For both productivity and cost efficiency reasons, water management should be a priority for every quarry or surface mine. Traditionally, water control was never the first thing that came to mind when thinking of productive and efficient operations. In recent years, however, this has all changed as operations place high value on their dewatering needs.
Why dewatering? In quarries and mines, water accumulation – whether from rain, groundwater seepage or both – can wreak havoc on operations through structural damages, equipment damages or even health and safety hazards, amongst other problems. Consequently, says Lee Vine, MD of IPR, dewatering plays an integral role in keeping mining areas free of flooding or water accumulation, thus ensuring uninterrupted operations.
Equally important is the selection of a pump that meets each operation’s unique dewatering needs, stresses Steve du Toit, sales manager at IPR. The effects of choosing the wrong pump for the application at hand, he says, can be detrimental, with low pumping efficiency and higher costs among some of the obvious downsides. There are several factors to consider when selecting a dewatering pump for optimal water management.
Supplier matters
Before delving into the technical aspects that inform pump selection, Du Toit says the principal factor is choosing the right supplier that offers both the correct product and the right expertise to guide the selection process.
It is true that selecting a dewatering pump is dependent on application requirements, says Du Toit. However, in IPR’s view, the principal consideration should always be the expertise of the supplier. After observing the prevailing site conditions and the future changes to the pit, a knowledgeable supplier will then advise on the type of pump required and all the other technical considerations to be made, based on these unique site requirements.
“Each installation starts with a detailed assessment of site-specific dewatering requirements. Through that process, IPR’s technical experts get a clear understanding of the unique conditions of the mine, such as water volume, pit dimensions and site-specific challenges. After that process, the company then recommends the most appropriate equipment and strategies for dewatering, ensuring optimal performance and cost efficiency for the customer,” says Du Toit.
Vine says choosing a reputable supplier such as IPR ensures peace of mind that mines will always be guided to make the correct decision to ensure optimal water management. “As a dredging and dewatering specialist, we have many years of experience in this field. Mines and quarries are there to produce, and we are there to take care of their dewatering needs. Getting us involved from the onset to ensure the right pump for the right application, results in efficient dewatering and cost savings for the mine,” says Vine.
Site conditions
Before selecting a pump for a mine’s dewatering needs, it is important to assess the specific site conditions, such as where the water is being pumped from and where it will be discharged. Considering the type and volume of water to be pumped, as well as the rate at which it accumulates will inform parameters such as head (the height at which a pump can raise the fluid up) and flow (the amount of water the pump can move at a given time), which in turn determine the size and type of pump required.
“When choosing the size of the pump, it is also important to remember that the prevailing conditions will change over time as the pit gets deeper, which also changes parameters such as the required flow and pump head. Consequently, a pump that would have been ideal for an operation today might not be the right fit some three months later, for example. That is why it is important to keep us involved throughout the project,” says Vine.
After the technical details such as flow and head have been established, then comes the type and capacity of pump required. Dealing with a supplier that can offer a wide range of choices to suit the operation’s needs is important. For example, IPR offers both diesel-driven and submersible dewatering pumps.
Designed to be fully submerged in water during operation, submersible pumps are ideal for operations where continuous dewatering is required. “These encapsulated pumps can be completely submerged in liquid and are most frequently used to transport drainage water, excess groundwater or any other liquids with suspended solids,” explains Du Toit. IPR’s submersible pumps range from 0,4 to 64 kW.
IPR’s self-priming diesel-driven pump sets are suitable for dewatering applications where power is not readily available. Engineered and sized to meet specific site dewatering requirements, these pump sets are built locally by IPR and offer the option of being either trailer- or skid-mounted, depending on site requirements.
Capital situation
After the technical specifications have been identified, says Vine, the next consideration should be the capital situation for the client. The financial position of the mine or quarry determines whether to buy or to rent a dewatering pump. If capital outlay is a problem, rental will be ideal.
“Rental eliminates the need for a substantial upfront capital expenditure, freeing up the much needed budget for other pressing needs. In addition, rental costs can be classified as operational expenses, and this is especially important where dewatering is a critical necessity, yet there is no capex available,” says Vine.
In addition to classifying rental costs as operational expenses, customers also have the benefit of having one fixed charge for their dewatering needs per month, with no ‘hidden’ costs such as maintenance, unexpected repairs and even professional training. As part of the rental facility, IPR services its pumps after every 250 hours, during which time it can determine any changes in the pit and offer the customer the right pump to meet the current needs.
In the event where the project is long term and capital is available, outright purchase would be the right option for the mine. Purchasing a dewatering pump, says Du Toit, also makes sense where the mine would like to have outright ownership and wishes to reduce the total overall cost of the dewatering pump installation. Large capital equipment such as dewatering pumps build equity over time, especially if the equipment is well maintained. Pumping equipment with long lifespans are assets that will grow the value of the business.
Product reputation
When choosing a mission-critical asset such as a dewatering pump, it is also important to factor in the reputation of the brand and the aftermarket regime behind it. For example, a premium product such as Atlas Copco, supplied and supported by IPR, ensures reliability, a good warranty programme and, more importantly, parts availability and aftersales support from IPR.
“Operations that buy or rent their dewatering pumps from trusted suppliers such as IPR can be confident that their equipment is always dependable and operates at peak performance because all repairs and servicing are done by expert technicians,” concludes Du Toit.
