Mining operations are demanding pumps with higher hydraulic efficiency, lower energy use and longer wear life to lower costs, improve environmental impact and meet modern operational demands, says pumps and valves manufacturer KSB Pumps and Valves mining market area manager Jacques Pretorius.

The mining industry is undergoing various changes, with underground operations exploring deeper and an increase in sustainability measures such as process plants aiming to reduce water consumption, along with unique challenges associated with emerging mineral markets.

These trends have prompted the pumps industry to innovate its offerings to meet the demands of the modern mining environment, he elaborates.

Operations exploring deeper underground is resulting in pumping heads increasing significantly, thereby placing higher demands on pump pressure ratings, materials and motor power.

Consequently, mines require pumps with greater hydraulic capacity and efficiency to manage rising energy costs associated with increased pumping requirements, he adds.

Many mines are also processing higher-density slurries to reduce water use, notes Pretorius, adding that while this improves sustainability, it creates harsher operating conditions for pumps, with higher concentrations of coarse particles accelerating equipment wear.

In addition, the global energy transition has led to increased demand for minerals used in associated technology, such as lithium, cobalt, graphite and rare earth elements, which presents unique pumping challenges, as equipment has to withstand many conditions, ranging from fine, abrasive slurries to highly corrosive process streams.

Amid these trends and under stricter environmental regulations, mines are placing greater emphasis on water recycling, contamination prevention and responsible discharge, he elaborates.

Pretorius says that as a result, the pumps industry is advancing energy efficient designs, digital monitoring tools and fully integrated water-handling systems.

KSB is developing pumps capable of handling higher heads, denser slurries and new minerals as well as the related handling processes, while meeting stricter regulations and maintaining reliability and efficiency.

Common Challenges
Mines continue to navigate various other operational challenges, notes Pretorius.

In process plants, for example, throughput is generally more structured and flows more predictable, with pumps operating as part of an integrated equipment chain.

In these applications, slurry pumps handle abrasive media with high solids content, while process water pumps ensure the constant recirculation and distribution of clean or clarified water across individual water processes.

“If these pumps fail without sufficient redundancy, even briefly, process flow is disrupted and production continuity is threatened,” he cautions, adding that reliability, wear resistance and efficiency are critical considerations in these applications.

In slurry pumping, abrasion and erosion are inevitable, as hard, sharp particles continually wear down wetted components, leading to frequent replacements, high maintenance costs and considerable waste when worn components need to be discarded, Pretorius explains.

To address this, KSB’s GIW range of slurry pumps employs slurry-tolerant materials and advanced wear-resistant coatings, consequently extending component life, reducing change-outs and waste while also lowering the total cost of ownership.



He notes that mines aim to achieve longer equipment life span and predictable wear life of slurry pumps in process plant applications, explaining that a key advantage maintenance planners aim to achieve is the ability to plan major pump overhauls to align with scheduled plant shutdowns.

To help streamline this process, mines now have the option to integrate digital monitoring systems, such as KSB’s Slysel, to not only accurately predict the timing of component failure, but also avoid the premature replacement of costly wear parts.

In contrast to processing plants, mine dewatering pump applications are significantly less predictable, with pumps required to manage unplanned inflows from rainfall and extreme weather, often at high volumes and from shifting collection points, he points out.

Mobility, redundancy and handling potentially abrasive mixtures are critical to equipment success in mine dewatering conditions, he says.

To meet these requirements, KSB’s high-performance centrifugal pumps are available in a range of configurations and materials, combined with supporting infrastructure, such as mobile skids, pontoons and trailers.

To further ensure that mines have fit-for-purpose solutions, Pretorius says KSB teams assess the operating conditions at every mine to design custom hydraulic solutions that integrate control systems, redundancy and materials science, ensuring reliability in harsh environments.

Digital technologies, such as KSB Guard, enhance this offering by providing operators with real-time visibility and predictive maintenance capabilities, helping to prevent costly downtime.

The company is also preparing to launch its solids handling, self-priming pumps range, designed for dewatering and large-particle wastewater applications. Developed and industrialised in South Africa, the range will be available in various hydraulic sizes and materials of con- struction.