MINING PUMPS
“HGL analysis was essential for all considered
pumping setups to ensure a sufficient gradient for
flow over the high point,” AFT said. “While
changes in pump setup increased the flow rate to
4,650 m 3 /h, the overall flow remained below the
target 6,000 m 3 /h peak flow rate for rapid
draining.”
To accommodate future operational needs, it
was determined a new booster pump station
should be installed in the middle of the pipeline,
AFT said.
The new booster pumps would be installed
alongside the existing overland pipeline,
downstream of the valve station, consisting of two
50% pumps operating in parallel. The booster
pumps would not be required for continuous
operation, instead only running when additional
flow was required to manage the TMF level. In
most cases, the booster station would be
bypassed by the pipeline.
One consequence of the higher flow rate was an
increase in fluid velocity, reaching 3.3 m/s
compared with the allowed 2.4 m/s. This
necessitated steady-state and transient hydraulic
analysis using AFT Impulse to ensure adequacy of
design and piping supports, according to the
company.
A steady-state simulation model incorporating
the supplementary diesel pumps was
benchmarked against reported client plant data,
AFT said.
The common discharge pressure at the
temporary pumps in the model was 93.5 psi
compared with 94 psi reported by the client. The
modelled pipeline flow rate was 4,660 m 3 /h
compared with the reported 4,650 m 3 /h. “These
differences were negligible and indicated
positive agreement between the simulation
model and the existing return water pipeline
system,” AFT said.
Using the calibrated model, Soni could size the
booster pumps with no fouling in the pipeline.
“He then tested these sized pumps with fouled
pipeline conditions to ensure HGL gradients were
sufficient for flow and the Maximum Allowable
Operating Head (MAOH) of the pipes was not
exceeded,” the company said. “He also
experimented with other pump combinations to
find the maximum possible flow rate unfortunately
below the desired design flow rate due to pipeline
fouling. Cleaning the pipe would easily improve
the peak flow rate.”
AFT Impulse helped Soni finalise a booster
pump data sheet, allowed him to analyse the
pipeline for MAOH, and ensure there was
sufficient HGL, according to AFT. He said the man
hours spent on finalising the booster pump data
sheet, related instrumentation, and creating
steady-state and transient models for various
scenarios was significantly reduced by using AFT
Impulse.
Heading to West Africa
DXB Pump & Power’s latest
pumps have been designed for
the lucrative West Africa mining
market, but by incorporating
sustainable water management
and environmental impact
considerations into their
design, the pumps could find
homes across the globe.
The new range of ultra-high
performance mine pump sets
leverage single stage high head and high flow dry
prime dewatering pumps, and are powered by
Caterpillar C188TTA twin turbocharged engines,
DXB says.
Designed and manufactured on either trailers or
drag skids in its UK factory, DXB’s pump sets
maximise the flow and head available from these
compact and powerful engines by using miningfocused,
high pressure 8 in x 6 in (203 mm x 152
mm) and 30 in x 24 in high efficiency pump ends
for maximum flows over 7,000 m 3 /h and heads
over 180 m.
The CAT 18 litre, 560 kW high pressure pump
set is manufactured to include an 800-litre
integrated fuel tank design complete with the DXB
Storm & Stone ® system as standard. This system
offers engine and pump protection from both
extreme weather and blasting that occurs during
mining operations, according to DXB.
Both pump sets operate up to 1,800 rpm, rather
than previous highs of 2,100 rpm, helping reduce a
mine’s fuel consumption and environmental
impact without incorporating complicated
emission compliance technology, DXB said.
The brand new DE700/160 high pressure pump
set directly mounts on the Cornell 6822MX pump
end, which is capable of maximum flows of over
900 m 3 /h and heads of over 180 m, and connects
to the CAT C18 engine through an SAE 1 housing.
This offers an ease of maintenance and compact
design that, DXB says, ensures it can ship three
complete units in a single 40 ft (12.2 m) container
to anywhere in the world for under $10,000.
The design also enables DXB customers to
airfreight the entire pump sets inside standard
cargo planes for more urgent delivery options,
according to the company.
Simon Ruffles, Owner of DXB Pump & Power,
said: “The mining industry has long demanded
rugged, high-performance pumps that historically
were always designed and manufactured in
Australia, where the largest demand for these
pumps is observed.
“We are the first European pump manufacturer
that has risen to the challenge posed by mines in
places like West Africa, where high heads and
flows are commonly seen. These mining
companies are delighted with our rugged
designs.”
The new range of ultra-high performance mine
pump sets from DXB Pump & Power leverage
single stage high head and high flow dry prime
dewatering pumps, and are powered by
Caterpillar C188TTA twin turbocharged engines
Ruffles added that the incorporation of the new
CAT C18TTA engine means the pump sets can be
used in either the European Union – in the Nordic
region where Stage 5 emissions compliance is
required – or, when the diesel oxidation catalysts
are removed, countries where Stage 3 emission
compliance is the minimum requirement.
However, DXB’s strategically located UK factory
means the company will be able to easily service
the West Africa mining market.
“Being located in the UK, there are miningfocused
supply chains already with very short and
direct routes of supply to ports like Takoradi
(Ghana) and Freetown (Sierra Leone) enabling the
pump sets to be swiftly and economically
delivered to the mines from our factory in the UK,
rather than being shipped three-quarters of the
way around the world,” he said.
“This ensures delivery timeframes for pump
sets and spares get shorter and shorter.”
The company is also launching a new compact
high-flow pump set using the same CAT C18TTA
engine for mines in need of moving large amounts
of water in the shortest possible time. This is
facilitated through a maximum flow range in
excess of 7,000 m 3 /h.
Driven through a custom-designed gearbox
manufactured in the US, the new DE5500/25 600
mm pump set also operates at 1,800 rpm and
comes as a drag skid with integrated fuel tank,
four point lifting and optional “shove bars” for
manoeuvring in place with on-site bulldozers, DXB
said.
These pump sets are designed for use with
large diameter pipelines, helping rapidly move the
largest volumes of water with maximum ease of
handling and minimum additional plant, such as
specialist cranes. Also available in custom-built
sound attenuated canopies, DXB says no other UK
manufacturer offers such a 600 mm pump set as
standard.
Both pump sets use DXB designed control and
satellite telemetry systems, which allow mines
and DXB to monitor the health and maintenance of
50 International Mining | JUNE 2020