putzmeister ts 3881 mining gb

8/6/2019 Putzmeister TS 3881 Mining GB

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Putzmeister IndustrialTechnology in Mining

TS 3881 GB

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Tailings pumping

24 hours a day and 365 days a year,Putzmeister double piston pumps trans-port tailings material through pipelinesystems to deposition areas. Our hydr-aulically driven positive displacementpump units transfer tailings from miningoperations to either a backfill systemunderground, or to a deposition area with-in 2 3 kilometres or more of the site.

The gold mine Bulyanhulu, located inTanzania, has both an underground oper-ation where backfill takes place, and aseparate paste deposition site for the tail-ings. This operation began production in2001.

The two HSP 25100 double piston pumpswith two 315 kW hydraulic power packsare designed for an output of 80 m3/heach and a delivery pressure of 8 MPa(1160 psi).The two pump systems are installed sideby side and are connected to one 200 mmdelivery line. A high pressure dampeneris integrated in the delivery line to reducepressure peaks.

Pump station at Bulyanhulu/Tanzania

Tailing material

HSP series seat valve pump

This kind of operation for the pumping oftailing material shows the potential andpossibilities of Putzmeister pumps:

s Paste material is pumpable over longdistances

s Transferring at high concentrationsminimizes the water usage

s Low water seepage into the environ-ment

s Reduced risk of embankment failures Stability of Paste reduces the costs

associated with the construction of aconventional tailings facility

s Paste pumping reduces the requiredtailings disposal area compared toconventional slurry embankments

High pressure dampener

Tailings transport pipeline

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Backfilling

HSP Triplex pump

To achieve higher outputs Putzmeisteroffers the HSP Triplex Pump: Threesingle cylinder pumps are combined toform one Triplex pump unit.

Beside higher output capacity the Triplexpump can operate as a Duplex pump.One cylinder can be taken out of operat-

ion during maintenance while the othertwo cylinders continue working. Due tothis a separate stand-by system is notrequired.

Putzmeister Constant Flow PCF

For reduction of pressure differencesduring the switchover of poppet valves,the Putzmeister HSP pumps can beequipped with a PCF control system.

Advantages of PCF:

s Constant flow with low pulsation inthe pipeline in a pressure loss rangeof up to 15 MPa (2176 psi)

s Provides precompression to reducethe gap in delivery

s Ensures almost constant output flowrate

s Minimizes water hammer, especiallywith slurries

s Increases lifetime of the delivery lineand fastenings

HSP pumps with PCF are suitable forconveying many materials such as:

s Mineral-based high-density solids(tailings) with a grain size below1000 m at a concentration of drysolids up to 80 %

Advanced mining methods such as Cutand Fill, safety considerations, environ-mental aspects as well as economic reas-ons are some of the main arguments forbackfilling. At the heart of any backfillsystem is the Putzmeister double pistonpump with S-transfer tube (KOS type) orwith seat valves (HSP type), and also theaccompanying ZX delivery pipelinesystem. For paste backfilling projects

Putzmeister pumps allow high pressuresin the pipeline system and therefore longtransport distances.

Pumping distances up to 11 km from thecentral surface mixing plant to the under-ground backfilling area can be achievedwithout intermediate pumps.

Some other system capabilities are:

s Output up to 500 m 3/h.s Operating pressures in the conveyed

medium of up to 15 MPa (2176 psi).s Pipeline systems designed up to

25 MPa (3626 psi)s Suitable for abrasive material

The advantages of the method:

s Closed mine waste circuitmine processing mine

s Improved stabilisation of mine work-

ing areass Increase of cut-off-grades Hermetically sealed conveying

path for material within the pipelines Increased working and operation

safety

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

Pump with intake shaft at Plutonic Gold Mine/West Australia

HSP Triplex pump

s Liquids with an abrasive materialcontent, such as mine water, kimber-lite slurries and pastes

s Electrostatic precipitator (ESP) ash,both as thick paste and as slurry

DisplacementZ1/mm

FD/0.1

MPa

Time / sec

Pipeline pressure diagram 8 MPa / flow rate 70 m 3/h

Pumping pressure characteristic ofan HSP pump with PCF: The redline shows a deliverypressure of8 MPa for an output of 70 m3/h,

conveying slurry with 60 % drysolids content.

A BackfillB OreC 1 U pp er s to peC 2 L ow er s to peD Mill holeE Pac king pipeF D is ch ar ge h op pe rG B ar ri er pi ll ar

Direction of removalDirection of face advance

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A

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B

C1

C2

D

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E

F

F

G

Systematic description ofupward stoping with backfill

HSP Triplex and Duplex pumps with PCFfor fine grained slurries and paste

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HSP series seat valve pump

Mine dewatering

Every underground mine requires a minedewatering system. In the case of themine water being loaded with mud,Putzmeister offers a reliable wear resist-ant solution.

In this application the frequently usedcentrifugal pumps create high lifetimeoperating costs. Putzmeister HSP pumpshowever are a cost-effective and high

performance solution:

s The pumps are fully automated andare reliable in continuous operation24 hours/day and 7 days/week

s Reliable technology reducesmaintenance costs and guaranteeslow life cycle costs

s Reduced sump dewatering costs

HSP 3080 high-density solids pump

Coal Sludge Handling

s Foreign-body separator to ensurethat oversized material is caught thatwould interfere with the combustionprocess

s Lubricant injection system to reducepressure loss for long transportdistances

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

Coal sludge with density up to 70 %

The majority of coal that is mined fromsurface or underground mines is usedfor the generation of electricity in powerplants.

Putzmeister Industrial Technology (PIT)supplies complete systems for handlingcoal or other sludges for combined com-bustion in conventional power plants.

Together with internationally operatingengineering companies, Putzmeister hassupplied many reliable sludge handlingsystems for the power industry. Our globalpresence allows us to do this t hrough thesupply of technology and service to pro-jects anywhere in the world.

Fuel costs are the most importanteconomic factor in the operation ofpower plants. Therefore secondary fuelsbecome more and more important toreduce the usage of primary fuel.Secondary fuels in bituminous or lignitepower plants could be:

s Coal sludge from coal processingplants or

s Sludge from sewage treatment plantsas well as

s Other materials from industrial pro-cesses with a suitable heating value

Depending on the sludge originPutzmeister designs together with thecustomer the most reliable and costefficient solution based on the followingequipment set:

s Reception facilities (e.g. if sludge istrucked in from another location)

s Storage silos to ensure a continuousfeed to the combustion process

s Conveyance of the sludge throughpipes which allows completeflexilility of routing

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Ash transport

HSP 25100 fly ash pump at Colstrip power plant

Concrete and mortar systems for coal mines

BSM 1002 E concrete pump with mixerbuilt to Atex specification

The BSM 1002 E is a multi-purposemortar and concrete pump fitted with anS-transfer tube system for use in coalmining. It is specially designed for highpressure pumping over long distances,and is used for spray application of mort-ar and concrete, backfilling and injection.The pump is equipped with a continuousmixer to handle dry construction mater-ial.

The BSM 1002 E is used for thefollowing applications:

Construction of roadway dams toincrease mine safety

s Reduced methane gas emission fromthe goaf into the roadways

s Supports gas drainage systemss Reduced danger of goaf fires Increased lifetime of the roadway

double uses Concrete instead of timber as con-

struction material

BSM 1002 E ready for roadway support

Immediate mortar backfilling ofsteel support while roadheading

s Fast stabilizing with stiff construct-ion material reduces deformation ofarches

s Good contact between arch and rocks Control of place where longwall face

and gallery junction is improved

Wet Shotcrete

s Immediate support while road headings Increased safetys No spray dusts Little rebound

Most fly and bottom ashes are pumpedinto embankments. Disposing of theseashes as a paste with a lower water con-tent has a lot of environmental benefits:

s Reduced risk of embankment failuress Reduced water loss due to seepage

and evaporations Reduced fresh water usages Reduced dust potentials Reduced footprint size of the

embankment facility

This results in an increased publicacceptance for coal fired powerplants.

Fly ash and bottom ashes with a grainsize up to 50 mm can be pumped anddisposed together.

KOS series S tube pump

Two KOS 25100 are pumping fly and bottom ash / Kogan Creek, Australia

Fly ash hardens within a short time

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Shotcrete systems

Putzmeister is the competent partner forthe Mining Industry, providing reliablecustomer orientated product solutionsfor owners and operators. Together withour alliance partners we are able to offerthe total package in preparation, trans-portation and usage of constructionmaterial.

For the mining industry today the utiliz-ation of various construction materials isessential to create a safe environmentand achieve high productivity even inchallenging geological strata. Cementbased construction materials are usedpredominately for ground consolidation,ventilation sealing and different civilworks in mines.

Systems for the following miningapplications are part of thePutzmeister program:

Underground hard rock mining

s Mobile shotcrete equipments Stationary transport systemss Mobile transport systemss Ground consolidation, injection and

rock boltings Sealing

Surface mining

s Bench stabilization

Solutions for underground shot-creting

In mining, sprayed concrete has becomemore and more relevant for ground sup-port. The usage for shotcrete in under-ground workings starts with the logisticalproblem of supplying the sprayingequipment with the required constructionmaterial, and finishes with the demandsof placing the material exactly whererequired on the mine walls. Putzmeisteris the only system provider who offerstotal package solutions from the concretemixing plant on the surface, to the shot-creting lining of the galleries in the mine

below.

In addition to pump systems, Putzmeisteris providing complete project solutionsfor the mining industry. Buffer silos, mix-ing plants, pig in gates and pipelinessupplement the range of pumps.

A team of technicians and engineers willcooperate with the customer in identify-ing the most suitable solution, which fre-quently leads to the existing componentsof a customers site providing the basisfor new constructions.

The Putzmeister team will assist thecustomer with the implementation ofspecific solutions and the coordinationof all procedures.However, our involvement does not endwith the supply and commissioning ofthe plant. The training of local staff at theplant, the setting up of storage facilitiesfor wear parts at the mine and the supplyof specific service and maintenancemanuals for the operation are all part ofthe deal, underpinning Putzmeistersimage as the reliable supplier for com-plete systems.

Complete systems for the mining industry

R ecei vi ng con ta in er wi th agi ta to r A ut om at ed scr ap er pi g g at e wi th tw o d if fe rentcontainers

Delivery linesfor building material transport

s Designed for installation in theshaft

s Brackets 200 m aparts Flanged lines Operating pressure maximum

0.45 MPa (65 psi)s Pneumatic transport of abrasive

building materials (granulation0 4 m m )

Delivery linesfor pneumatic stowing

s Designed for installation in the drifts Delivery line lengths approx. 800 ms Centred couplings Pneumatic deliverys Transport of sand and limestones Granulation 0 8 mms Low levels of oversized grains,

max. 32 mm

Sika-PM 407 P

Sika-PM 702

Within the Putzmeister group of companies Esser-Werke providesthe pipeline systems.

PM Lorenzana mover

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7/7TS 3881 GB Right to make technical amendments reserved by Putzmeister AG 2007 All rights reserved Printed in Germany (20703RR)

Putzmeister AG

Max-Eyth-Str. 10 D-72631 Aichtal

P.O.Box 2152 D-72629 Aichtal

Tel. +49 (7127) 599-0

Fax +49 (7127) 599-520

www.putzmeister.com

E-mail: [email protected]

The right pump for every application

Putzmeister Products and ServicesConcrete Pumps Industrial Technology PIT Telebelt Mrtelmaschinen GmbH Dynajet

High Pressure Cleaners Services ConcreteProject Division CPD Consulting and DataTechnology Academy

Pump type Field of application Output Pressure

KOS-Series S-tube pump Backfilling and muck pumping 10 500 m3 /h up to 13 MPaof coarse grained slurries and paste (1886 psi)with particles of up to 80 mm

HSP-Series Seat-valve pump Transport of fine grained slurries 10 250 m3/h up to 15 MPaand paste like tailings, mine water, (2176 psi)fly ashes

HSP Triplex Transport of fine grained slurries 30 440 m3/h up to 15 MPaSeat-valve and paste like tailings, mine water, (2176 psi)pump fly ashes

KOV-Series Ball-valve pump High pressure pumping of fine slurries 0 50 m3/h up to 10 MPalike waste coal, tailings, (1450 psi)mortar and sump sludge.

Hydraulic power pack All Putzmeister pumps are driven by a Performance: 15 1,000 kWhydraulic power pack.

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putzmeister ts 3881 mining gb

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