Underground Nickel Mine Case Study

Location: Kalgoorlie, Western Australia

Application: Underground Nickel Mining

Overview

The mining industry is one of the toughest environments for pumping equipment. The extremely harsh conditions present numerous hazards that even the most reliable pumps can struggle with, such as:

These challenges can severely impact submersible pump performance, often leading to costly repairs or replacements and affecting overall mine productivity.

Another issue in the mining industry is the preference for a standardized fleet. Mines often use the same pump size for various applications to reduce the number of spare parts needed. However, different submersible pump applications and locations within the mine demand different performance levels, leading to undue strain on undersized pumps or inefficiencies from oversized pumps.

These challenges were encountered first-hand at an underground nickel mine near Kalgoorlie, Western Australia. Competitor pumps on-site were typically failing every three months, resulting in reduced productivity and unnecessary expenses.

Tsurumi's Approach

Site Audit

A thorough audit of the existing system and pumps was conducted to gain a comprehensive understanding of the mine site, including its unique operational needs and environmental challenges. This step was critical in tailoring solutions to the specific requirements of the site.

Water Sample

A water sample was taken to analyze the exact composition of the liquid being pumped. This analysis allowed us to determine the properties of the liquid.

Pump Selection

Careful consideration was given to selecting the most appropriate pump. Factors such as head pressure, required capacity, pipe size, and the liquid properties were all evaluated to ensure optimal performance, suitability and durability.

Other

To mitigate corrosion and enhance the longevity of the Tsurumi pumps, sacrificial anodes were added for protection. Additionally, regular maintenance routines, including washing the pumps to remove debris and calcium buildup, were implemented to keep the equipment in top condition and minimize downtime.

Results & Benefits

After carefully evaluating the liquid properties and duty application requirements, we selected the Tsurumi KTZ series pumps. Replacing the competitor’s pumps with KTZs provided the mine with significant cost savings, with upfront expenses reduced by approximately 30%. By tailoring the pump selection to each specific application, rather than relying on a standardized fleet, the lifespan of the KTZ pumps was effectively doubled. Furthermore, the introduction of regular maintenance routines helped lower servicing and repair costs, contributing to overall operational efficiency.

Conclusion

Challenging applications demand durable and reliable pumping equipment, and the Tsurumi KTZ dewatering pumps exemplify an excellent choice for the underground mining sector. The mine has expressed great satisfaction with their replacement pumps, highlighting the KTZ’s reliability and performance in harsh conditions over its competitors.