Technology in Mining Safe and economic transportation of material

Industrial Technology Mining ∙ Energy ∙ Environment ∙ Oil & Gas

Tailings pumping 24 hours a day and 365 days a year Putzmeister hydraulically driven positive displacement pump units transfer tailings from mining operations to either a backfill system underground, or to a deposition area through pipelines within 2 – 3 kilometres or more of the site.

HSP 25100 HP – High performance pump for mining tailings and fly ash

HSP series seat valve pump

The powerful solution The gold mine Bulyanhulu, located in Tanza­ nia, has both an underground operation where backfill takes place, and a separate paste deposition site for the tailings. This operation began production in 2001. The two HSP 25100 HP double piston pumps with two 315 kW hydraulic power packs are designed for an output of 80 m3/h each and a delivery pressure of 8 MPa (1160 psi). The two pump systems are installed side by side and are connected to one 200 mm deliv­ery line. A high pressure damper is inte­grated in the delivery line to reduce pres­ sure peaks.

Benefits of the piston pump at a glance ■■

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 aste material is pumpable P over long distances T ransfering at high concent­rat­ ions minimizes the water usage L ow water seepage into the environment  educed risk of embankment R failure at the tailings deposit  tability of paste reduces the S costs associated with the construction of a conventional tailings facility  aste pumping reduces the P required tailings disposal area compared to conventional slurry embankments Tailings transport pipeline

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– Putzmeister Constant Flow for fine grained slurries and paste

Backfilling Safe and economic

The solution for long lifetime of pipelines and less noise

Advanced mining methods such as “Cut and Fill”, safety considerations, environmental aspects as well as economic reasons are some of the main arguments for backfilling.

For reduction of pressure differences during the switchover of seat valves, the Putzmeister HSP pumps can be equipped with a “PCF” control system. Each hydraulic drive cylinder has an own hydraulic circuit. The hydraulic drive cylin­ ders are synchronised with each other by the control system for a nearly constant material flow.

At the heart of any backfill system is the Putzmeister double piston pump with transfer tube (KOS type) or with seat valves (HSP type), and also the accompanying ZX delivery pipeline system. For paste backfil­ ling projects Putzmeister pumps allow high pressures in the pipeline system and there­ fore long transport distances.

Pump with intake shaft at Plutonic Gold Mine/West Australia

HSP pumps with PCF are suitable for con­ vey­ing many materials such as:

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 ineral-based high-density solids M (tailings) with a grain size below 1000 μm at a concentration of dry solids up to 80 % L iquids with an abrasive material content, such as mine water, mineral slurries and pastes E lectrostatic precipitator (ESP) ash, both as thick paste and as slurry

Advantages of the system ■■

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Pumping distances up to 11 km from the central surface mixing plant to the under­ ground backfilling area can be achieved without intermediate pumps.

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 onstant flow with low pulsat­ C ion in the pipeline in a pressure loss range of up to 15 MPa (2175 psi)  rovides precompression to P reduce the gap in delivery E nsures almost constant output flow rate Minimizes pulsation, especially with slurries I ncreases lifetime of the delivery line and fastenings L ess noise, especially with slurries

Some other system capabilities are: ■■ ■■

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Output up to 400 m3/h  perating pressures in the con­ O veyed medium of up to 15 MPa (2175 psi).  ipeline systems designed up to P 25 MPa (3625 psi) Suitable for abrasive material

A Backfill B Ore C1 Upper stope C2 Lower stope D Mill hole E Packing pipe F Discharge hopper G Barrier pillar ➞ Direction of removal ➞ Direction of face advance

Two HSP 25100 pumps with PCF control to reduce pressure peaks (Lisheen Lead/Zinc Mine, Ireland)

Advantages of the system ■■

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Systematic description of upward stoping with backfill 4

Pumping pressure characteristic of an HSP pump with PCF: Pipeline pressure diagram 8 MPa / flow rate 130 m 3 /h

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 losed mine waste circuit C ‘mine ➞ processing ➞ mine’ I mproved stabilisation of mine working areas Increase of cut-off-grade  ermetically sealed conveying H path for material within the pipeline I ncreased working and operation safety HSP 25100 HPS

PCF valves

Hydraulic Powerpack HA 400 + 400 E-SP

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Mine dewatering Upward conveyance of sludge – high performance

Advantages of the system ■■

Every underground mine requires a mine dewatering system. In the case of the mine water being loaded with mud, Putzmeister offers a reliable wear resistant solution. In this application the frequently used cen­ trifugal pumps create high lifetime operating costs.

Coal sludge handling

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Energy requirements are reduced to 25 % I ncreased capacity – 250 m³/h is pumped at a flow rate of 2.7 m/s at a pressure of 15 MPa (2175 psi) Constant solids concentration T he size of the 2.5 m delivery cylinder length guarantees low wear and quiet running

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T he reliable technology increases availability and considerably re­duces maintenance costs T he pumps are fully automated and are reliable in continuous operat­ ion 24 hours/day and 7 days/week Reduced sump dewatering costs

Complete systems for handling coal or other sludges for combined combustion in conventional power plants Together with internationally operating ­engineering companies, Putzmeister has supplied many reliable sludge handling ­systems for the power industry. ­ Our global presence allows us to do this through the supply of technology and serv­ice to projects anywhere in the world. Fuel costs are the most important economic ­factor in the operation of power plants. Therefore secondary fuels become more and more important to reduce the usage of primary fuel.

High-density solids pump KOS in Jaworszno Power Plant, Katowice/Poland

Secondary fuels in bituminous or lignite power plants could be: ■■

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 oal sludge from coal processing C plants  ludge from sewage treatment S plants  ther materials from industrial O processes with a suitable heating value

Reliable and cost efficient solution based on the following equipment set: ■■

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The HSP at work in an underground site

 eception facilities R (e.g. if sludge is trucked in from another location)  torage silos to ensure a con­ S tinuous feed to the combustion process  onveyance of the sludge C through pipes which allows complete flexilility of routing

Coal sludge with density up to 70 %

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F oreign-body separator to en­ sure that oversized material is caught that would interfere with the combustion process L ubricant injection system to re­duce pressure loss for long transport distances

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Ash transport

Concrete and mortar systems for coal mines according to Atex specification

Economical fly- and bottom-ash transport as high density slurries

Creating tunnel linings for targeted mine ventilation

After the incineration of coal in coal fuelled power stations the resulting waste ash such as fly-ash from the electrofilters or the bottom-ashes from the boiler have to be disposed of. Most fly and bottom ashes are pumped into embankments.

Mining companies are constantly searching for ways to ensure that working underground is economical and safe. This is particularly true of coal mining companies. With the BSM 1002, it is possible to mix and pump building materials on site, e.g. concrete or other mineral substances mixed with cement. These materials are for example best suited for building tunnel linings in a coal mine.

By using the Putzmeister KOS type piston pumps a mixture of both fly- and bottom-ashes can be transported successfully without operational disturbances. Due to the fact that the Putzmeister KOS piston pump has no valve between the inlet and outlet of the pump even coarse particle can pass the pump without stopping the process. High dry solid contents can be handled and water content can be reduced to a minimum. Due to the low water content the lifetime of the disposing area can be extended or a smaller disposing area can be de signed. Also the environmental fact of large amount of contaminated water can be reduced to a minimum.

The BSM 1002 is a multi-purpose mortar and concrete pump fitted with an S-transfer tube system for use in coal mining. It is specially designed for high pressure pumping over long distances, and is used for spray application of mortar and concrete, backfilling and injection. The pump is equipped with a continuous mixer to handle dry construction material.

Applications for the BSM 1002 Construction of roadway dams to increase mine safety ■■

 educed methane gas emis­ R sion from the goaf into the roadways

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Supports gas drainage systems

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Reduced danger of goaf fire

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I ncreased lifetime of the road­ way double use  oncrete instead of timber as C construction material

Immediate mortar backfilling of steel support while roadheading Left: KOS series S tube pump Right: Fly ash hardens within a short time

BSM 1002 ready for roadway support

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Lower water requirements

 Fast stabilizing with stiff construction material reduces deformation of arches  ood contact between arch and G rock  ontrol of place where longwall C face and gallery junction is improved

Wet Shotcrete

 educed risk of embankment R failures

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 educed water loss due to seepage R and evaporation

I mmediate support while road heading

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Increased safety

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Reduced fresh water usage

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No spray dust

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Reduced dust potential

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Little rebound

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 educed footprint size of the R embankment facility

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High availability

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Long service life

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L ow maintenance and operating costs Service-friendly

A KOS 25100 pump installation (Kogan Creek, Australia) for fly and bottom ash

BSM 1002 concrete pump with mixer built to Atex specification 9

Complete systems for the mining industry

Shotcrete systems Safe ground support under toughest working conditions

Systems engineering from a single source In addition to pump systems, Putzmeister is providing complete project solutions for the ­mining industry. Buffer silos, mixing plants, pig in gates and pipelines supplement the range of pumps. A team of technicians and engineers will cooperate with the customer in identifying the most suitable solution, which frequently leads to the existing components of a customer’s site providing the basis for new constructions. The Putzmeister team will assist the customer with the implementation of specific solutions and the coordination of all procedures.

In mining, sprayed concrete has become more and more relevant for ground support. The usage for shotcrete in underground workings starts with the logistical problem of supplying the spraying equipment with the required construction material, and finishes with the demands of placing the material exactly where required on the mine walls. Putzmeister is the only system pro­ vider who offers total package solutions from the concrete mixing plant on the sur­ face, to the shotcreting lining of the galleries in the mine below.

However, our involvement does not end with the supply and commissioning of the plant. The training of local staff at the plant, the setting up of storage facilities for wear parts at the mine and the supply of specific service and maintenance manuals for the operation are all part of the deal, underpinning Putzmeister’s image as the reliable supplier for complete systems.

For the mining industry today the utilization of various construction materials is essent­ ial to create a safe environment and achieve high productivity even in challenging geo­ logical strata. Cement based construction materials are used predominately for ground consolidation, ventilation sealing and differ­ ent civil works in mines.

KOS 2180 HP piston pump with mixer and Jumbo Trough (JT 7000)

Putzmeister is the competent partner for the Mining Industry, providing reliable customer orientated product solutions for owners and operators. Together with our alliance part­ ners we are able to offer the total package in preparation, transportation and usage of construction material.

Longlife pipeline systems – extremely resilient at high pressures and with abrasive materials Pumping under high pressure – this is where particularly high demands are placed on the delivery line. They must be absolutely leak-proof, stable and wear-resistant. The ZX delivery line system from Putzmeister fulfils these criteria with ease, and is therefore ideal for fixed, stationary pipe systems and longdist­a nce placement. However, beyond construction sites, the system is tried and tested in a wide variety of industrial applications, not least due to it being absolutely leak-proof which is created thanks to the connection between male (ZXV) and female (ZXM) flanges. In this case, the O-ring inserted in a groove acts as a press-in seal which is pressed firmly in its place during as­ sembly. In this way, the ZX system is particularly suitable for highly liquid materials and pulsating pressures. In addition to the high pressure resist­ ance, the wall thicknesses, which are up to 11 mm, also provide a long wear lifetime.

Systems for mining applications Surface mining

Underground hard rock mining ■■

Mobile shotcrete equipment

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Stationary transport systems

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Mobile transport systems

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 round consolidation, injection G and rock bolting

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Bench stabilization

Sealing

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Pump type

Field of application

Output

Pressure

KOS-Series S-tube pump

B ackfilling and muck pumping of coarse grained slurries and paste

10 – 400 m 3 /h

up to 15 MPa (2175 psi)

Foreign bodies up to 2/3 of the size of the discharge outlet can be conveyed without any issue

HSP-Series Seat-valve pump

T ransport of fine grained slurries and paste like tailings, mine water, fly ashes

10 – 250 m3/h

up to 15 MPa (2175 psi)

KOV-Series Ball-valve pump

 igh pressure pumping of fine H slurries up to 8 MPa like waste coal, tailings, mortar and sump sludge

0 – 70 m 3 /h

up to 8 MPa (1160 psi)

Hydraulic power pack and control cabinet

A ll Putzmeister pumps are driven by a hydraulic power pack

Performance:

5.5 – 1800 kW

Putzmeister Solid Pumps GmbH Max-Eyth-Str. 10 · 72631 Aichtal / Germany P.O. Box 2152 · 72629 Aichtal / Germany Tel. +49 (7127) 599-500 · Fax +49 (7127) 599-988 [email protected] · www.pmsolid.com

Industrial Technology Mining ∙ Energy ∙ Environment ∙ Oil & Gas

Right to make technical amendments reserved © by Putzmeister Solid Pumps GmbH 2014 All rights reserved Printed in Germany (21407Sc) TS 3881-2 GB

The right pump for every application