At an iron ore loading site in Australia, seasonal torrential rains produced a lot of abrasive mud here, and the existing cantilever pumps did not handle the mud efficiently. To solve this problem, ITT Flygt provided the mining company with a solution that eventually solved the 30-year-old problem. BHP Billiton Corporation is the world's largest multi-resourced company headquartered in Melbourne, Australia with a leading position in the aluminum, iron ore, copper, energy and coal industries. One of the company's mills is an iron ore loading dock at Port Hedland, Pilbara, Western Australia. From November to April each year, hurricanes regularly visit the coast with heavy downpours. When a mineral is loaded on a bulk carrier, it is inevitable that the caked mineral will fall off the conveyor. The minerals are mixed with a large amount of water from heavy rains to form highly abrasive mud that is collected at pumping stations for storage at the loading site for further processing. For more than 30 years, these old-fashioned cantilever pumps have typically failed due to buildup of mineral powders and solids, resulting in pump wear, high maintenance costs, and unreliability of the mud treatment process. Failure of the pump not only leads to high costs due to maintenance and downtime, but is also replaced by private contractors. For these reasons, BHP Billiton started looking for new equipment to solve the problems they encountered: mud accumulation, periodic pump failure and high maintenance costs. The hardest-quest problem in the loading yard was the catchment next to the ferry terminal, where a large number of bulk carriers were loaded to carry minerals and the spill of the catchment became an environmental issue. BHP Billiton uses a fly-by pump in different processes, so they turn to ITT Flyer (Australia) for assistance with a suitable pump. Flygt decided not only to replace the old cantilever mud pump, but also to optimize the catchment design, pumping, mixing and pool cleaning processes. That is, existing fly-force equipment and new methods are used to solve the problem of agitation and removal of heavy mineral slurries. An analysis of the problem shows that a larger catchment is needed than a conventional catchment. This is not just about collecting water from the washing process and the rain, but also acting as a storage device in the face of an unavoidable torrential rains during the hurricane season. Each pump has different tasks, but in order to achieve the interchangeability of on-site maintenance personnel, the pump standard must be unified. Another priority is the catchment cleanup and the build-up of mineral powders and solids. For this application, Flygt selected its submersible HP 5540 wear-resistant high chromium alloy mud pump. To achieve this goal, the bottom of the pump is equipped with a high-chromium alloy mixer. In order to ensure long life and long-term effective stirring, blades and shafts are coated with a special coating (HVOF). The pump sump is designed according to the new TOP concept of Flygt, that is, the use of a sloping sump to aggravate the turbulence and keep the solids in suspension, preventing settling of the deposits. The top of the sump is fitted with an inlet screen with a 15 mm opening, allowing the pump to effectively remove caked minerals that have been washed down with the powder and liquid. The screen can move, easy to clean, if necessary, can enter. The three pumping stations are all supplied with two concrete blocks with outlet connections, guide rods, chain hooks, caps and screens that are already in place. Then the rest of the equipment: Pumps, rails, internal drains and controls are very easy to install. The HP 5540 pump provides the application with hydraulic components made of high-chromium alloy, 75 l / s flow and 13.5 kW (18 hp) motors. Australia-based Flywheel solved its 30-year old problem with a complete system solution. The final application and design solve all the problems of BHP Billition. Caption: Figure 1. BHP Billition's outsourcing facility in Port Hedland, Australia. Figure 2. Stirrer mounted on the bottom of a Flygt HP 5540 centrifugal pump with HVOF coating. Figure 3. Optimized Pump Set The sink has a removable screen for easy cleaning.
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