Tag Archives: Integrated Pump Rental

DESILTING COAL FINES FROM PROCESS WATER PONDS

A total turnkey solution to desilt a process water dam at a coal mine in the Middelburg area of Mpumalanga province was all in a day’s work for pump solutions specialists Integrated Pump Rental.

According to Integrated Pump Rental managing director Lee Vine, it is not uncommon for factors like high rainfall or an unexpected process fault to cause overfilling of a process dam with silt.
In a recent case, a mining customer urgently needed a process dam that had become filled with coal fines to be emptied.
The situation raised the risk of an environmental incident which could have potentially interrupted the smooth operation of the coal processing plant.

“One of the specific issues with coal fines is that they settle very quickly and create a highly compact layer at the bottom of a pond.
This makes it more difficult to create a slurry that can be pumped away,” says Vine. “The SlurryBlaster is our effective hydro mining solution for removing slurry and sediment accumulation on dam walls and inside dams, boasting a capacity of up to 2,800 litres per minute with a nominal inlet pressure of 7 bar.”

In this case, the coal fines could be blasted into an accumulation point where a slurry pump was then used to transfer high tonnages of the sediment to a location specified by the customer.
Integrated Pump Rental also provided the pipelines and fittings that the solution required.

“As part of our project assessment, we ascertained that the slurry demonstrated a low pH level of just three,” he says. “This high acidity meant that we had to deploy our stainless steel range of pumps and equipment to ensure corrosion-resistance.”

Vine highlights that the mine was able to take the dam off-line, and that water from another source was used to feed the mine’s process plant while the desilting process was underway.

“To conduct the hydro-mining option on this project, we secured an external water source and used two monitoring guns to attack the silt – turning it into a slurry that we could then pump through our own pipeline to the tailings dam,” he says.

INTEGRATED PUMP TECHNOLOGY SHOWCASES PUMP RANGES

Integrated Pump Technology will showcase its range of global OEM pumps at Electra Mining Africa.
The company was established four years ago as the official southern African distributor for the well-respected Grindex range of electrical submersible pumps and last year introduced the Italian manufactured Faggiolati pumps to its product offering.

Grindex pumps incorporate a unique air valve that allows the impeller to pass air instead of water protecting the unit in dry run conditions. These robustly constructed pumps are engineered to operate in harsh environments offering end-users reliability and energy efficiency.

The range of Grindex dewatering pumps range in sizes from 0.5 kW to 90 kW with a new 145 kW unit currently in field trials. This unit will be released to market early next year.

The Grindex slurry pumps are robust workhorses made for use in mines and quarries and sizes range from 3 kW to 70 kW. These pumps are equipped with an agitator mechanism that directs settled material to the pump’s intake.

The sludge pump range has all the advantages of the other two ranges as well as a recessed vortex impeller and split hydraulics with replaceable rubber linings. This allows these pumps to handle larger solids with increased abrasion resistance.

Manufactured in Italy, the Faggiolati quality submersible drainage and wastewater pumps are considered a natural complement to the company’s Grindex pump and accessory range.
One of the most significant advantages that Faggiolati pumps offer is that all units are equipped with Premium Efficiency IE3 motors. This is particularly important on a continent that needs energy efficient products and solutions.
The extensive product line-up, more than 800 items, ranges from 0.5kW to 350 kW and pumps are available in grey cast iron as well as marine bronze and stainless steel for specialised applications.

Integrated Pump Technology has a strong network of 16 strategically located distributors each of which has a solid track record.
This facilitates rapid local access to sales and technical information with the distributors being supported by dedicated account managers ensuring effective and optimal solution providing and service.

LEADING PUMP RENTAL OPERATOR TO SHOWCASE PRODUCTS

Integrated Pump Rental intends to reinforce its position as one of the leading pump rental operations in southern Africa with its participation at Electra Mining Africa.

The company will showcase a range of its pump rental solutions aimed at showing the diversity of product available, and its ability to service all pump rental needs within the mining sector.

As the official representative of Sykes diesel driven self-priming pumps in the SADC region, Integrated Pump Rental offers a comprehensive range of these pumps for hire.
Offering characteristics such as high head and high flow, these large pumps are trailer mounted for ease of use. This range offers pumping capabilities up to 500 litres per second and a maximum head of up to 208 metres. Series and parallel configurations are available to facilitate higher heads and an increased flow.

Visitors to the stand can view a range of Grindex pumps. These robust units are easy to install, simple to operate and offer pumping efficiencies with low energy consumption.
The Integrated Pump Rental fleet includes drainage, slurry and solid handling and sludge pumps as well as stainless steel pumps for use in highly corrosive or low PH applications.

The company’s hydro mining solutions have gained traction over the last few years, and both the SlurrySucker and the SlurryBlaster dredge unit will be on the stand.
The SlurrySucker is ideal for the regular cleaning of process water ponds and return water dams, while the SlurryBlaster is suitable for hydro mining sludge out of water storage areas.
Both units are compact in design, and easy to transport from site to site. In addition, these units have been engineered to operate without causing damage to plastic lined dams and ponds.

Of interest on the stand will also be the latest addition to Integrated Pump Rental’s fleet – the Urban LED mobile tower light. With most dewatering and other pumping applications conducted on a 24/7 basis, there is a need to ensure optimum visibility and these tower lights provide reliable lighting ensuring the safety of personnel.
Completing the product offering will be a range of accessories including hose and pump flotation devices, hoses and control and automation solutions.

Integrated Pump Rental can be found at P73.

INTEGRATED PUMP RENTAL LIGHTS THE WAY WITH LED MOBILE TOWER LIGHTS

Lighting has a crucial role to play in allowing people to see clearly and avoid obstacles, obstructions, dangers and hazards. This is especially so when working on site, making lighting a critical safety issue.

Lee Vine, managing director of Integrated Pump Rental, says better lighting also enhances productivity and in response to this demand the company recently bolstered its pump rental fleet with the inclusion of Urban LED mobile tower lights. Units are mine specific and comply with all safety requirements.

Manufactured by AllightSykes, the Urban MLLED200K-9AC mobile tower light is built to the highest quality standards ensuring reliable operation. The tower light’s power coated full steel body and galvanised hydraulic mast assembly are integrated with its maintenance free axle suspension.

The Urban MLLED200K-9AC is equipped with a nine metre mast which ensures maximum output reaches the work area for optimum productivity and safety. The 359 degree mast rotation with lightbar tilt capacity is standard. Powered by a Perkins engine, the 240 Volt AC tower light delivers 200 000 lumens through four powerful 500 Watt LED lamps.

The unit is equipped with four adjustable outriggers facilitating optimum stability in all underfoot conditions.

Leading safety innovations have been incorporated into this latest generation LED tower light, and this includes an audible voice alarm should the hand brake not be engaged, or the unit is not level. When either or both conditions are not met, the mast cannot be raised, or if it is raised it will automatically lower. These integrated features prevent the incorrect deployment of the tower light on site.

The Urban is integrated with the purpose built Smartgen ALC708 lighting tower controller. This offers effortless operation, auto start/stop capability and engine protection.

“The inclusion of the Urban tower lights in our rental fleet is a natural progression and is aimed at addressing customer needs,” Vine says. He says the tower lights are also available for purchase.

Integrated Pump Rental offers a range of pumping rental solutions all engineered to deal with the harsh operating conditions on the African continent. Options include both medium and long term turnkey rental solutions.

DEMAND FOR FAGGIOLATI STAINLESS STEEL PUMPS

With the increased levels of acidity in mine water and associated slurry handling applications, Integrated Pump Technology has reported an increased demand for the Faggiolati stainless steel slurry pump.

Constructed from 316 stainless steel, the Faggiolati pump is engineered to operate in the toughest applications dealing with the handling of corrosive water and sludges.

“In all dewatering applications, whether in underground mine shafts, mine waste dumps, ore stockpiles, tailings facilities or power stations, reliability remains a key requirement, and there is no doubt that a stainless steel pump is by far the best choice for use in acidic environment,” Colin Adams, managing director of Integrated Pump Technology, says.

The excellent corrosion resistant properties of stainless steel ensure reliable operation even under the harshest conditions. By eliminating the risk of corrosion in pumps unscheduled downtime is dramatically reduced and the risk of pump failure is averted.

Faggiolati stainless steel pumps are able to withstand highly acidic water, even when it contains high concentrations of metals and sulphates. The pumps are also capable of handling abrasive particles and a high content of solids up to the size of the pump inlet diameter opening.

Adams says the cast stainless steel impeller ensures pumping capacities in the corrosive fluids and can handle pH values from two to 10.

The most recent order received by Integrated Pump Technology was for six Faggiolati stainless steel channel pumps, and Adams says the pumps will be operating in an extremely acidic environment at a power utility.

Integrated Pump Technology is the official distributor for the full range of Faggiolati submersible drainage and wastewater pumps, mixers and aerators, and the product is supported through the company’s network of 16 strategically located, specialised pump distributors. All these products are available in a flameproof option. The company is also the sole importer and principal distributor for the Grindex range of dewatering, slurry and sludge pumps for southern Africa.

SYKES PUMPS ARE THE SOLUTION FOR MINE DEWATERING IN AFRICA

Two Sykes XH150 trailer mounted pumps will soon be doing dewatering duty at a mine in Africa, supplied by southern African distributors Integrated Pump Rental based in Jet Park, Gauteng.

This range of diesel powered units is ideal for dewatering an open pit, offering characteristics that include high head and head flow, according to Lee Vine, managing director of Integrated Pump Rental.

Vine emphasises that even the best run mine sites can be plagued by expensive challenges if they do not effectively control groundwater ingress into the open pit.

“This can cause not only programme delays but could also adversely affect health and safety on site,” he says. “So, when addressing the need for dewatering, it is vital that contractors deal with a supplier that understands dewatering applications and is able to provide the correct level of technical assistance; this will ensure that the most efficient methods are selected for the demands of a specific site.”

The Sykes Xtra High Head pump set boasts automatic priming and solids handling, so it dewaters more efficiently and effectively; it also has one of the best shaft stiffness ratios of any automatic priming pump on the market.

“These are fully automatic priming pumps and can run dry for extended periods due to the oil bath mechanical seal assembly,” he adds. “The low fuel consumption makes them cost effective to use for extended periods for time when dewatering.”

The pumps – designed for robust and reliable performance with high volumes of water – have an established reputation for the fast and effective control and removal of sub-surface water, he says. They can be primed with long suction hoses and can manage suction lifts of up to nine metres.

The pumps can even operate in ‘snore’ condition, which accommodates fluctuating suction levels; the pump will snore until the liquid is available for the pump to fully reprime itself automatically.

MINES URGED TO DREDGE PONDS BEFORE RAINS ARRIVE IN EARNEST

With the rainy season approaching in most of South Africa’s mining regions, monitoring the capacity of process water return ponds becomes increasingly critical – to monitor whether silt build-up is jeopardising the dams’ functioning.

“Managing the water balance on mines is becoming more demanding as mines work to become more self-sufficient, and to draw less water from municipal sources,” says Lee Vine, managing director at dredging and dewatering specialist, Integrated Pump Rental. “Process water ponds therefore need to be carefully monitored and regularly dredged to prevent too much sediment from accumulating.”

More sediment means less water storage capacity, which can affect the efficient running of the process plant as well as create a potential environmental hazard if heavy rainfall leads to tailings over-topping the pond. Exacerbating the risk of insufficient water storage capacity is the widely held opinion that rainfall is becoming increasingly variable as a result of climate change factors.

“In many areas, this means that summer rains will include a higher number of heavy downpours within relatively short periods of time. And this will place an increased load on these ponds to contain more water than usual,” says Vine. “It is therefore vital that they are operating optimally, and do not have their capacity constrained by excess silt.”

He highlighted the environmental risk of tailings spilling out of ponds, and perhaps even out the boundaries of the mining lease area – an eventuality that mines work hard to avoid due to the stringent legal requirements.

“The regular desilting of return water ponds and dams is becoming more and more important, as we begin to appreciation the proper value of water on our planet, and especially in relatively dry countries like South Africa,” he says. “Not only must mines ensure there is enough capacity to receive and retain excess water during the rainy season, but there is also the need to store as much as possible for the dry season.”

He argues that purchasing treated municipal water to ‘top up’ their requirements is becoming less of an option for mines due to the rising cost of water and the growing competition for water among stakeholders like communities, industry and agriculture.

Applying a regular dredging programme need not be onerous, he adds, and can readily avoid a situation where silt or slimes threatens the water retention and water holding capacity of ponds and dams. Integrated Pump Rental has locally designed, engineered and manufactured the SlurrySucker dredge unit for precisely this purpose, and offers the technology on a rental or turnkey contract basis for mine pond maintenance.

“There are even conditions under which a mine may find it worthwhile to procure their own SlurrySucker, for permanent and ongoing use on desilting operations,” says Vine. “The equipment can be moved easily by road trailer and commissioned within a day. The operation of the equipment can be conducted by just one person, and we provide all the necessary training, support and maintenance required.”

Using the high quality Grindex brand of slurry pumps and a purpose-engineered dredge head, the units are capable of extracting high tonnages; 240 m3 per hour of slurry/water mixture in the case of the smaller SlurrySucker Mini (30 to 40 dry tons per hour) and double this using the SlurrySucker Maxi, which will remove 70 to 80 dry tons per hour.

Vine suggests that in many operations the retreatment of sediment may even pose an economic opportunity that would more than cover the costs of the dredging.

“We are able to assist the mine in designing arrangements that would allow the pond sediment, which is usually enriched to some extent with the ore being mined, to be pumped back to the process plant for retreatment,” he says.

The SlurrySucker’s design ensures that there is no danger to the high density polyethylene (HDPE) lining of the ponds, as the agitation of the sediment is conducted using only water jets. Recent modifications to the original model even allow for the system to suck up large solid objects, such as gloves, boots, plastic packets and hessian bags, without blocking up and slowing down operations.

“The benefits of being proactive about maintaining return water ponds cannot be overstated, but we realise that mines have many competing priorities to manage and this aspect of their operations is sometimes overlooked,” concludes Vine. “For this reason, we even offer a service where our technical team will schedule regular visits to the relevant water storage or treatment facilities to check what needs to be done, and when. We will then conduct the dredging as and when necessary, significantly reducing the operational and environmental risk to the customer.”

SYKES PUMPS ARE THE SOLUTION FOR MINE DEWATERING IN AFRICA

Two Sykes XH150 trailer mounted pumps will soon be doing dewatering duty at a mine in Africa, supplied by southern African distributors Integrated Pump Rental based in Jet Park, Gauteng.

This range of diesel powered units is ideal for dewatering an open pit, offering characteristics that include high head and head flow, according to Lee Vine, managing director of Integrated Pump Rental.

Vine emphasises that even the best run mine sites can be plagued by expensive challenges if they do not effectively control groundwater ingress into the open pit.

“This can cause not only programme delays but could also adversely affect health and safety on site,” he says. “So, when addressing the need for dewatering, it is vital that contractors deal with a supplier that understands dewatering applications and is able to provide the correct level of technical assistance; this will ensure that the most efficient methods are selected for the demands of a specific site.”

The Sykes Xtra High Head pump set boasts automatic priming and solids handling, so it dewaters more efficiently and effectively; it also has one of the best shaft stiffness ratios of any automatic priming pump on the market.

“These are fully automatic priming pumps and can run dry for extended periods due to the oil bath mechanical seal assembly,” he adds. “The low fuel consumption makes them cost effective to use for extended periods for time when dewatering.”

The pumps – designed for robust and reliable performance with high volumes of water – have an established reputation for the fast and effective control and removal of sub-surface water, he says. They can be primed with long suction hoses and can manage suction lifts of up to nine metres.

The pumps can even operate in ‘snore’ condition, which accommodates fluctuating suction levels; the pump will snore until the liquid is available for the pump to fully reprime itself automatically.

INTEGRATED PUMP RENTAL EXPANDS INTO INDUSTRIAL SECTOR

Signalling its expansion into the economy’s industrial segment, pump and dredging specialist, Integrated Pump Rental recently made short work of cleaning the sediment from the reservoirs of a customer in tile manufacturing.

According to Integrated Pump Rental managing director Lee Vine, the tile making process involves wastewater being fed into storage tanks and then through a filter press.

“During this process, an aeration system keeps the slurry in suspension and ensures the correct consistency for pumping,” says Vine. “With the aeration system under-performing, the slurry tended to settle in the reservoirs, reducing the water storage capacity and undermining the efficient running of the plant.”

The sediment also creates a potential environmental hazard should the tanks overflow, but its density makes it difficult to pump out.

This challenge in the water storage tanks – which measure about eight metres square and hold some 200 m3 of waste water each – then has a knock-on effect down the line, causing inefficiencies in the downstream process. In this particular operation, it also became necessary to incur the additional cost of introducing municipal water to the system.

“Our team was quickly able to assess the situation, and proposed the use of our innovative hydro solution, which has proven so successful and cost effective in desilting water reservoirs at mines or wastewater treatment plants,” he says. “The solution proved to be very successful and cleared the tanks of the sediment that had built up, allowing the customer to get their process back on track.”

With its high quality Grindex slurry pumps and purpose engineered hydro mining monitor guns, Integrated Pump Rental’s hydro cleaning units are capable of extracting high tonnages of sediment from reservoirs.
Vine emphasises that applying a regular cleaning programme need not be onerous for end-users, and will ensure that their tanks are sediment-free in a range of applications.

NEW SLURRYSUCKER MODEL PASSES TRIAL WITH FLYING COLOURS

The new, high solids capacity SlurrySucker dredging unit from Integrated Pump Rental recently proved its mettle at a Limpopo municipality’s wastewater treatment plant.

“We were requested to clean two wastewater settlement ponds which had silted up and were no longer performing their function of settling the sewage before it left the property,” says Lee Vine, managing director at Integrated Pump Rental. “Each dam measured about 100 metres by 100 metres and was about three metres deep; we estimated that they were about 70% filled with sediment.”

The company’s new SlurrySucker Mark II, with a vortex-type impeller in the slurry pump and a redesigned dredge head achieves up to about 50% solids concentration by volume. Vine says this significant especially when compared to the 30-40% concentration with the standard dredge head. The larger holes and the vortex-type impeller allow for larger solid objects like boots, gloves and hessian bags to pass through without blocking the system.

“After being awarded the contract, we quickly moved our equipment onto site; the total weight of the SlurrySucker is only about two tonnes – perhaps four tonnes with accessories – so it is relatively lightweight and easy to move around by road trailer,” says Vine. “We spent a day setting up the unit, then spent 25 days cleaning each dam, working an eight hour shift each day.”

Operated by just one person, the six metre long and three metre high unit agitates the sediment in single metre wide paths as it moves up and down the pond.

“After about two months on the job, we were pleased to have completed our mandate successfully without a single blockage,” he adds. “It took just one day at the end of the process to decommission the equipment and move off site.”

Vine emphasises that the design of the SlurrySucker allows it to be used on plastic-lined dams without risking any damage to liners, as it uses water to agitate the solids, and does not have cutters that could damage the pond liner.

“This is particularly important from an environmental perspective, as wastewater could leak out if the liner was cut or damaged, and could contaminate groundwater,” Vine says.

In addition to the turnkey service provided here, Integrated Pump Rental also offers contracts where the team will come to site every year to inspect and dredge the dams to ensure they are kept operational and efficient.

Also, if the end-user has a more regular and ongoing need, the company can also sell the equipment to the customer and provide training so that the application of the equipment can be effective.

Service levels are high on the SlurrySucker dredge units, as they are manufactured using locally produced components, and incorporate quality Grindex slurry and dewatering pumps. This means that spare parts are readily available and the expertise is on hand to maintain the equipment.