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Putzmeister IndustrialTechnology in Mining

TS 3881-1 GB

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TS 3881-1 GB2

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

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HSP series seat valve pump

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

Paste material is pumpable over longdistances

Transferring at high concentrationsminimizes the water usage

Low water seepage into the environ-ment

Reduced risk of embankment failure Stability of Paste reduces the costs

associated with the construction of aconventional tailings facility

Paste pumping reduces the requiredtailings disposal area compared toconventional slurry embankments

High pressure dampener

Tailings transport pipeline

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Backfilling

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 projectsPutzmeister 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:

Output up to 500 m3/h. Operating pressures in the conveyed

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

25 MPa (3626 psi) Suitable for abrasive material

The advantages of the method:

Closed mine waste circuit ‘mine processing mine’

Improved stabilisation of mine work-ing areas

Increase of cut-off-grade Hermetically sealed conveying

path for material within the pipeline 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

A BackfillB OreC1 Upper stopeC2 Lower stopeD Mill holeE Packing pipeF Discharge hopperG Barrier pillar

Direction of removalDirection of face advance

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B

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C1

C2

DD

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FF

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Systematic description of upward stoping with backfill

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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:

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

Provides precompression to reducethe gap in delivery

Ensures almost constant output flowrate

Minimizes water hammer, especiallywith slurries

Increases lifetime of the delivery lineand fastenings

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

Mineral-based high-density solids(tailings) with a grain size below 1000 µm at a concentration of drysolids up to 80 %

HSP Triplex pump

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

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

Disp

lacem

entZ

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Pipeline pressure diagram 8 MPa / flow rate 70 m3/h

Pumping pressure characteristic ofan HSP pump with PCF: The redline shows a delivery pressure of 8 MPa for an output of 70 m3/h,conveying slurry with 60 % drysolids content.

HSP Triplex and Duplex pumps with PCF for 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 highperformance solution:

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

Reliable technology reducesmaintenance costs and guaranteeslow life cycle costs

Reduced sump dewatering costs

HSP 3080 high-density solids pump

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Coal Sludge Handling

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

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 through 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:

Coal sludge from coal processingplants or

Sludge from sewage treatment plantsas well as

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:

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

Storage silos to ensure a continuousfeed to the combustion process

Conveyance of the sludge throughpipes which allows complete flexilility of routing

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Ash transport

HSP 25100 fly ash pump at Colstrip power plant

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:

Reduced risk of embankment failures Reduced water loss due to seepage

and evaporation Reduced fresh water usage Reduced dust potential 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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Concrete and mortar systems for coal mines

BSM 1002 E concrete pump with mixer built 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

Reduced methane gas emission fromthe goaf into the roadways

Supports gas drainage systems Reduced danger of goaf fire Increased lifetime of the roadway

double use Concrete instead of timber as con-

struction material

BSM 1002 E ready for roadway support

Immediate mortar backfilling ofsteel support while roadheading

Fast stabilizing with stiff construct-ion material reduces deformation ofarches

Good contact between arch and rock Control of place where longwall face

and gallery junction is improved

Wet Shotcrete

Immediate support while road heading Increased safety No spray dust Little rebound

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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

Mobile shotcrete equipment Stationary transport systems Mobile transport systems Ground consolidation, injection and

rock bolting Sealing

Surface mining

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 minebelow.

Sika®-PM 407 P

Sika®-PM 702

PM Lorenzana mover

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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 customer’s 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 Putzmeister’simage as the reliable supplier for com-plete systems.

Complete systems for the mining industry

Receiving container with agitator Automated scraper pig gate with two differentcontainers

Delivery lines for building material transport

Designed for installation in theshaft

Brackets 200 m apart Flanged line Operating pressure maximum

0.45 MPa (65 psi) Pneumatic transport of abrasive

building materials (granulation 0 – 4 mm)

Delivery lines for pneumatic stowing

Designed for installation in the drift Delivery line lengths approx. 800 m Centred coupling Pneumatic delivery Transport of sand and limestone Granulation 0 – 8 mm Low levels of oversized grains,

max. 32 mm

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

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The right pump for every application

Pump type Field of application Output Pressure

KOS-Series S-tube pump Backfilling and muck pumping 10 – 500 m3/h up to 13 MPa of 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 Concrete Pumps GmbHMax-Eyth-Str. 10 · 72631 Aichtal /GermanyP.O.Box 2152 · 72629 Aichtal /GermanyTel. +49 (7127) 599-0 · Fax +49 (7127) 599-520E-Mail: pmw@pmw.de · www.putzmeister.com

The Putzmeister Group Concrete Technology PCT · Mortar Technology PMTPipe Technology PPT · Water Technology PWTIndustrial Technology PIT · Belt Technology PBTUnderground Technology PUC

Right to make technical amendments reserved© by Putzmeister Concrete Pumps GmbH 2009All rights reserved · Printed in Germany(20904Sc)

TS_3881_1_GB 06.04.2009 11:06 Uhr Seite 12