of the operation to 2038.
Viktor Lotous, chief executive officer at Ferrexpo Poltava Mining, said: “Our Poltava operation is one of Europe’s largest iron ore mines. We believe that Weir Minerals’ pumps and valves will ensure minimum downtime as we look to maintain high productivity levels over the coming years.
“We were impressed by the wide use of Warman pumps and Isogate valves for tailings across Europe and Ukraine, which demonstrates their suitability for Ferrexpo’s operations at FPM. An additional benefit for us is the proximity of Weir Minerals’ service centre in Krivoy Rog.”
Tony G Locke, managing director at Weir Minerals Europe, said: “Ferrexpo required a complex solution and the versatility, reliability and ease of maintenance of Warman pumps and Isogate valves will provide this.
The valves on order, at up to 40” [101.6cm] will be some of the largest in use in the world, which speaks volumes of the size of the operation at Ferrexpo Poltava Mining and Weir Minerals’ expertise in this area.
“We hosted Ferrexpo at our UK-based foundry, which was an opportunity to demonstrate the breadth of our offering, and this agreement typifies the through-lifecycle support we can provide to mine operators.”
In another application,
Integral to the day-to-day operation of the mine, the pumps remove groundwater, rainwater and highly acidic liquids (pH 2) unearthed by explosive excavation. The pumps have been working fault-free at the site for two years and counting.
Pumps and mines go hand-in-hand on this job: as land is excavated groundwater is unearthed, which must be removed quickly to keep the site safe and functioning at maximum efficiency.
The Tsurumi pumps, supplied by D.I.S. Power Plant, Tsurumi’s Cypriot dealer, are mobile units that are moved around the site to wherever they are needed. They include models from Tsurumi’s SFQ range, which are specially developed for corrosive liquids and made from austenitic steel, and the PU range, which is made from stainless steel and high-tech resin moulds making it durable and lightweight.
“Acidic liquids, explosions and outdoor work makes this a pretty challenging environment but our customer is delighted to have finally found a pump that works in this demanding and highly toxic environment,” says Demetris Demetriou, owner of D.I.S. Powerplant.
Atlas Copco says that its Weda electric submersible pumps will make their debut on the American market with a new range for professional users.
The new, c-UL-us approved additions to the range are drainage, sludge and residual pumps, and come in two voltage variants, 115V and 230V, and join the 50Hz range that is already popular in Europe and in the rest of the world.
Each of the Weda electric submersible pumps is now available in a 50Hz and a 60Hz version, and consists of the Weda 04 and Weda 08 drainage pumps; the Weda 04B residual pump and the Weda 04S and 08S sludge/trash pumps.
The Weda 04 and Weda 08 are single-phase electric submersible dewatering pumps with maximum flow rate capacities of 66-86gallons (250-325.5litres/minute) and maximum heads of 37-50feet (112.7-152m), can be quickly put to work in a wide range of dewatering situations, while the Weda 04B residual pump draws water down to 1mm. The Weda 04S and Weda 08S sludge/trash pumps are sand and mud-resistant. Designed with a vortex cast iron impeller, particles and debris with a 1inch (2.54cm) diameter can go through the pump housing with minimal wear.
“After the success of Weda in Europe, we are looking forward to demonstrating our commitment in developing products that respond to the requirements of contractors, rental companies and pump dealers in the American market,” says Abet Cantuba, product marketing manager pumps for Atlas Copco Portable Energy.
